In 2021, Nation’s Roof just completed a studio roof for Lionsgate near Yonkers, NY. Once production began in the studio, the recording engineers identified a serious problem that needed to be solved in the design and construction of the studio. The studio was adjacent to the Yonkers train station with over 100 trains passing daily. The exterior sound levels were so high and that the sound was being picked up by the microphones inside of the studio.
When they were approached with an opportunity again to create another stage building a few blocks away from the original, they knew they had an opportunity to improve the soundproofing. They mobilized a team of manufacturers including Georgia-Pacific, Carlisle, Rockwool, and Beacon to solve the sound problem in the roof assembly itself before installation. The team delivered the client a strong, durable roof with a robust STC rating of 55, that will help keep exterior noise outside, and protect the building envelope.
There are three fundamentals to reducing sound transmission through a roof assembly MASS, ABSORPTION & DECOUPLING.
To keep the unwanted exterior environmental noise outside where it belongs a plan was established with the assistance of ROCKWOOL. The ROCKWOOL Building Science team used the results from their highest performing assembly to model a further improved assembly using INSUL. The resulting STC rating of 55 is a very robust rating which exceeded the client’s demanding requirements
for this challenging site.
Measuring over ten and a half inches deep, the full assembly is an array of roofing products. Together they provide the sound blocking properties required to reduce outside inside sound transmission.
The roof assembly included Georgia-Pacifi c’s DensDeck® products. Directly over
the roof deck, three layers of DensDeck Roof Board not only provide additional
mass but also serve as a thermal barrier. Two layers of DensDeck® Prime board
protect the assembly as a double coverboard — both mechanically attached and
adhered. While ROCKWOOL provided extra sound absorption, DensDeck and
Rockwool were able to provide a superior sound proofi ng system suitable for the
studio’s needs.
The Partially Adhered Roof System (PARS) is separated into two sections between
the top two layers of DensDeck Prime. The layers of the lower section are fastened
using 12” Carlisle Insulfast™ fasteners with 3” insulation plates. The upper layer of
DensDeck Prime is adhered using Carlisle Flexible FAST™ Adhesive which provides
the decoupling – reducing sound transmission through the assembly.
The Lionsgate Studio on 90 Warburton opened in the beginning of 2024. The studio
will now be home to both episodic and motion picture productions without outside
distraction thanks to the collaboration between all four manufacturers. In 2024, the
assembly won the NRCA’s Gold Circle Award for Innovative Solutions demonstrating
the power of teamwork. When you watch a Lionsgate fi lm recorded in Yonkers, you’ll
only hear the sounds that were meant to be heard inside the studio thanks to this
roof system.