Lionsgate Studios

Title: Lionsgate Studios

Award Category: Roofing

Project Address/Location

28 Wells Ave

Yonkers, NY 10701
United States

Submitted By: Laura Parker

Company Info

Georgia-Pacific Building Products: DensDeck® Roof Board

133 Peachtree ST Ne

Atlanta, Ga 30303
United States

4043862909

[email protected]

Project Description and Background: The 90 Warburton sound stage building is part of the Lionsgate Studios property in Yonkers, NY. The studio will be home to episodic and motion picture productions beginning in 2024. Once production began in the first studio, the recording engineers identified a serious problem that needed to be solved in the design and construction of this project. The location of the first studio building is adjacent to the Yonkers train station. With over 100 trains passing daily, exterior sound levels were very high and were able to be picked up by the microphones during recording.

Scope: To keep the unwanted exterior environmental noise outside where it belongs a plan was established with the assistance of ROCKWOOL, a key manufacturing partner for this project. ROCKWOOL has a solid reputation as a manufacturer of stone wool insulation products with sound absorbing properties. This isn’t your typical single-ply polyiso roof. Lionsgate required a unique plan to accommodate the loading for the large amount of materials required in this roof assembly. The ROCKWOOL Building Science team used the results from their highest performing assembly to model a further improved assembly using INSUL. The resulting STC of 55 is a very robust rating which exceeded the client’s demanding requirements for this challenging site. With a complex adhered hybrid assembly like this, it can be a real challenge to have everything show up on time and in the proper sequence so that the roof could be loaded properly, and work could commence without delay. Coordination with multiple manufacturers was absolutely critical. Adding to the complexity the location is on a busy urban street requiring additional safety planning and execution.

Solution: Measuring over ten and a half inches deep, the full assembly is an assembly of roofing products. Together they provide the sound blocking properties required to reduce outside inside sound transmission. All of the material for the project were sourced through Beacon Building Products, a Carlisle distributor, and covered by a Carlisle 20-year warranty. The roof assembly included Georgia Pacific’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 attached and adhered. The PARS - Partially Adhered Roof System is separated into two sections between the top two layers of DensDeck® Prime. The layers of the lower section are fastened using 12-inch 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. To increase the overall R-Value of the assembly a layer of 2-inch Carlisle InsulBase was added. The ROCKWOOL Building Science team evaluated the performance of the innovative hybrid roof system using THERM and estimated a total R-value of 38.

Value: In the first studio built, minimizing exterior sound transmission required an under-deck solution inside the building envelope to remediate the condition, after the original roof was completed. On this project we mobilized a team of manufacturers 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 55, that will keep exterior noise outside, and protect the building envelope. Our crew was able to draw on experience installing all the individual components to complete the innovative assembly. When you watch a Lionsgate film recorded in Yonkers, you’ll only hear the sounds that were meant to be, heard inside the studio thanks to this roof system.

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