FINALLY!! The saga begins

Posted: Mon May 05, 2008 8:38 pm

Rod,

Been doing a BUNCH of political rally gigs and am pretty wiped out, but I'll try to start on the mason's and masonry supply houses Tuesday morning.

Posted: Wed May 07, 2008 5:41 pm

I have called every single roofing, masonry and plumbing supply house in NC and 7 masonry supply houses in Virginia... NO ONE has any roll lead flashing!

The ONLY lead I can find are the 3lb-30x30 sheets at roofing supply houses.

If there is ANYONE within 3 states of NC that has access to lead flashing, and you would be willing to post or email me the source, I'd greatly appreciate it.

Thanx!

Posted: Thu May 08, 2008 10:55 am

MadMax wrote:

If there is ANYONE within 3 states of NC that has access to lead flashing, and you would be willing to post or email me the source, I'd greatly appreciate it.

I'm glad you wrote three states.Mayco Industries in Alabama makes the stuff. Contact info is on their website.

Good luck. Great build and great blog.

Andre

Posted: Thu May 08, 2008 6:46 pm

Andre,

I'll be calling them first thing in the morning!

THANK YOU!!!

Max

Posted: Thu May 08, 2008 7:35 pm

For some reason, I feel a tiny bit of how happy you must be to find this out.

Hope it works for you.

Posted: Thu May 08, 2008 7:49 pm

Hey, Alabama has something for everybody!

Posted: Thu May 08, 2008 7:56 pm

Even me? Actually our minister went on holiday to Alabama, with his family. No idea where to though.

Posted: Fri May 09, 2008 9:33 am

WOOOOOO HOOOOOOOOOO!!!!!

Found some lead sheeting!

Blue Ridge X-Ray
4361 Federal Drive, Suite 160
Greensboro, NC

1/32" Sheet lead=$475/Roll x 2 Rolls

Also contacted SPI in Greensboro!
Getting a quote for 1" and 4" mineral wool as well as fire rated caulk and putty pads.

Reid Black
Speciality Products and Insulation
207A Creek Ridge Road
Greensboro, NC 27406

Today is a GOOD day!

Posted: Sat May 10, 2008 6:16 am

Well,

The lead is in the studio... that's about all it is... GREAT GOOGLY MOOGLY! That stuff will wear ya out!

The Hallway/Iso floor is stained! It looks pretty good, but it does need a second coat.

I've GOT to get the HVAC platform done TODAY! I've got a gig tonight and we're heading to my Mother-In-Law's for Mother's Day tomorrow. So, you can guess I'm a bit pressed for time.

I hope I got time for some pix this afternoon before I bail out.

Posted: Mon May 12, 2008 8:53 pm

OOF!

The exterior door now has two layers of lead contact cemented and screwed to the inside face.

That door is starting to get pretty heavy!

I'll try to get pix tomorrow morning, along with the HVAC and the the air handler's getting here!

Rod, I got quotes back from SPI...

Just asking for the sake of asking.... is it safe to substitute 8 lb/sf mineral wool for 703? I'm guessing not, but the 703 is $.40/sf and the 8lb is $.32

Fire board is $.22/sf (1.5x16x48).. for the fire breaks.

Posted: Tue May 13, 2008 7:01 pm

Lets start with the exterior loading door...

I started yesterday by contact cementing the 2nd layer of lead sheeting up.

I screwed that down w/self-taping screws.

Next, I cut a sheet of 3/4" MDF to relative size and used a 1/2" rounover bit to shape the edge, so I'd be able to get a nice solid bead of caulk in the joint between the door seal and the MDF.

Next, I put up the Zero Industries door seal.

Here's the first look at the floor stain.

This is the Hall/Iso view leading from the Tracking Room to the Lounge. It looks OK, but I think I got a bit much red brick tint to it. It needs a second coat, and when I do that, I'll hit it with more of the brownish tint and the yellowish tint.

Whatcha' think??? Send me a comment if you want...

The base signal box and a roughed in electrical in the Hall/Iso.

Electrical box in the Control Room... (Exciting stuff, huh?)

These next couple of shots ARE exciting!!! (to me anyway)

The HVAC contractor showed up and brought along some goodies!

This big boy is the 3 ton unit for the Control Room and the Server Room!

This cute little 2 ton fella' is for the rest of the facility!

One 2 bay air return bay for the Tracking Room is done!.... (I had to clear a couple of braces.)

The 2nd 2 bay return unit goes here. We will also pull the freon lines in through the space in this cavity.

All the lines will be collared, sleeved and suspended so as not to squeek and rattle when the compressor kicks on and off.

We actually ran into some major space issues when we were laying out everything.

This is where stuff will bite you on the arse REAL hard and REAL bad if you aren't lucky... or at least organized enough to think through major issues.

This issue I'm referring to, goes ALL the way back to the beginning of the build when I found out that there was an 8" block drop, from the tracking room end of the building, dropping to the lounge end of the building.

The question was raised as to whether to hold the low side or hold the high side. We elected to hold the high side.

I knew full well, that this 8" was going to come out of the interstitial space between the top of the Control Room and the bottom of the existing ceiling truss. I was just hoping it would still be enough to get all the HVAC in the space... well...

It can't sit on top of the Control Room. We miss being able to get everything in there by a hard 4".

As God's grace is evidently shining on me, Rod and I had elected to make the Hall/Iso a standard 8' ceiling height with a flat ceiling. We have just enough room to put both of the air handling units above the Hallway!

The ducting is gonna all have to change, but I think it's going to be OK.

We're going to have to use more flex duct, but we can still keep the same sizes as originally called for... a couple will have to be larger, but larger and slower air flow is quieter air flow.

Thank goodness Billy and this crew have done 2 television stations. They understand the need for total quiet.

They worked through all the ducts, boxes and and damper schedules. Then they packed it up and headed to their shop to make the custom pieces.

William, the lead installer is about as picky as they come. They guy knows his stuff. He thinks he'll have the custom work done by Thursday. So, they'll be here Thursday morning to start installing the returns.

Posted: Wed May 14, 2008 11:24 am

MadMax wrote:

Just asking for the sake of asking.... is it safe to substitute 8 lb/sf mineral wool for 703? I'm guessing not, but the 703 is $.40/sf and the 8lb is $.32

Sorry buddy - but you no can do - there is a world of difference between the 703 and 8psf rockwool.

Rod

Posted: Wed May 14, 2008 12:07 pm

Rod Gervais wrote:

MadMax wrote:

Just asking for the sake of asking.... is it safe to substitute 8 lb/sf mineral wool for 703? I'm guessing not, but the 703 is $.40/sf and the 8lb is $.32

Sorry buddy - but you no can do - there is a world of difference between the 703 and 8psf rockwool.

Rod

Rod,

No problem! At least the SPI price is reasonable compared to some of the pricing I've seen! You know I had to ask, right? ($.08 s/f is some cash to put in the green glue!)

+2000 sf of 703 it is... (heheheheh) Reid's gonna LOVE me!

What about 48" Super Chunk Traps in the CR corners... safe to use the 8psf there isn't it?

I picked up what I hope is enough of the 1.5" 8psf to do the fire breaks... Time to go get itchy!... and I WILL document this stage. If nothing else, for proof to the inspectors that the barriers were indeed filled correctly!

Pix a bit later!

Posted: Thu May 15, 2008 6:40 pm

I took pix, but left the camera in the studio... and it's raining... grrrrrrr.

The mineral wool is going pretty slow. I'm cutting a few panels up and then stuffing them in the gaps.

After a few feet, I fight the fire caulk.

That stuff is a ROYAL PITA!

It's kinda' like trying to spread runny peanut butter on bread that it won't stick to! You compound the problem when you work on the bottom side of the joints.

Maybe I'll figure out a faster way to apply it... I sure hope so! Because if I don't... this is gonna take DAYS to get done.

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