by Chin-Chin Chen, Peter Roubal, Ann Warde, and Brad Wilhelmson
The design process began with Professor Wyatt supplying each member of the class with a handout from the Americans with Disabilities Act (1992) highlighting the Acts specifications pertinent to a design project such as the class was going to undertake. It was stressed that not only was handicap accessibility an ideal of the project but it was also the law, and any designs class members submitted had to comply with ADA specifications. With that in mind the class discussed ideas, and in particular, concerns about the future design and types of uses of Studio E.
In the past Studio E was designated solely as editing studio where composers would remix and re-edit pieces after the initial recording had been done in another studio. As such, the studio saw particularly heavy use toward the end of semesters when projects were due and/or time was running out for the semester. With the current interest being to re-design Studio E into a complete recording and editing workstation, several issues arose: A.) Would the studio be able to handle the additional demand sure to be generated by its increased capabilities? B.) How was the class going to be able to fit the extra equipment needed into an already cramped working space while at the same time increasing its level of efficiency for using that space? and C.) What was the best equipment and design to do the job?
Class members were asked to start working on designs and submitting them for discussion immediately. As much review and revision of designs would have to take place in a short period of time in order for the class, Professor Wyatt assisted the class in reaching a consensus and finalized design approach.
It was decided that the best approach would be to keep everything along one wall with the operator in the middle and all equipment within arms reach. This would keep the floor space clear allowing for proper wheelchair access and turning radius. Maximizing clear floor space also served a second purpose. Studio E would also serve as a classroom where Professor Wyatt or other faculty member would have to bring in a class of 15-20 students to watch him demonstrate studio techniques in a "hands on" manner. It was important that everyone be able to see what was going on. Finally a "wish list" of audio equipment was compiled. This list included existing equipment already in Studio E that would be reinstalled after renovation such as: DAT and cassette recorders, reel-to-reel tape decks, JBL monitor speakers, and the computer. Also on the list were items to be replaced immediately such as the mixer and the power amp, items to be replaced in the future: a larger more powerful computer, phasing out of the reel-to-reel decks, more reliable DAT recorders; and items to be added in the future as finances permitted: two ADAT recorders, a multi-timbral synthesizer, various rack-mountable tone generators, the KYMA sound synthesis system new computer programs for digital editing, and near-field monitors.
As was stated earlier, the ADA specifications had to be complied with. The next step after deciding on a general design was to calculate exact specifications/dimensions and make sure that they were in compliance with ADA code. Regarding clear floor space, the ADA requires at least 60" of clear floor space for a wheelchair to make a 180 degree turn. This required no revision of plans as there was more than enough clear floor space. The next issue did cause several problems. The ADA makes two requirements for what are called "Forward Reach" and "High Forward Reach" (see ADA reach diagram below).
In order to locate all equipment on one wall it necessarily involved building shelves to put certain components up out of the way. When it was realized that this caused the design to violate ADA code by exceeding the "High Forward Reach" an alternate location for the reel-to-reel tape decks was suggested. This involved building a low table angled along the East wall in front of the white board. This would also allow easier later removal of the tape decks when they were finally phased out of studio use. A problem soon arose when it was realized (after careful measurements) that the table would not only obstruct access to the white board (necessary for instructional use) but that it severely reduced the number of occupants the studio could hold for observational purposes. Professor Wyatt came up with the solution of locating the decks in existing cabinetry but sinking them partially below the surface level so they would not obstruct access to components already designated for that location.
A second major problem was discovered shortly after construction had begun. Due to the small budget allocated for building materials, industrial grade particle board had to be purchased in many cases when 3/4" plywood was clearly the best choice. This led to insufficient structural strength for the larger table that would have to support a great deal of weight for many years. Again, Professor Wyatt solved the problem by quickly revising the design to accommodate reinforcement by way of 2x4's just under the tabletops on certain pieces of furniture. This subtly increased the size and weight of these pieces which was not desirable, but more importantly it solved the problem and allowed construction to proceed uninterrupted.
Bloodborne Pathogens:
Issues of saftey were also important to consider before we began the construction process. When working with power tools, there is always an inherent danger involved and unless special care is taken, it is possible for people to get hurt. The class took an exam over safety that covered both power tool use and what to do if there was an accident. The test covered material from the following bloodborne pathogen information and power tool safety procedures handouts.
Universal precautions must be observed in order to prevent contact with blood or other potentially infectious substance/materials. All blood or other potentially infectious substance/materials will be considered infectious regardless of the perceived status of any source individual.
HIV (human immunodeficiency virus) and Hepatitis B are BLOODBORNE PATHOGENS (pathogenic microorganisms transmitted by contact with blood or body fluids). HIV attacks and gradually depletes the human immune system. There is no cure for HIV infection. Hepatitis B attacks the liver causing it to inflame and may severely damage the liver leading to cirrhosis and almost certain death from the contamination.
In accordance with the Illinois Department of Labor's (IDOL) adoption of the OSHA Bloodborne Pathogens standard. 29 CFR 1910.1030, the following exposure control procedures are to be utilized.
If any individual injures himself or herself causing any blood or any other body fluid to appear, the injured individual must take every precaution to prevent the body fluid from being transferred to other surfaces or to other individuals. Pressure should be applied to the wound immediately and go to the washroom where the wound area should be washed and then dried with a paper towel (note the paper towel must then go into a plastic biohazard bag for proper disposal). Should garments be penetrated by any body fluid spills, the garments must be removed in the closest washroom and placed in the plastic biohazard bag(s) provided for appropriate disposal (biohazard bags are located on the tool cart).
A First Aid Kit containing bandages is located in the tool cart. Scott Wyatt and Mike Pounds have access to an additional First Aid Kit. The custodial service must be informed immediately so that disinfection procedures for the washroom sink(s) can be accomplished.
Please keep in mind, latex gloves must be used at all times when any other individual comes in contact or anticipates coming into contact with any body fluid spills. Latex gloves are located on the tool cart. Anyone wearing latex gloves who comes in contact with any body fluid spills must not come in contact with any other individual. To do so will spread contamination. Paper towels can be used to absorb any body fluid spill. Place the used paper towels into a plastic biohazard bag for proper disposal. Should garments be penetrated by any body fluid spills, the garments must be removed in the closest washroom and placed in the plastic biohazard bag(s) provided for appropriate disposal. Protective eyeware and a mask or faceshield must be worn when splash or splatter of blood, body fluids or other potentially infectious materials is anticipated.
Any possibly contaminated surface area must be appropriately cleaned with a disinfecting solution (located on the tool cart) and then dried once again with paper towels. Again these towels must be placed into a plastic biohazard bag for proper disposal.
Once the immediate emergency is over, the latex gloves must be carefully removed by pulling them off inside out and then placing them in the plastic biohazard bag(s) provided for appropriate disposal. After removal of latex gloves, the individual must wash his or her hands and any other potentially contaminated skin area immediately or as soon as feasible with disinfecting soap and water for at least 10 seconds. If any individual should incur exposure to their skin or mucous membranes, then those areas must be washed with disinfecting soap and water or flushed with water as appropriate as soon as feasible following contact. If any individual should incur exposure, the incident must be reported to the School of Music administration and McKinley Health Center for post-exposure evaluation.
Upon removing contaminated latex gloves, thoroughly wash your hands with soap and water for at least 10 seconds. Disposable latex gloves are not to be washed or decontaminated for re-use.
No one is allowed to operate a power drill, saw, or router on site without operating with an assistant and following proper power tool operating guidelines listed below. A power sander may be used without an assistant.
All students must purchase eye and ear protective devices and dust masks at the beginning of the semester.
Eye and ear protection must be worn whenever operating any of the following power tools:
It is required that whenever you are performing an operation that creates dust or particles of wood, plastics, etc., that you wear a "Dust Mask".
A first aid kit is located within the tool cart. Be careful - be wise - be sure - be preventative! Contact Scott Wyatt or Mike Pounds immediately concerning all injuries.
The Operator's Role and Assistant's Role:
The operator is the individual holding and operating the power tool. The assistant is an individual who is responsible for assisting with the supporting of the work area, and for guiding the operator when the power tool is engaged. The operator is responsible for acquiring an assistant, supporting all structures involved, informing the assistant exactly what work needs to be done (location, length and direction of cut, location and direction of the drill point, routing, and sanding), and following power tool usage communication procedures. Both the operator and the assistant are responsible for remembering to use eye and ear protective wear and dust mask if necessary.
Power Tool Usage Communication
Procedures:
The operator is responsible for informing the assistant exactly what work needs to be done (location, length and direction of cut, location and direction of the drill point, routing, and sanding). Once the operator has done this, the assistant must either ask questions to avoid any misunderstanding or confirm understanding. Once the operator has received a confirmed understanding from the assistant, the operator must audibly say:
READY (wait for positive acknowledgement from the assistant)
CLEAR (indicating the operator is about to turn ON the power tool. The assistant must be certain to keep his or her hands, arms, feet, and legs at the designated safe distance way from the contact area [a minimum of 8 inches away from the operation location]. Should the assistant see a problem, the assistant must audibly and forcefully say STOP to the operator.)
DONE (upon completion of the operation)
Power Drill:
Safety Practices: When changing a drill bit, be certain that the drill's power cord is disconnected from the AC power source. Be certain to use the chuck key to tighten the teeth of the geared chuck onto the drill bit you have selected. Inspect the positioning of the drill bit to see that the bit is properly aligned and tightened within the chuck. Locate the FORWARD/REVERSE switch and be certain that the switch is set to FORWARD. Locate the motor LOCK-ON switch. Be certain that this switch is OFF. Do not use the motor LOCK-ON feature of the drill. Again, when using any power tool, be certain that the work items are firmly supported, or secured so that it will not shift during the operation to be performed. The drill insertion point must be marked with a marker prior to drilling. Always be sure how deep the drill bit must penetrate before beginning. Make certain that the power cord is well out of the way so it will not interfere with the operating procedure. Prior to drilling, inform the assistant what you plan to do and where the drill will be inserted. The operator must keep a firm grip on the drill with his or her operating hand, and the other hand well away from the drill (designated safe distance = a minimum of 8 inches away from the cut point). The assistant must also keep his or her hands at the designated safe distance. Follow standard operator and assistant procedures and communications: ready, clear, done. Upon completion of your work with the drill, disconnect the power cord and appropriately remove the drill bit. Return the drill bit to its proper storage location.
Power Jig Saw or Sabre Saw:
Safety Practices: When using any power tool, be certain that the work items are firmly supported, or secured so that it will not shift during the operation to be performed. When changing a saw blade, be certain that the saw's power cord is disconnected from the AC power source. Be certain that the blade is correctly seated within the blade holder, and that the blade locking screw is tight. Draw or indicate with masking tape the exact cutting line - including start and stop points. Be certain to work with an assistant. Both the operator and the assistant must wear a dust mask. Follow standard operator and assistant procedures and communications: ready, clear, done. The assistant's role is to support any loose piece while maintaining the designated safe distance for his or her hands, arms, feet, and legs. The operator must make certain that the power cord is well out of the way so it will not interfere with the operating procedure. Start the saw before the blade enters the work and guide it straight along the cutting line. The operator must keep a firm grip on the saw with his or her operating hand, and the other hand well away from the saw (designated safe distance = a minimum of 8 inches away from the cut point). The assistant must also keep his or her hands at the designated safe distance. The operator must be certain that the saw is level, perpendicular to the work area's surface, and that the bottom guide plate comes in direct contact with the work area's surface. Maintain a strong grip on the saw to keep it fromtipping or dropping at the end of the cut. Once the operator has reached the end point of the cut, stop all forward cutting motion and turn OFF the power to the saw PRIOR to removing the saw from the cutting zone. WAIT FOR THE BLADE TO COME TO A COMPLETE STOP before removing the saw from the cutting zone. Upon completion of your work with the saw, disconnect the power cord.
Router:
Safety Practices: When using any power tool, be certain that the work items are firmly supported, or secured so that it will not shift during the operation to be performed. CAUTION: the router bit and shaft turn at an extremely high speed and can cut very fast - severe damage can occur at the blink of an eye. GREAT CAUTION MUST BE TAKEN WHEN WORKING WITH A ROUTER. Router bits should not have to be changed often, and can be left secured in the router. If a router bit must be changed, be certain that the router's power cord is disconnected from the AC power source. Never adjust a router bit or the router unless the power cord is disconnected. Be certain that the bit is correctly seated within the collet/chuck shaft, and that the collet/chuck nut is tightened with the router wrench. Be certain to work with an assistant. Follow standard operator and assistant procedures and communications: ready, clear, done. Both the operator and the assistant must wear a dust mask. The operator must be absolutely certain as to what operation he or she is about to pursue. The assistant's role is to support any loose piece while maintaining the designated safe distance for his or her hands, arms, feet, and legs. The operator must grasp the router with BOTH hands and move the router always from left to right. The assistant must also keep his or her hands approximately 2 feet away from contact point of the router bit. Maintain a strong grip on the router to keep it from tipping or dropping at the end of the cut. Once the operator has reached the end point, stop all forward cutting motion and turn OFF the power to the router PRIOR to removing the router from the cutting zone. WAIT FOR THE BIT ROTATION TO COME TO A COMPLETE STOP before removing the router from the cutting zone. Upon completion of your work with the router, disconnect the power cord.
Power Sander:
Safety Practices: When using any power tool, be certain that the work items are firmly supported, or secured so that it will not shift during the operation to be performed. The use of a sander does not require the use of an assistant, however, there are times in which an assistant would be helpful - be smart! Prior to sanding, determine the grade of sandpaper required for the specific job. Prior to changing the sand paper be certain to disconnect the power cord from the AC power source. When working with a sander, check the condition of the sandpaper from time to time to see if it needs replacing. Always wear a dust mask. Prior to beginning work, be certain that the dust which will be created will not adversely interfere with other work occurring within the same work space. ASK your fellow workers prior to beginning.
Sanding creates much dust. Upon finishing your work, clean up ALL dust from the work area (dust will usually extend as far as 50 feet away from the job site). Even the smallest amount of dust left on the floor surface can be a significant hazard (creating an extremely slippery surface). CLEAN THE ENTIRE AREA WHEN YOU ARE FINISHED!!
During our regular class meeting, Tuesdays 1-3 pm, we worked together on construction and wiring. Construction began in March, and actual wiring (following a period of practice) began in mid-April. We worked in pairs, which allowed familiar ways of working to develop, and which contributed to our safety and efficiency in working. Each pair of students met for at least one additional 2 hour period on either Thursday or Friday afternoon.
At each of the following stages instruction and practice was included along with construction of the actual cabinetry. In addition, due to the small space and the large amount of sawdust generated, time was spent on cleaning the floors at the end of each work session. The construction process included the following stages:
Both Studio E and Studio D were used for construction space, as well as occassionally the hallway connecting them. Generally, preparation involved the installation of several layers of plastic sheets to prevent the carpet in Studio E from becoming damaged. In addition, tools and equipment were organized within the spaces. During the construction process holes developed in the plastic (even though there were 3 layers). These were patched with duct tape - though some damage did occur despite our precautions.
The original design diagrams were used, along with the labeling system given to the lumberyard, to group wood and laminate (formica) pieces that were to be used in constructing each unit. One piece was discovered to have been cut incorrectly, and was redone by the lumber yard.
The corner cabinet surfaces were cut out of larger pre-cut pieces. Other smaller pieces were also cut, including shelves, and 2"x4"s and 1"x1" for structural support. A problem occassionally encountered was crooked cuts (due to inexperience). This was solved by sanding, and ultimately by caulking after the units were completed.
The usual construction process involved marking and drilling holes, applying wood glue, and fastening pieces together with either nails or screws. The nails or screws had to be put on before the glue dried, and in at least one instance this was a problem: because of the shape of the cabinet being constructed, and the inexperience of the builders, the glue dried before screws were inserted, and the corners were crooked. This was solved by hammering apart the glued corners, regluing, and finally inserting screws. Another problem involved the rebuilding of a shelf unit toallow for a continuity of overall design in the studio. Holes were drilled in most of the cabinets to allow for cables to pass through underneath the surfaces. Additional structural support not originally designed was added to all the cabinets.
When the cabinets were completed, all of the corners were sanded to create flush surfaces so that formica could be applied evenly.
Although most of the formica arrived pre-cut, some pieces were cut to fit the smaller and irregularly shaped surfaces. Contact cement was applied to both the cabinet surfaces and the underside of formica pieces. A number of coats were necessary, particularly for the particle board surfaces, which tended to absorb a great deal of glue. When both surfaces had almost dried, one corner was lined up and the formica was applied. Often small strips of wood were placed between the formica and the cabinet surface to allow positioning of the formica since the surfaces bonded on contact.
The pieces of formica were intentionally cut larger than their corresponding cabinet surfaces to allow routing. As with previous construction processes, instruction and practice were included when the router was used. After routing, the edges of all cabinets were filed and sanded to remove burrs.
Black paint was applied (using a roller and brushes) to the interior lower sections and to the undersides of cabinets to seal all unfinished surfaces. White paint was applied to the interior of upper sections, particularly shelving.
Finally, the cabinets were positioned in Studio E. At this time, it became evident that some of the surfaces were not flush with each other. This problem was solved by realigning the assembly of the corner cabinet shelving. In addition, caulking material was applied to create a smooth surface between adjacent cabinets.
Below is the final design of Studio E indicating location of components as well as a listing of all equipment to be installed.
The final design of Studio E (bird's eye view).
The side view (above) and front view (below) of each console.