Acoustic Panel Fabrication

On-Site DIY Fabrication Guide for Acoustic Treatments

Type C — Construction Guide · Acoustically Critical [AC] · 14 absorption + 2 QRD = 16 installed · 12 bass traps + 1 soffit · 3 ceiling clouds · 10 125Hz membrane traps · Order 16 absorption panels (10% waste buffer)

Overview

All acoustic treatment panels, bass traps, and QRD diffusers for the MediaVerse Studio Complex are fabricated on-site using readily available materials. This guide covers the construction method for each treatment type, from frame building through fabric wrapping and mounting. All treatments must be installed before commissioning tests (Phase 10).

Prerequisites: All room construction complete (Phases 1–9). Walls finished and painted. Ceiling tiles installed. French cleat mounting positions marked on walls.

Quantities Summary

Production Schedule

Treatment Counts by Type

TypeInstalledOrder / BuildBuffer
Absorption panels (1200 × 600 mm)141610% waste buffer
QRD diffusers (800 × 800 mm)22No spare (custom build)
Bass traps (full-height VO+CR / 400–600mm superchunk Video/Podcast; + 1 Control soffit)13141 spare
125Hz membrane traps (1200 × 600 mm)1011VO 3 + Control 3 + Video/Podcast 4
Ceiling clouds33VO 28% + Control 28% + Video/Podcast 28%
Total installed treatments14 + 2 + 13 + 10 + 314 absorption + 2 QRD = 16, plus 13 bass traps + 3 clouds + 10 membrane traps

Distribution by Room

RoomPanelsBass Traps125Hz MembraneQRDCeiling CloudNotes
VO Live (B304)53 (full-height)3028%+ manual curtain (not DIY) · vinyl floor
Control Room (B311)33 (full-height) + 1 soffit3228%First-reflection panels on side walls · carpet [AC]
Video/Podcast (B312-1)66 superchunk (400–600mm)4028%NE curtain backdrop (multi-colour) · perimeter bass soffit · in-shot rug · COL-W wrap · vinyl
TOTAL INSTALLED1412 + 1 soffit1023 clouds14 absorption + 2 QRD = 16 installed

Treatment count logic (MediaVerse S3 / acoustics5): 14 absorption panels (5 VO + 3 CR + 6 Video/Podcast — the NE multi-colour curtain backdrop now carries video mid/high) + 2 QRD diffusers = 16 treatments installed. Order 16 absorption panels to cover 10% waste buffer. Bass traps: 12 (VO 3 + CR 3 + Video/Podcast 6 superchunk 400–600 mm) + 1 Control soffit trap (NE corner, above D3), order 14. Video/Podcast also gets a deep perimeter bass soffit (the MEP bulkhead built as a bass device). 125Hz membrane traps: 10 (VO 3 + Control 3 + Video/Podcast 4). Ceiling clouds: 3 (VO 28%, Control 28%, Video/Podcast 28%).

Absorption Panels (Build 16)

Standard Absorption Panel

Finished Dimensions

ParameterValue
Outer frame size1200 × 600 mm
Frame depth50 mm
Frame material25 × 50 mm pine or poplar
CoreRockwool RWA45, 50 mm thick
Core fittingFriction-fit into frame (no adhesive needed)
FabricAcoustically transparent, Class A fire-rated
MountingFrench cleat system

Frame Construction

  1. Cut 25 × 50 mm lumber to length: 2× 1200 mm rails + 2× 550 mm stiles (600 − 2×25 = 550)
  2. Assemble with butt joints — glue + 2× screws per corner (pre-drill to prevent splitting)
  3. Check frame is square: measure diagonals, must match within 2 mm
  4. Sand all edges smooth (120 grit) — any sharp edges will push through fabric

Core Installation

  1. Cut Rockwool RWA45 to 1195 × 595 mm (5 mm undersize for easy fit)
  2. Use a sharp utility knife and straight edge — score and snap for clean cuts
  3. Friction-fit into frame — the slight compression holds the panel in place
  4. If panel is loose, add a strip of scrap wood behind as a retainer
Handling Rockwool: Always wear gloves, long sleeves, and a dust mask when cutting mineral wool. Work outdoors or in a well-ventilated area. Fibers are an irritant.

Fabric Wrapping

  1. Cut fabric to 1400 × 800 mm (100 mm wrap allowance on each side)
  2. Lay fabric face-down on clean surface, place panel face-down on fabric
  3. Pull fabric taut over one long edge, staple to rear of frame every 50 mm
  4. Pull opposite long edge taut, staple — fabric should be smooth with no wrinkles
  5. Fold short edges: hospital corners (like wrapping a gift), staple to rear
  6. Trim excess fabric
Fabric test: Hold fabric up to a bright light and blow through it. If you can feel air pass easily, it is acoustically transparent. If light is significantly blocked, the fabric is too dense and will reflect sound instead of allowing it to pass through to the absorber. [AC]
Do NOT: Use adhesive on the front face of the fabric — it can block pores and reduce acoustic transparency. Do NOT use canvas, denim, or other tightly woven fabrics. Do NOT stretch fabric so tight it compresses the Rockwool — moderate tension only.

Mounting: French Cleat System

  1. Cut aluminum or plywood cleat strip: 500 mm long, rip at 45° bevel
  2. Screw one half to the rear of the panel frame (bevel pointing down and out)
  3. Screw the mating half to the wall (bevel pointing up and out), level
  4. Hang panel by hooking the two beveled edges together
  5. Panel should hang flush and level, easy to remove for inspection or replacement

Bass Traps (Build 14 — 13 installed + 1 spare; full-height VO+CR / 400–600mm superchunk Video/Podcast)

Corner Bass Trap

Specifications

ParameterValue
Core materialRockwool RWA45, 150 mm thick
HeightFloor-to-ceiling: 275 cm
Width / depth (corner placement)300 mm face (VO/Control full-height); 400–600 mm superchunk (Video/Podcast)
FrameL-shaped pine bracket, secured to wall studs
FabricSame acoustically transparent fabric as absorption panels

Frame Construction

  1. Cut 2× vertical 25 × 50 mm pine battens to 275 cm (ceiling height)
  2. Screw battens to wall studs at 300 mm from corner on each wall face
  3. Add horizontal cross-members every 90 cm for fabric attachment points
  4. The battens form an L-shape that holds the Rockwool in the corner

Core Installation

  1. Stack Rockwool RWA45 150 mm slabs vertically in the corner space
  2. Start from floor, stack to ceiling — friction-fit between battens and walls
  3. Ensure no gaps between slabs — stagger joints if using multiple layers

Fabric Wrapping

  1. Staple fabric to the two vertical battens, wrapping the exposed face of the trap
  2. Pull taut but not tight enough to compress the Rockwool significantly
  3. Fold and staple top and bottom edges cleanly

Placement Schedule

RoomCornersCount
VO Live (B304)3 corners (SW blocked by D3/OW-1)3
Control Room (B311)3 corners + 1 soffit trap (NE corner, above D3)4
Video/Podcast (B312-1)6 DEEP superchunk (corners + span)6
Installed total13
Why 150 mm thickness: Bass traps need significantly more depth than mid/high absorbers to be effective at low frequencies. The 150 mm Rockwool provides useful absorption down to approximately 100 Hz in corner placement, where room modes are strongest. [AC]
Do NOT: Use 50 mm Rockwool for bass traps — it will not absorb below ~500 Hz. Do NOT leave gaps between Rockwool slabs. Do NOT skip any designated corner — untreated corners create uneven bass response.

QRD Diffusers (Build 2)

Quadratic Residue Diffuser (N=7)

Specifications

ParameterValue
Overall size800 × 800 × 120 mm
Diffuser orderN = 7 (7-well QRD)
Well count7 wells per period
Divider material18 mm MDF
Back panel18 mm MDF
FinishPaint or fabric-wrap exposed face

QRD Sequence (N=7)

The quadratic residue sequence for N=7 determines the depth of each well. The sequence is calculated as n² mod 7:

Well #nn² mod 7Depth (mm)
1000.0
21117.1
32468.6
43234.3
54234.3
65468.6
76117.1

Unit depth = 17.1 mm (depth per sequence unit). Maximum well depth = 4 × 17.1 = 68.6 mm. Total diffuser depth including back panel = 68.6 + 18 (back) + 18 (divider stock extending behind) ≈ 120 mm overall.

Construction Steps

  1. Cut back panel: 800 × 800 mm from 18 mm MDF
  2. Cut 8 divider strips: 800 mm tall × 120 mm deep × 18 mm thick (MDF)
  3. Mark divider positions on back panel: 7 wells, each approximately 97 mm wide (800 ÷ 7 ≈ 114 mm per well, minus 18 mm per divider)
  4. Glue and pin-nail dividers to back panel at marked positions
  5. Cut well depth spacers: for each well, cut a block of MDF to the required depth from the sequence table above
  6. Glue spacer blocks to the back panel inside each well (the spacer fills the well from the back to the correct depth)
  7. Sand all edges smooth
  8. Finish: paint with latex paint (any color) or wrap the front face with fabric
Precision matters: QRD performance depends on accurate well depths. Measure and cut spacers carefully. A table saw with a stop block ensures consistent cuts. [AC]

Placement Schedule

RoomPositionCount
Control Room (B311)Rear wall (behind listening position)2
Purpose: QRD diffusers scatter reflected sound evenly across a wide angle rather than absorbing it. In the Control Room, rear-wall diffusers prevent strong late reflections from coloring the stereo image while preserving the room’s sense of space. [AC]
Do NOT: Place diffusers at first-reflection points (use absorption panels there). Do NOT orient diffusers with wells running horizontally — wells must be vertical for proper frequency-dependent scattering. Do NOT paint the inside of wells with thick, textured paint — it changes the effective well depth.

Materials List

Bill of Materials — All Treatments

Rockwool

ProductThicknessQuantityUsed For
Rockwool RWA4550 mm16 sheets (1200 × 600 mm)Absorption panels (1 sheet per panel, order 16 = 10% waste buffer)
Rockwool RWA45150 mmnet face area TBC (14 traps; Video/Podcast superchunks 400–600 mm need extra fill)Bass traps (order 14 = 13 installed + 1 spare) — recompute volume for deep superchunks
4mm plywood + RWA45 50mm1200 × 600 mm11 units (100mm sealed cavity)125Hz membrane traps (order 11 = 10 installed + 1 spare), f0≈123Hz

Timber

MaterialDimensionsQuantityUsed For
Pine or poplar25 × 50 mm~115 m totalPanel frames (16 panels × ~3.5 m each) + bass trap battens

MDF

MaterialThicknessQuantityUsed For
MDF board18 mm~2 sheets (2440 × 1220 mm)QRD diffuser back panels, dividers, and spacers

Fabric & Hardware

ItemQuantityNotes
Acoustically transparent fabric, Class A fire-rated~40 m² (recompute for superchunks)Panels (16) + bass traps (14) + membrane traps (10) with wrap overhead
T50 staples (10 mm)2 boxes (~5000)Fabric attachment
Wood screws (35 mm)1 box (~200)Frame assembly
French cleat strips (aluminum or plywood)31 pairsPanel mounting (1 pair per panel, matches order count of 31)
Wood glue (PVA)1 literFrame joints
Latex paint (for QRD finish)1 literOptional — or fabric-wrap

Room Placement Guide

Installation Positions

VO Live (B304) — 5 panels, 3 bass traps

  • 3× bass traps: 3 room corners (SW blocked by D3/OW-1), floor-to-ceiling [AC]
  • 5× absorption panels: distributed on walls at ear height (center of panel at 130 cm AFF)
  • + manual curtain: 450 g/m² velour on ceiling C-rail (not DIY — separate procurement)
  • + ceiling cloud (28% coverage) · vinyl floor

Control Room (B311) — 3 panels, 3 corner + 1 soffit trap, 2 QRD

  • 3× corner bass traps + 1 soffit trap (NE corner, above D3), floor-to-ceiling [AC]
  • 3× absorption panels: first-reflection points on left and right side walls + rear wall [AC]
  • 2× QRD diffusers: rear wall (behind listening position), centered vertically [AC]
  • + ceiling cloud (28% coverage) · carpet floor
Finding first-reflection points: Sit at the listening position (1.54 m from front wall). Have an assistant slide a mirror along the side wall at tweeter height. The point where you can see the monitor tweeter in the mirror is the first-reflection point. Mount the absorption panel centered on that point. [AC]

Video/Podcast (B312-1) — 6 panels, 6 superchunk bass traps, 0 QRD

  • 6× absorption panels: distributed on the south, west and east-south walls (not clustered, and clear of the curtain zone — north wall + east north-half)
  • 6× DEEP superchunk bass traps (400–600 mm): SE + SW wall corners + 4 at COL-W re-entrant angles (NOT NW — the north wall is curtain), floor-to-ceiling [AC]
  • + deep perimeter bass soffit (the MEP bulkhead built as a real bass device: ≥300 mm mineral-wool fill + sealed cavity) [AC]
  • + NE multi-colour curtain backdrop (N wall + E north-half, motorised track hung from the structural slab on neoprene isolation hangers, chroma-green / white / black molton / mid-grey velour + vinyl floor-sweep)
  • + ceiling cloud (28% coverage) · in-shot area rug (≈6 m²) · isolated Unistrut lighting pipe grid · COL-W free-standing wrap · vinyl floor
Note: Video/Podcast absorbed the former Editing footprint and now has a HIGH 3.40 m ceiling — superchunk depths and cloud coverage account for the larger volume. [AC]

Safety Notes

Workshop Safety

Personal Protective Equipment

  • Rockwool handling: Gloves, long sleeves, safety glasses, P2/N95 dust mask
  • MDF cutting: P2/N95 dust mask (MDF dust contains formaldehyde resins), safety glasses, ear protection
  • Staple gun: Safety glasses, keep fingers clear of staple path
  • Power tools: All standard workshop safety practices

Fire Safety

  • All fabric must be Class A fire-rated — verify certification before purchase
  • Rockwool RWA45 is non-combustible (Euroclass A1) — no fire risk from the core
  • MDF is combustible — do not place QRD diffusers near heat sources
  • Keep fire extinguisher accessible during fabrication

QC Checklist

Fabrication & Installation Verification

Per-Panel Checks (all 31)

  • Frame square: diagonals match within 2 mm
  • Rockwool fills frame completely, no gaps at edges
  • Fabric taut, no wrinkles or sagging
  • Fabric acoustically transparent (light/air test passed) [AC]
  • French cleat securely attached to frame and wall
  • Panel hangs level and flush to wall

Per-Bass-Trap Checks (all 14)

  • 150 mm Rockwool fills corner completely, floor to ceiling [AC]
  • No gaps between stacked Rockwool slabs
  • Battens secured to wall studs (not just drywall)
  • Fabric taut and neatly finished at top and bottom

Per-QRD Checks (all 2)

  • Well depths match sequence table within 1 mm [AC]
  • All 7 wells clear and unobstructed
  • Wells oriented vertically [AC]
  • Mounted securely to wall (heavy — use appropriate anchors)

Installation Totals (MediaVerse S3 / acoustics5)

  • Absorption panels installed: 14 (5 VO + 3 CR + 6 Video/Podcast) [HP]
  • QRD diffusers installed: 2 (2 CR) [HP]
  • Panels installed total: 28 + 2 = 30 [HP]
  • Order count (absorption only): 16 (10% waste buffer) [HP]
  • Bass traps installed: 12 + 1 soffit · 3 ceiling clouds · Order: 14 (1 spare) · 125Hz membrane traps: 10 [HP]
  • Control Room: first-reflection panels at mirror-verified positions [AC]
Acceptance: Acoustic treatment installation is accepted when all counts match the schedule, all QC items pass, and the installation is ready for RT60 and NC commissioning tests (Phase 10).