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Construction Sequence

Critical path installation order — acoustic isolation depends on correct sequencing. Every phase must be completed in order. Skipping or reordering steps will compromise the acoustic envelope.

10
Construction Phases
0
Total Tasks
6–8 wks
Estimated Duration
Before modifying any element: Check the Modification Policy to determine if it is [AC] Acoustic Critical or [DEC] Decorative.
BUILDER CUSTOMIZATION GUIDE -- INSTALLATION SEQUENCE

CUSTOMIZABLE -- Scaffolding and temporary works supplier, site safety signage style, worker scheduling and shift patterns, tool brands, dust protection and site cleaning methods, delivery logistics and staging areas, progress reporting format.

DO NOT ALTER -- Phase sequence order (slab & float floor with floor box stub-ups before walls, electrical rough-in during perimeter wall construction while cavities are open, buffer spine before internal partitions, door frames before HVAC rough-in, HVAC and above-ceiling cables before ceiling systems, door hanging after ceiling systems, finishes & fixtures last before testing), hold-point inspection requirements, curing times between phases, seal-before-close protocol, STC verification testing at each stage. Changing the build order compromises acoustic isolation. Follow the sequence exactly as specified.

Timeline Overview

Project Schedule

Visual timeline showing all phases with estimated durations. Total estimated: 6–8 weeks.

W1 W2 W3 W4 W5 W6 W7 W8 1. Slab + Floor 2. Walls + Electrical 3. Buffer Spine 4. Partitions + Stageboxes 5. Door Frames 6. HVAC + Cables 7. Ceiling Systems 8. Door Hang + Seal 9. Finishes 10. Testing & Commissioning
Construction Phases

Installation Checklist

Complete each phase in order. Check off tasks as they are completed. Progress is saved automatically.

1
Slab & Float Floor + Floor Box Stub-Ups
Week 1 • HOLD POINT
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WHY FIRST: Walls sit ON the float floor. If floor comes after walls, you lose the isolation break. Floor box stub-ups must be installed during floor layup — cannot be added later without destroying the floating floor.
SLAB PREPARATION
Slab flatness check — ±3mm over 3m straightedge
Clean concrete surfaces, seal any cracks (non-expanding foam)
FLOAT FLOOR CONSTRUCTION
Float floor isolation pads placed (Sylomer SR 28, grid pattern, 400mm centers)
Install 1st plywood layer (18mm T&G, screw to pads only)
Apply damping compound between plywood layers
Install 2nd plywood layer (joints offset 200mm)
Perimeter gap 10mm maintained all around — DO NOT seal yet (seal AFTER walls complete)
⚡ FLOOR BOX STUB-UPS — Install BEFORE closing the floor
Floor box conduit stub-ups in place — use liquidtight flexible conduit (NOT rigid conduit) to avoid bridging structural slab to floating floor
CR-FB and ST-FB positions match SSOT coordinates — CR-FB (Control Room, x=100, y=76) and ST-FB (Video Studio, x=671, y=310)
CRITICAL: Rigid conduit between slab and floating floor defeats acoustic isolation. Liquidtight flex is the ONLY acceptable method.
Check floor level (max 3mm deviation over 2m)
2
Perimeter Wall Framing + Electrical Rough-In
Week 1–2 • HOLD POINT
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Electrical boxes MUST be installed DURING wall construction — mounting boxes to studs while the cavity is open, BEFORE gypsum closes. Cutting into finished acoustic walls to add boxes later loses 2–5 STC points even with perfect patching.
STEP A — Frame all perimeter walls (leave cavities OPEN)
Steel stud spacing 400mm OC verified
No rigid connections to structure — resilient channels installed
North concrete wall — RSIC-1 clips → hat channel → rockwool (STC-65 target). Do NOT install gypsum yet.
NW diagonal wall — RSIC-V clips → hat channel → rockwool (STC-65 target). Do NOT install gypsum yet.
East server wall — independent stud wall, rockwool fill (STC-62 target). Do NOT install gypsum yet.
South wall — double stud frame, rockwool fill (STC-50 target). Do NOT install gypsum yet.
⚡ STEP B — Electrical rough-in while wall cavities are OPEN
Electrical boxes mounted to studs while cavity OPEN — no back-to-back boxes across STC walls (600mm min offset)
Putty pads on all 5 exposed sides of every box (Metacaulk SSP or equivalent)
Conduit runs complete before gypsum closure
Seal all cable penetrations through studs/plates with non-hardening acoustical sealant
✓ STEP C — Close walls with gypsum (2 layers + damping)
Install 1st layer gypsum — cut box openings (max 3mm gap), seal perimeter with acoustical sealant
Apply Green Glue (2 tubes per 4×8 sheet) + install 2nd gypsum layer, offset seams by ≥300mm
Seal all edges to float floor with acoustic sealant — continuous bead, no gaps
All perimeter walls completed BEFORE internal partitions (Phase 4)
3
Buffer Spine Construction
Week 2–3 • HOLD POINT
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The buffer spine is the central acoustic barrier separating studio zones. Double-leaf construction with maintained air gap is critical — any bridging destroys isolation between east and west studio halves.
Double-leaf wall construction both sides — center partition frame (X=206–221, STC-55 target)
Air gap maintained — verify no bridging between leaves (no rigid connections)
MEP penetrations sealed with Tremco sealant + fire-rated putty
Stagebox conduits (SB-01, SB-02) routed through open cavity — 32mm steel EMT
Duct sleeves oversized and gasketed for HVAC penetrations
Close buffer spine: 2× gypsum + Green Glue both sides, seal all perimeters
Buffer spine must be complete before internal partition framing begins (Phase 4)
4
Internal Partition Walls + Stagebox Install
Week 3–4 • HOLD POINT
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Same principle as perimeter walls: frame first, install stagebox conduits and electrical through open cavities, then close with gypsum. Observation window rough opening must be framed now.
STEP A — Frame all internal partitions (leave cavities OPEN)
Partition Y positions match SSOT — verify against SSOT-GEOMETRY.html
STC-rated assembly per wall schedule — cavity insulation full-fill
Observation window rough opening framed (80×50cm, VO/Control partition, STC-53 target)
⚡ STEP B — Stagebox install + electrical through open partitions
SB-01 conduit through voControlPartition while cavity open — 32mm steel EMT
Run data conduit (25mm EMT, 600mm separation from power) to all Cat6A outlet locations within partitions
All electrical boxes installed with putty pads BEFORE closing with gypsum
✓ STEP C — Close partitions with gypsum + seal
Internal walls connect to float floor, NOT to slab
Internal walls must NOT touch ceiling — leave 10mm gap + seal
Close all partitions: 2× gypsum + Green Glue, putty-pad all boxes, seal all conduit penetrations with Tremco sealant + fire-rated putty
5
Door Frame Installation
Week 4 • HOLD POINT
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Door frames must be installed and sealed before HVAC rough-in and ceiling work. Frames define the acoustic envelope openings — head gap sealant dimensions are critical.
Frames plumb and level — ±1mm tolerance
Acoustic sealant all perimeters — continuous bead, no gaps
Threshold gaskets continuous
Head gap sealant bed: 20mm for D1 (Entry) / 18mm for D2–D4
Doors are NOT hung yet — frames only. Door hanging occurs in Phase 8 after ceiling systems are complete.
6
HVAC Rough-In + Above-Ceiling Cable Pulls
Week 4–5
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In-wall electrical boxes, power conduit, and stagebox conduits were already installed during Phases 2–4 (while wall cavities were open). This phase covers HVAC ductwork and above-ceiling cable pulls — all work that must complete before ceiling systems close in Phase 7.
HVAC DUCTWORK
Duct routing through buffer only
Install silencers per schedule: A (trunk), B (trunk), B1/B2 (branch), C
Flex connectors at IDU — ALL hangers must include neoprene isolation pads (no direct metal-to-slab suspension)
Crosstalk silencers installed on B1 and B2 branches — prevents sound transmission between Control and Editing via shared duct
Silencer straight-run: Maintain 300mm minimum straight duct upstream AND downstream of every silencer — elbows or transitions at the silencer face reduce attenuation by 3–8 dB
Connect flex duct from silencers to diffusers (min 1m flex)
Seal all duct penetrations through walls with acoustic boots
ABOVE-CEILING CABLE PULLS — Must complete before ceiling systems in Phase 7
Above-ceiling cable runs on resilient hangers — 600mm audio-to-power separation maintained
Pull Cat6A S/FTP cables — all data runs through conduit to patch panel
Pull signal cables through stagebox conduits — C-SB01 and C-SB02
Run lighting power cables to fixture positions above T-grid — dimmed circuits in separate conduit from non-dimmed
Cable separation: Verify 600mm minimum between power and audio cables. Data cables: 300mm from power. 90° crossings only where paths must intersect
Conduit sharing rules: Audio (XLR/TRS) in own conduit — NEVER with digital (ethernet, DMX). NO signal cable shares conduit with AC power
Test HVAC before ceiling closes — run for 48hrs minimum, measure NC in each room
HVAC noise levels verified acceptable. Photo-document all above-ceiling cable routing before ceiling closes.
7
Ceiling Systems
Week 5 • HOLD POINT
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Ceiling systems close the acoustic envelope from above. All HVAC ductwork and above-ceiling cable runs (Phase 6) must be complete and verified before ceiling tiles go in.
Plenum barriers at buffer walls — full-height gypsum from tile level to structural slab
Ceiling grid at 2.75m AFF — verify level
Above-tile insulation laid (Rockwool, cut to 610×610mm, butt joints, no gaps)
Ceiling tiles installed per room spec — Rockfon Sonar E (VO, Control, Video) / Armstrong Ultima+ (Editing)
Access panels for IDU service — verify operable
Lighting fixtures surface-mounted or suspended — no penetration of acoustic ceiling plane
Ceiling grid must NOT touch any wall (10mm gap all around)
Seal perimeter gap between ceiling grid and walls with acoustic sealant
8
Door Hanging & Sealing
Week 5–6 • HOLD POINT
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Door frames were installed in Phase 5. Now that the ceiling is closed and the acoustic envelope is sealed, doors are hung into their frames and sealing is verified.
Door leaf STC matches schedule — Entry STC-50, Control STC-45, VO STC-45, Video Studio STC-40
7-layer leaf assembly verified (85mm total thickness)
Drop seals functional on all doors
Light test pass — no visible gaps around any door perimeter
Install observation window — triple-pane glass assembly (6mm + 100mm air + 10mm lam + 75mm air + 8mm), 5° tilt toward Control room
Seal all frames with acoustic sealant — continuous bead
Door closer installed: verify latching force pulls door fully into seal contact. Closing speed 3–5 seconds from 90° to latch.
9
Finishes & Fixtures
Week 6
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Finishes are applied after the acoustic envelope is fully sealed. These address internal room acoustics (reflections, RT60) and final fit-out.
Acoustic panels mounted per elevation drawings — rockwool + fabric wrap on designated wall areas
Bass traps installed in all corners (12× total across VO, Control, Video Studio — 4 per room)
Diffusers mounted at specified positions — QRD diffusers on Control room rear wall
Lighting fixtures connected and dimmer tested — connect to pre-run cables from Phase 6
Floor box lids flush with finished floor — CR-FB (brass lid, flush with carpet) and ST-FB (flush with vinyl)
Install carpet (VO, Control, Editing — NOT Video Studio) and vinyl flooring where specified
Mount green screen and all wall fixtures into the acoustic wall assembly, NOT through to concrete (would create flanking path)
10
Acoustic Testing & Commissioning
Week 6–8 • HOLD POINT
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All construction complete. This phase verifies that the installed systems meet acoustic performance targets. STC acceptance tests require Green Glue 30-day cure.
NC measurement all rooms — targets: VO NC-20, Control NC-25, Video Studio NC-25, Editing NC-35
RT60 measurement all rooms — 6 octave bands per room
STC field test key partitions — ASTM E336
HVAC crosstalk test between Control and Editing (shared duct) — verify B1/B2 silencers provide adequate isolation
All systems energized and verified — lighting, HVAC, network, signal paths
Network & signal test — verify all XLR, TRS, BNC, HDMI-over-Cat6 paths end-to-end
Punch list — fix any deficiencies found during testing
Green Glue 30-day cure check — verify walls reached cure date before final STC acceptance test. Early readings are indicative only.
Final sign-off — all rooms meet acoustic targets, all systems operational
Critical Path

Sequencing Warnings

These sequencing rules are non-negotiable. Violating any of them compromises the acoustic isolation envelope.

X Slab & float floor (Phase 1) MUST come before walls. Walls sit on the float floor to maintain the isolation break from the concrete slab.
X Floor box conduit stub-ups MUST use liquidtight flexible conduit between slab and floating floor (Phase 1). Rigid conduit bridges the isolation gap and defeats the floating floor.
X In-wall electrical boxes and conduit MUST be installed during wall construction (Phases 2–4) while cavities are open. Cutting into finished acoustic gypsum to add boxes later loses 2–5 STC points.
X Buffer spine (Phase 3) MUST be complete before internal partitions (Phase 4). The central acoustic barrier defines the isolation between studio zones.
X Door frames (Phase 5) before HVAC rough-in (Phase 6). Frame openings define the acoustic envelope before ductwork is routed.
X HVAC and above-ceiling cables (Phase 6) MUST be tested and completed BEFORE ceiling systems close (Phase 7). Once acoustic ceiling tiles are installed, re-entry is destructive and costly.
X All sealing MUST be continuous — any gap = flanking path. Even a 1mm crack can reduce wall STC by 10+ points.
X Cable separation: power and audio cables 600mm minimum parallel separation. Power and data cables 300mm minimum. Crossings at 90° only. Analog audio NEVER shares conduit with digital (ethernet, DMX) or AC power.
! Green Glue needs 30 days cure for rated STC. Acoustic testing before 30 days will show lower performance than final. STC readings taken before Day 30 are indicative only — do NOT fail a wall based on early readings. Final acceptance STC test must occur after full 30-day cure.
! Allow 48hrs between HVAC install and noise testing. System needs to reach thermal equilibrium for accurate NC readings.
Estimated Timeline

Gantt Chart

Overlapping phases shown with dependencies. Critical path highlighted.

PHASE Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 1. Slab + Float Floor 2. Walls + Electrical 3. Buffer Spine 4. Partitions + Stageboxes 5. Door Frames 6. HVAC + Cables 7. Ceiling Systems 8. Door Hang + Seal 9. Finishes & Fixtures 10. Testing & Commission Red dashed = critical dependency
Quality Assurance

Quality Checkpoints

After each phase, perform these verification steps before proceeding.

1
Dimensional Check
Verify all dimensions against SSOT-GEOMETRY.html
2
Seal Continuity
Acoustic seal continuity check — no gaps, no cracks
3
Level & Plumb
Level/plumb verification on all walls and ceiling grid
4
Photo Documentation
Photograph all work before it gets covered by the next phase
SSOT Version: --
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