The last three weekends I've locked myself in the basement, but I feel like I've made a lot of progress. The first 80% of the insulation goes really fast, but all the little cuts and extra things takes just as long if not longer. I'm doing the whole basement at one time (about 1000sf) with 9' walls. I could only find 96" batts so there are a lot of cuts to make. The walls are all done now, (yay!).
I then focused on the theater ceiling, since I need to get channel and osb on before drywall. I wanted to purchase R19 faced, 24" OC, but the supply place I was going through only had unfaced, 24" OC, 4ft batts, that covered 144 sq ft. I could get the faced stuff from big box, but it is 175% the price and covers less sq footage. My joists are open truss web joists, so even though they are 24" OC, there is only 19-21" between the joists, depending on how crooked they are. So yeah, the insulation doesn't fit perfect, but friction keeps it up there. I bought insulation hangers and those vinyl straps used for HVAC lines as backup just in case I needed some extra support. So even though the insulation fits up there, between the HVAC ducts, conduit, wiring, water pipes, backer boxes, and blocking, there is so much stuff to work around that I rarely get to use an unaltered 4 ft length, which makes the installation take forever. I finally finished this yesterday.
Last night after I finished the ceiling insulation, I started to install the hat channel into the clips that were previously installed and spaced out. I was missing 5 clips, so I ordered 15 from Ted the other day, thinking that was way overkill, but then I just realized last night that I need to add extra clips for all the splices. I worked and reworked the clip spacing plan but kept coming up 1 or 2 short. On top of all that, a handful of my wall clips in the corners were too close since they were installed prior to having any actual channel. So went too bed discouraged, but woke up early and started to install the channel on the ceiling. I found two rows where I could use the existing ones to border the splice I needed in that row, which allowed me to have exactly the number I need.
I also pulled some favors and some trucks to meet me down at the big box to pick up the OSB for first layer of the theater this afternoon. After hauling 36 sheets home and moving 24 of those to the basement (left the rest in the garage for cuts), I was pretty dead, but I was able to finish up the ceiling channel and install the first osb sheet on the ceiling. I'm not quite sure the best practice for doing this, but I ended up just measuring from the edges and drawing the backer box outline on the OSB itself. Not sure how well that will work for the others that are further from the wall though. I also am not sure if it would be better to cut the hole for the can light before I put the sheet up or after it's up there. Everything looks pretty good, I think, with the exception of two things.
1.) Corner is a bit out of square so the bead of caulk I put on the edges didn't seal very well. Planning to seal the edge against the wall before putting the wall OSB up. Hopefully this issue doesn't cascade and become a larger issue as I continue.
2.) A bit more of a concern is that there is one spot where the OSB doesn't seem to be pulling tight to the channel. It's on the 4th channel over from the wall and looks to be only in the one spot. For that particular channel, I screwed that spot first, it seems to pull tight , but then popped down (or the channel popped up). I used a second screw and it drew close again, but when I did the spot 12" down the channel, it drew tight, and my original spot popped back down again, A third screw didn't help matters and they just spin now. So its almost like the channel is a bit bent here, or the joist height is a bit off in this area. I'm not really sure. Anyone want to comment if I should be concerned with this?
Here are some pics:
The first board
Here is a picture of where the screws are not pulling tight. You can see the space between the top of the OSB and bottom of channel and the screws.Edited by jcorbin - 6/10/12 at 9:22pm