Quiet on the set.

CASE STUDY: Silvercup Studios in New York 

The only noise a film producer wants to hear coming from outside the studio is the sound of silence - and when "outside" is New York City, that's a big order. For Silvercup Studios, a bustling film production complex, the varied assortment of doors servicing its 12 massive sound stages adds to the challenge of blocking out unwelcome city noise as well as extraneous interior sounds.

Since opening the first of those stages in 1983, Silvercup has provided the exceptional sound control levels that its business demands by using door assemblies that include highly specialized acoustic gaskets. However, even the most durable assemblies take a beating in this high-traffic, high-impact production environment. Silvercup has embarked upon a major rehabilitation and upgrade program that incorporates the most recent technological advances in acoustic door seals to achieve optimal cost-effective customized solutions for each door assembly.

It is not uncommon for all of Silvercup's production stages to be in use at the same time. In part, due to the advantages of its New York City location, the facility attracts a regular clientele of film and television production companies. Silvercup has also become the leading commercial production center in the country and is home to many national and regional advertising campaigns such as Wendy's, Macy's and Red Lobster. Another powerful draw is the full array of services provided by the company's principals, Alan and Stuart Suna. In addition to support services such as lighting and grip equipment rentals, Silvercup's 250,000 sq. ft. plant includes office space available for client use. The new Q2 home-shopping cable network is a tenant with both administrative and broadcasting operations based at Silvercup.

The demands of these uses in both their range and volume were fully anticipated in the original design recommendations by Silvercup's acoustical consultant, Robert A. Hansen Associates. To ensure no interference with recording in the studios, the firm's president, Robert Hansen, specified acoustic partitions and roof materials as well as doors based on his analysis of intrusive outdoor noise from street traffic, subways, elevated trains and aircraft. His design goals also reflected maximum acceptable air distribution and floor vibration sound levels.

In his recommendations for all of Silvercup's sound control doors, Hansen specified acoustic door seals designed and manufactured by Zero International. Says Hansen, "I have specified Zero products for years in part for the company's exceptional responsiveness and personal service. To provide the best service to my clients, I need to be able to depend on the companies I recommend."

Personal service is playing an especially important role in Silvercup's current facility upgrade program, which is being conducted under the supervision of architect consultant Peter Mickle. Direct assistance in the door-by-door review and enhancement of the sound seals is being provided by Zero's installation division - which was established specifically because of the need for precision in installations of some of the company's specialized systems.

Although the sound doors throughout the complex vary widely in dimensions and construction, the door configuration in Studio 10 is typical of Silvercup's sound stage entranceways - and the recently-completed improvements there are also representative, according to Mickle. For pedestrian and routine equipment traffic, this studio has several "sound locks" each consisting of a pair of gasketed doors separated by a vestibule of several feet. Access for mobile production trailers and other large equipment - not to mention buffalo, giraffes and elephants - is through oversized double doors at opposite ends of the 113[feet] x 70[feet] space.

Where the space between doors in the sound locks serves to deaden noise from the outside, the same effect is achieved for a pair of 5-1/2[feet] x 12[feet] equipment doors in Studio 10 by using multiple sets of continuous seals, which the 6[inches] thickness of these doors makes possible. And double seals for additional sound insulation remain standard equipment on the sound-lock doors in accordance with Hansen Associate's original designs.

The answer to optimizing the performance of Silvercup's door sealing systems is found with compression seals and adjustable gasketing. Combinations of these features are available in gaskets such as Zero's Model #475 for head and jamb protection, which is being installed to update one of the existing seals on the sound lock doors. The specially-designed neoprene in this gasket conforms to irregularities in the door or frame. In addition, the gasket incorporates a neoprene bulb with a protruding rubber "finger" that compensates for misalignment in the door - as the finger compresses against the rubber bulb in the gasket, it is also compressed by the door itself. A snap-on cover provides protection from impact.

Compression seals are also essential in the operation of Zero's automatic door bottoms, which are present in various models on virtually all of Silvercup's sound doors. The advanced technology common to these components utilizes a concealed fiat spring mechanism which activates when the door is closed, lowering a neoprene seal insert firmly against the floor or saddle. Triggered by a protruding, hinge-side "plunger" that is compressed by the frame as the door closes, the spring activates, dropping the seal in a scissors-like motion from the hinge side and adjusting to the floor from a pivoting point. This motion ensures a smooth drop without drag and a tight seal, even on an uneven floor. As the neoprene seal compresses, it forms a tight, secure bond against the saddle or floor. The seal retracts automatically as the door is opened.

For the sound-lock doors in Studio 10, High Sound automatic door bottoms (Model #367) have been surface-mounted to provide a double seal with existing mortised door bottom gaskets. This gasket includes double neoprene seals to minimize sound penetration, and lock-side magnets and a steel plate which amplify the action of the spring mechanism to ensure a controlled, uniform drop and seal.

Other specialized gaskets are being judiciously employed to address the special needs and quirks found in numerous doors throughout Silvercup's various sound stages. Zero is also assisting in solving acoustical challenges with new construction. Installation of gaskets has recently been completed for a new pair of double doors connecting an actively-used storage area with a corridor that opens on to several stages. Designated as an emergency exit which requires both doors to be active at once, this doorway required Zero's "deluxe" sound control system, including a special-purpose magnetized gasket for sealing the gap at the meeting stile.

For Peter Mickle, Zero's attention to the unique conditions and parameters of each opening has added the greatest value to Silvercup's investments in acoustical improvements. He notes for example, "Replacing old seals sometimes leaves us with very little space between the door frame and existing hardware, and moving the assembly can be both difficult and costly." Mickle also has to contend routinely with unusual hardware needs such as heavy duty padlocks mounted on exterior sound-lock doors, which can interfere with the continuity of acoustic seals.

"Through its installation division, Zero is working with us to develop solutions to each of these problems. And the ability to provide the sound control levels we need without the expense of replacing existing doors is the best solution of all," he concludes.