The First Facility Management Blog

This Web Exclusive article was contributed by Brad Lynch of Wright Line, a Worcester, MA-based manufacturer of products for technology intensive environments. Lynch leads Wright Line’s Technical Environments Business Unit, and he can be reached at (508) 926-6022 or Brad.Lynch@wrightline.com.

Rethinking Off-The-Shelf Console Design

The selection of command and control consoles for mission-critical facilities has traditionally occurred late in the planning and construction phases of a new facility or the expansion/renovation of an existing one. Until recently, off-the-shelf console templates have been employed and have met the needs of most applications.

The advancement of new command, control, communication, and computer (C4) technology is driving the need for a new approach to console design. Generic, off-the-shelf templates are no longer viable solutions to meet the demands of today’s C4 environments.

These environments include a variety of 7/24 workplace functions, such as network operations, 911 centers, incident command, emergency operation centers, process control, medical imaging, security/ transportation management, and many other types of command and control operations centers. These centers now require higher performance levels from their consoles

High performance console design is an integral element of the overall facility design, and will reap productivity benefits when centers are brought on line. The console must be viewed as much of an integral part of the technology solution as the hardware/software solutions being deployed. When executed correctly, this console perspective positively impacts how each employee interacts with the technology, the enterprise infrastructure, and the rest of the working team.

New Dimensions in Design Methodology

As technology transition expands its reach within C4 operations, the challenge of achieving a balanced integration of people, technology, workspace, and workflow becomes increasingly difficult. Architects, designers, engineers, and facility planners need to consider each of these four dimensions as an integral element of the overall operational system and peel back predetermined concepts of traditional console design methodology.

People: In C4 environments, people operate at high emotional states, often in anticipation of a critical event taking place. Understanding how people interact with other elements of the system within the environment is the basis of high performance console design.

It’s very important to understand who will be interfacing with the console. This information is integral to the design process as business productivity is directly correlated to individual productivity. One must consider the operator level—the individuals in the seat—as well as secondary levels of the operation including supervisors, system or network administrators, facilities engineers, technicians, and even systems integrators who come into contact with the console on a regular basis. The ability to service the technology and infrastructure, while maintaining operational uptime, is directly impacted by the console design and configuration.

Technology: Technology and its supporting infrastructure are the backbone of C4 operations. High performance console designs efficiently and effectively store, cool, power, manage, and secure the technology housed on or within the console.

As the primary human-machine interface, the console can essentially be described as the point at which the data center and mission critical personnel meet. Consoles tend to house technology locally. Because of this, safeguards must be designed into the console to avoid accidental power or data loss, equipment overheating, or other unintentional consequences resulting from human error.

Power and data cables must be neatly managed and provide easy access for IT and facilities personnel. Yet, they must also be out of reach to avoid accidental disconnection. Airflow management solutions that include material selection must also be in place to ensure that higher density computer and network gear is adequately ventilated. In C4 applications, these measures should not be afterthoughts, because data and power downtime can result in life and death consequences.

Workspace: Physical space is, by far, the most constraining and least forgiving of the four dimensions. The space must be examined independently from the operation and from the console itself. Space planning identifies the space available for console design.

Additionally, physical and conditional attributes of the space, such as cable cut-outs in raised floors, power drops from ceilings, ADA requirements, and other local building codes, also play an important role in the design of a high performance console for a C4 environment.

The main objectives in space planning are to ensure that the space can support the appropriate number/types of consoles and that the consoles can be adequately located to meet the workflow demand of the overall operation. Cabling, data, and power distribution requirements of the operation must also be accommodated appropriately. In addition, it’s important to build in as much modularity or scalability—to allow for future system upgrades and equipment transitions—as operational needs change and technologies evolve.

Workflow: Workflow is the integration of people and technology working collaboratively in the physical workspace, as well as individuals in various operations center job functions interacting seamlessly while functioning at peak performance.

It’s important to understand the relationship between the work types within the center. This includes managers, supervisors, operators, engineers, risk managers, and each employee seated at the consoles.

Additionally, the interaction of all people who may not be seated at a console must be clearly understood. These can be technical or administrative staff, facilities or support personnel, or even in some cases, the general public.

Is an uninterrupted sight line to the entire facility required by a supervisor or manager? During critical events, will supervisors or managers need to have remote access or need to monitor an operator station? Are there specific times or physical points where there is interaction between supervisors, office administrators, other center personnel, or the general public?

In C4 environments there are two distinct work flow modes: normal day-to-day operations and critical event or crisis mode. The interdependencies of all the personnel working within any mission critical C4 environment need to be considered and evaluated to ensure that operator consoles are designed to meet these requirements and optimize operations.

Visit this link for questions that can help address the challenges of your C4 environment.

Transitioning to High Performance

As the primary human-machine interface, today’s sophisticated consoles play a central, critical role in mission critical C4 environments. Console design has evolved to the point at which it is as effective a contributor to operational performance as are the people and technology that work at them.

Higher levels of ownership and buy-in are achieved when the mission critical team has greater input into the four dimensions of the discovery process. This detailed input ultimately enables higher performing people and more efficient operations during normal operational periods, and especially, during periods of crisis management.

Understanding the four dimensions of high performance console design provides the necessary freedom to deliver a high return on investment and a lower total cost of ownership in the mission-critical environment.

(All images provided by WrightLine.)

This post was submitted by Jay Rintelmann, president of Hartford South.

Proper maintenance is a key aspect to extending a roof’s lifespan. Once there is an active leak, it is too late for proactive measures.

Many variables and issues can cause damage and lower the roof’s performance. Check for these five common problems affecting low-slope commercial roofs:

• Proper drainage – Debris from wind and storms can clog drains and gutters. Drains should be checked and cleaned every six months to one year to ensure proper flow of water.
• Ponding water – Older roof systems, and sometimes systems where insulation was not installed correctly, have the propensity to pond water. Ponding can occur anywhere on the roof deck, stressing the roof and causing premature failure of most membranes.
• Flashings – Identify roof membrane problems at vertical surfaces including walls and curbs. Look for holes in the membrane, open laps, hail damage, or membrane slippage.
• Penetrations – Inspect condition of roof at locations where vent pipes, soil pipes, heater flues, electric conduits, or gas lines pass through the roof. These penetrations and pitch pans are often the first areas to fail on a roof, but their lifespan can be extended indefinitely through proper maintenance.
• Walk pads – Facility managers should request that any individuals accessing the roof use these pads while performing maintenance or repair services to equipment on the roof.

Of course, age and severe weather can also affect the longevity of your building’s roof. Most have a lifespan of about 20 years – although the factors mentioned above can cause damage that necessitates a re-roof or repair. So, check your building’s roof regularly, because proactive maintenance can help save money (and hassle) in the long run.

Hartford South specializes in low-slope commercial roofing applications – both re-roof and new construction. Since 1984, Hartford South has installed more than 60 million square feet of product and completed numerous high-profile jobs throughout Central Florida. Clients have included Orange County Convention Center, Orange County Public Schools, Florida Hospital and Rosen Shingle Creek.

This Web Exclusive comes from James Anderson, vertical market manager for Holliston, MA-based Lista International.

Purchasing a workbench or workstation may at first seem like a simple task. Your employees have work to do, and they need an efficient, comfortable, and practical place to do it. But behind that deceptively simple proposition may lurk a number of variables that must be considered to make sure you get what you actually need.

Employee needs vary widely among industries and applications. What’s perfect for an automotive dealership won’t work in a laboratory. What works for manufacturing facilities just won’t fly for a classroom setting. And a configuration that suits one laboratory may not be appropriate for another.

So, whether you are looking for technical workstations, height adjustable workstations, assembly workstations, industrial benches, packing and shipping benches, or accessory systems, take the time to perform the necessary research upfront by following this step-by-step self examination that will help you choose the right workbench for all your needs.

The number one consideration – what work are you doing on the bench?
The answer to this question will affect everything from the size of the workbench to the surface material, to storage requirements, to ergonomic considerations.

Once you determine what work will be performed on the bench, conduct an analysis of tasks associated with the work and use it to make a checklist of features needed to perform them. For example, say you’re in the business of assembling and maintaining cell phones, and you need to furnish a workspace for your repair technicians. You want a small workbench, perhaps one that is height adjustable, to bring the detailed repair job up to an optimal work zone and distance. Along with the workbench, you will also need an excellent lighting accessory. You’ll likely also need bins above the work surface to provide direct access to small parts, and an articulating arm that can hold assembly guidelines or diagrams. And depending on the flow of your repair operations, you might want to consider a material transfer work surface, or even a conveyor workstation, both of which can cost effectively expedite material handling.

Or maybe you’re working in a pharmaceutical lab where the work surface material becomes a more important part of the decision. Depending on the liquids and solids you’re handling, you might want either a stainless steel or epoxy resin chemical resistant work surface to ensure long lasting, durable use. If your laboratory is in a clean room environment, your workstation will need to meet certain NSF International public health and safety standards. You might also need to store a combination of small beakers and instruments with large testing equipment—requiring a variety of storage solutions both above and below the work surface.

For example, Bob Smith, production manager for Automated Circuit Design (ACD), said, “All the workstations are electro-static dissipative, so they are an ideal solution for every department. In the kitting area, technicians can safely work with ESD sensitive components. And in the assembly and production departments, every technician can perform the most precise processes effectively. The workstation provides the lighting needed to perform every task with attention to every detail. Additionally, the substantial shelving space offers the area needed to set up stations for testing completed products.”

Sizing up the solution
The size of your workbench is determined by a number of factors. First up is how much space is available in the work environment – how big a footprint will it occupy? With today’s modular workbenches making maximum use of vertical space, you may not need as big a workbench as you think.

Next, how much work surface area does your application demand, both in terms of width (left to right) and depth (front to back)? Does the entire work surface need to be within easy arm’s reach (by, say, an assembly technician)? Can you position needed items above the work surface on a vertical accessory system for easier access? Will you be working with large equipment or parts? If so, you may not only need a larger work surface, but might also need to factor in the weight bearing capacity of your workbench.

Workstation meets workflow
After thinking about size and footprint, you should consider whether your company’s workspace, type of work, and workflow are best served by a group of workstations laid out in a particular configuration. Some companies offer modular workstations that are specifically designed to accommodate different configurations and different types of workflow. Use a design that positions your team for maximum efficiency.

If you’re operating with a progressive workflow, you may want to configure your workbenches to create an integrated, moving production line. Flow racks can then be used to stage and deliver parts using gravity, reducing material handling time, point of use storage, and cost.

If your team functions in cells or groups, it may be served best by different shaped configurations that encourage easy communication. Some workstations are available in modules, so they can easily be combined to create everything from in-line and in-line back-to-back configurations to T, U, X and Y-shaped configurations.

Finally, consider transforming from stationery to mobile workbenches. Effortlessly accomplished with mobility enhancing accessories, mobile workbenches can provide for easy, smooth rolling relocation. This will accommodate both day-to-day and future changes as well as simplify cleaning activities.

Storage – everything in its place and a place for everything
Spend some time doing some careful planning to get a workstation that exactly addresses your storage needs with little or no wasted space. Simplify your storage decisions by reducing the items being stored to only those that directly address your workbench applications. When doing your planning exercise, consider the size, shape, weight, quantity, and fragility of the items to be stored, as well as how accessible they need to be and how much security they demand.

Do you need a home for shipping documents? A bar code scanner? Test equipment? Small parts? Tools? There are plenty of options for storage, both above and below the work surface. From plastic parts bins to a variety of shelving options to every size and configuration of drawer, there’s a lot to consider.

After determining exactly what needs to be stored, zero in on making the workspace more efficient. Create a designated storage location for every item. Modular drawer cabinet interiors are ideal for custom configuring to produce almost infinite layout options. This high level of organization is particularly important if different people are using the same workbench at different times. Time savings are maximized and inventory control becomes a non-issue.

Let there be light
Lighting needs of the different workbench tasks is an important consideration. Does each station need separate lighting? Does the room itself have lighting deficiencies? Does the room light cast an unwanted color? And if you decide you need to equip your workbenches with lighting accessories, are your technicians best served by overhead fluorescent lighting or a swing arm that can be easily positioned and/or moved out of the way when not needed? Do you need an accessory that can diffuse the light and reduce glare?

Power to your people
After you weigh your lighting needs and options, you should next move on to your electrical requirements. From clean rooms to quality control departments to research and development functions, a convenient source of power at each workbench can be essential. There are diverse options to consider—from power beams and air beams to air supply brackets and cable management accessories. You can narrow your selections down to the necessary few by asking the right questions:

First consider the applications. Will each workbench be home to a computer monitor and other computer equipment? Do you need a data beam? Will the tasks at hand require compressed air, and what is the source of that air?

How many outlets do you need at each workbench (and how much power)? Where should the outlets be positioned? Do you require a ground fault circuit interrupter (GFCI) to provide protection against severe shock and electrocution? Consider cord management, both from an aesthetic point of view, as well as the safety factor. To keep power cords from becoming tripwires, cable trays may be needed.

The right accessories make the space more efficient
Think about the impact that add-on accessories might have in improving the employees’ job functions. No matter what the task, there’s an accessory option to help get the job done more efficiently and conveniently. By taking advantage of the abundant vertical space above the work surface, and the many interchangeable accessory options available, you can create a highly efficient work center that is tailored completely to the needs inherent to jobs being performed in the workspace. Examples include shelving for manuals or instruments, parts bin rails, a monitor bracket, or a keyboard holder.

Pay attention to ergonomics for safety and productivity
It is essential to factor in ergonomics to improve safety and productivity. To minimize stress and strain for seated employees, a 30.5″ work surface height will accommodate 99.5% of all male and 99.9% of all female workers. The optimal work surface height for standing employees depends entirely on the type of work being performed. Precision work usually requires a higher work surface, while heavier work demands a lower work surface.

But what if different shifts are using the same bench? And/or what if different tasks are being performed on the same bench? If so, consider an adjustable height workstation. With such a bench, users can adjust the bench height with the simple turn of a crank or with a motor drive, and the work surface can move between approximately 25 and 41″.

Standardization leads to improved adaptability
Most companies have multiple departments, from manufacturing to testing to shipping. Consider using a common workbench platform throughout the facility to gain such benefits as better utilization of inventory, easier reconfiguration, interchangeability of accessories, and aesthetic appeal.

Standardization allows efficient swapping of accessories among departments, and facilitates adjustments if work tasks change. Colors and designs match, and there are no surprises when employees shift to a different department.

Design standardization (and an attractive price point) is important, but the quality and durability of the workbenches and other furniture was also a key consideration. “Schools are a very hard environment for furniture, especially where students are constantly using the table to perform different tasks,” notes <!– @page { margin: 0.79in } P { margin-bottom: 0.08in } –>Tom Buechele, associate vice president of facilities, operations and planning at the School of the Art Institute of Chicago (SAIC).

Putting it together with design assistance
If this list of considerations poses questions for which you need help to find answers, maybe you’d prefer to have help with your quest for the perfect workbench. Many workbench providers offer design planning assistance to guide you through the process and advise you of the most appropriate choices. Free services such as surveys and CAD drawings can make the process virtually painless.

If you choose a workbench provider who offers maximum breadth of product and flexibility, you’ll be able to view all of your workbenches as part of a complete picture, although each may have been custom built to accomplish a unique task. The end result? Many smart steps for each department and one giant leap for your business.

This Web Exclusive article was provided by Sasha Bailey, LEED AP, a corporate sustainability manager in ThyssenKrupp Elevator’s Americas Business Unit. She can be contacted via e-mail at Sasha.Bailey@thyssenkrupp.com.

With a growing emphasis on cost-effective building maintenance practices, many facility managers, engineers, and architects are looking for ways to increase elevator efficiency and performance, while also reducing costs by employing modernization and repair techniques.

Experienced technicians and engineers can customize modernization packages or upgrade recommendations that are both time- and cost-efficient. Since budget planning is critical for capital expenditures such as these, recommendations can be submitted in a multi-year plan prioritized by the overall savings realized in energy efficiency. Below are options to consider, ranging from simple cosmetic cab refurbishments to complete elevator system overhauls, all of which will provide dual benefits: to the environment, and to the bottom line.

Enabling the elevator controller to shut off the cab’s lights and fans automatically when the elevator meets certain criteria can increase energy savings.

Cab Modernization
Installing light emitting diodes (LEDs) can save up to 80% of the energy costs associated with traditional fluorescent lighting. LED lighting reduces heat loss and increases life span—in some cases up to 10 years per light. LEDs also eliminate the use of ultraviolet light, which can cause damage to elevator cab interiors over time. In addition, they do not contain harmful mercury common in fluorescent lighting.

Enabling the elevator controller to automatically shut off the cab’s lights and fans when the elevator meets certain criteria, can increase energy savings.

Another consideration is to replace elevator panels with urea-formaldehyde free panels, which can improve the indoor air quality (IAQ) of the building as well.

Upgrading the Motor
Upgrading from a motor generator (MG) drive to a variable voltage variable frequency (VVVF) could save approximately 40% of energy consumption, depending on the elevator type and size. The move away from the old MG sets also eliminates potential IAQ issues associated with carbon dust created by the use of carbon brushes in the machines themselves.

In addition, the oil that is used in hydraulic elevators can be replaced with biodegradable hydraulic oil, designed to minimize environmental impact.

Recycling Energy
Building owners can also implement advances like installing regenerative drives, which put some of the elevator’s unused energy back into the building. The power that is transferred back into the building would traditionally be dissipated via heat into the machine room. With the regenerative drive, the excess energy is captured and reused and the system reduces traditional cooling of the elevator machine room.

Remote Monitoring
Remote monitoring is a service feature for control systems that monitors the performance of an elevator. These systems provide real-time progress reports that can be enabled and viewed at any time and from anywhere. The advanced notification also helps reduce unnecessary service calls to the site and can eliminate unneeded paperwork. If something out of the ordinary were to occur, or if the elevator was not performing optimally, the monitoring system would alert the service provider, sometimes before a problem is even exposed to the facility managers, thus ensuring seamless adjustments and repair and minimizing costly elevator down time.

Destination Control Software
Installing destination control software can create more efficient passenger transportation, ultimately improving building efficiency—not to mention the “cool” factor—which can increase a facility’s overall property value. Destination control software improves routing by grouping elevators by the floor the passengers intend to travel to.

Destination control software, such as ThyssenKrupp's Destination Dispatch, allows passengers to register which floor they are traveling to from the lobby. Shown here is the touchscreen component.

Because passengers designate which floor they are traveling to using a centralized screen input system in the building’s lobby, buttons are not needed inside each car. The touch screen directs passengers to their designated elevator, as determined by a formula that considers requested destinations and estimated time to destination. Riders are evenly dispersed to their appropriate elevators. The destination control software groups all passengers travelling to the same floor in the same cab, reducing the number of stops and improving the elevator’s efficiency. This practice can increase handling capacity up to 30%.

Systems equipped with destination control software also allow facility managers to accommodate occupants with high-traffic needs during peak travel times of the day.

With the increased pressure on facility management professionals to reduce energy consumption and increase building efficiencies, modernizing and upgrading elevators prove to be economical solutions. These improvements can also create a more sustainable environment, which can save money and time over the long term.

The Web Exclusive comes from Doug Todd, North America market manager, Dow Building Solutions.

Continuous insulation—”ci” for short—is a term facility managers will be hearing more often in the planning stages of their new construction and major renovation projects. Like a coat that provides greater warmth when it’s zipped rather than not, “ci” covers the entire wall surround—not just the cavity spaces between the framing studs. “Ci” is a proven energy saver that is gaining attention across the U.S.

For at least 20 years ASHRAE has mandated “ci” for the coldest U.S. climate zones—places like northern North Dakota, northern Wisconsin, and Alaska. Now, changes to the ASHRAE 90.1-2007 Energy Efficiency Standard make “ci” a prescriptive requirement for above-grade, steel frame commercial construction in six out of eight climate zones, which is essentially all of the U.S. except for its southernmost points. See this link for climate zone breakdown.

In terms of LEED certification, in version 3.0 of the LEED rating system, the Energy and Atmosphere (EA) credit category now uses ASHRAE 90.1-2007 as its baseline. And the range of points for EA Credit 1 has increased from 1-10 to 1-19.

There are wall systems on the market that make it easier to integrate “ci” into building plans. These types of systems are gaining traction across climate zones as architects, contractors, and facility managers discover that they can improve thermal efficiency with less labor and cost than traditional gypsum wall systems or alternative “ci” components.

Why “ci”?
Heat transfer through steel studs can decrease effective R-value of cavity insulation by more than 50% (see Figure 1). If not addressed, the issue can overwork a facility’s HVAC system, requiring much more energy to heat and cool than it should.

Figure 1

Energy loss is most pronounced in wall systems that place batt insulation on the interior wall between the studs and use un-insulated sheathing on the exterior, such as gypsum board. This configuration, while very common in the vast majority of commercial structures, encourages heat transfer through steel studs (see Figure 2). Left unprotected by insulation, the building’s steel frame turns into a kind of thermal super highway, where indoor heat moves out during winter and outdoor heat moves in during summer.

Figure 2

Heat transfer through steel framing also encourages condensation within the cavity. The moisture build up further reduces the effectiveness of the batt insulation and if it does not dry out, can lead to mold and mildew, as well as material degradation.

Adding thicker insulation between the studs will not significantly improve thermal performance. In fact, it’s physically impossible to design an R-19 steel stud wall system with R-19 rated batt insulation alone.

A Different Approach
Wall systems that integrate “ci” represent a fundamentally different approach to steel frame wall construction. Those that combine “ci,” an air barrier and moisture-resistant barrier in a single-source solution can help to reduce materials and labor costs, as well as installation time.

One system, the THERMAX Wall System from Dow Building Solutions, integrates an acrylic-coated polyisocyanurate foam sheathing, flashing and spray polyurethane foam in a single-source solution.  Lightweight, rigid foam insulation panels installed outboard of the stud deliver a high level of heat resistance to the entire envelope—not just between the studs. The effect is to shut down the thermal superhighway of heat transfer. The sheathing’s facer protects against moisture intrusion. Seams, windows, doors and other thru-wall penetrations are taped with flashing for further moisture protection. Sealing the interior wall cavity with spray polyurethane foam effectively reduces air infiltration through building gaps, cracks and pinholes that can account for up to 38% of heat transfer in a typical building.

Whether it’s for new construction or a major re-model, the choice of insulation affects a facility’s energy efficiency long after construction ends.  By combining “ci” with air sealing, these types of wall systems go beyond the ASHRAE 90.1 standard and moves closer to the ultimate goal of carbon neutrality in building operation.

This Web Exclusive comes from Rob Haddock, director of the Metal Roof Advisory Group, Ltd. of Colorado Springs, CO. He is a consultant to The Metal Initiative, the educational arm of the metal roofing and wall industry in North America.

Standing seam metal roofing can represent the state of the art when it comes to a durable, sustainable, eco-friendly approach, providing three or four decades of reliable service life. Unfortunately, this roofing option and the maintenance freedom it affords is often sabotaged when it comes to mounting essential rooftop equipment and ancillary mechanicals.

Regardless of the roof type, the best way to prevent rooftop problems is to clear the roof of any unnecessary equipment. And while facility managers would prefer an uncluttered roof, it is sometimes necessary or convenient to mount HVAC equipment—as well as screens to hide it, piping to fuel it, scuttles to access it, and walkways to service it.

There may also be a need for satellite dishes, lightning protection, solar panels, advertising signage, fall protection systems—and the list goes on. However, with some basic understanding of the “dos and don’ts,” rooftop equipment mounting, while unavoidable, can be made simple and trouble free on low-slope metal roofing.

Seam clamps ease rooftop mounting. One instance where this comes into play is mounting photovoltaic solar arrays.

Penetration-Free Attachment
Standing seam metal actually offers advantages over other roof types when mounting of ancillary fixtures does become necessary. These roofs are particularly well suited to accept special seam clamping hardware that grips the standing seam systems without puncturing their membranes (see example at right).

Unlike other roof materials, metal is rigid. The standing seam area creates a beamlike structure that can provide an anchor for things like walkways, solar arrays, condensing units, and gas piping without harming the weathering characteristics of the roof. Mechanicals can be secured safely and cost effectively to these seam clamps leaving the roof membrane free of penetrations. The clamps provide great holding strength, last the life of the roof, and preserve thermal cycling characteristics of the roof system.

If roof attachments are required, here are some tips that could prevent problems over time:

• Use penetration-free attachments whenever possible.
• Never use adhesives to secure attachments to metal roofing.
• Use only attachment clamps made of non-corrosive metals such as aluminum along with stainless steel mounting hardware. These metals are compatible with anything that may be found on a metal roof.
• Be sure that round-point setscrews are used to secure the clamp to the seam. This will prevent galling or other damage that could lead to corrosion.
• Any loads placed on the clamp will be transferred to the panels and their anchorage, and subsequently to the structure. That anchorage must be capable of withstanding the added load.

When Penetration Is Unavoidable
In the case of HVAC and plumbing vents, the roof membrane is often penetrated. The soil stack must carry gases from inside out, and the HVAC unit must bring either inside air out, outside air in, or both (see example below). Consequently, holes in the roof are inescapable. The challenge is to waterproof the holes, while also maintaining the thermal cycling integrity of the roof system.

Soil stacks and other round penetrations are flashed with unitized rubber pipe flashings.

There are a few rules for handling these kinds of rooftop penetrations in low slope standing seam that will help ensure trouble-free service. HVAC units and/or related ductwork penetrations should use pre-formed equipment curbs specifically designed to integrate with the roof profile being used. The curb is sealed to the roof and maintains the thermal cycling integrity of the system.

The best curbs are made of all-welded aluminum construction. This material is very compatible with sheet steel (or aluminum) used for roofing and should provide decades of service if designed, fabricated, and installed correctly. Often these curbs are load bearing “structural” varieties that simultaneously provide support and waterproofing. Roof curb suppliers are located throughout the U.S. and can be readily identified by most metal roofing manufacturers.

When penetrations are necessary, pre-formed structural curbs support weight and seal tightly to the roof.

When unusual HVAC equipment sizes and weights are involved, often the support and weatherproofing functions are divided as the unit is mounted on a structural curb, which is integral to the building’s structural framing system. When such a design is used, a second “flashing curb” must be employed to satisfy the specific waterproofing challenges of a metal roof. The first curb (or frame) supports the weight of the unit, while the second does the waterproofing and is integrated into the roof system. The outer curb features the same design and material as previously described.

When equipment curbs are used, it is imperative that:

• Welded, aluminum curb construction be used
• Curbs be equipped with diverters on the upslope flange
• Curbs be shingled into the roof so as to avoid “back-water” laps
• Curb walls are at least 6″ high
• Curb and installation be “floating” and not pinned to the building structure
• All seals be made with butyl tape/tube grade within the joints (not exposed sealants), with careful attention paid to “marrying” seals at the panel seams
• Curb sidewalls be located at least 6″ from the nearest adjacent seam to allow sufficient drainage to the sides of curbs
  

  Frame mounted HVAC unit using pipe supports extending down to the building structure and flashed through the roof using rubber pipe flashings

Round Penetrations
Round shapes, such as plumbing vents or pipe supports for rooftop equipment, should be flashed through the roof using EPDM (Ethylene Propylene Diene Monomer) rubber pipe flashings. The cone-shaped rubber is field cut to size and stretch-fitted to the pipe. It is recommended that a stainless steel draw band be used at the top of the flashing to ensure that the flashing never inverts itself. The part has an integral aluminum compression ring that is laminated to the rubber base.

The pipe flashing must be anchored to the roof panel only, and not to the building structure or deck. To do the latter would create an inadvertent “pinning” of the roof panel, compromising its freedom of thermal movement. Ideally these flashings should be centrally located to ensure free drainage.

In any event, interrupting a seam should be avoided. This flashing assembly, which is sealed to the roof with butyl copolymer tape sealants, should offer 20 or more years of service life. In summation, when using these rubber pipe flashings, it is important to remember the following:

Detail of pipe flashing through a standing seam metal roof (Click on image to see larger version.)

• Use unitized EPDM rubber pipe flashings (black preferred) with stainless steel draw band.
• Locate round penetrations centrally in the panel
• Seal with butyl tape beneath base; then fillet with one part polyurethane
• Do not pin flashings to the structure or deck

Rooftop mountings and penetrations are a challenge for any roof type or material. But following these guidelines will help to ensure trouble-free and enduring performance for low-slope metal roof systems.

This Web Exclusive comes from Peter M. Leahy, segment manager, Office Building & Lodging, Kimberly-Clark Professional.

It happens around this time every year. The sore throats, runny noses, and coughs herald the start of flu season.

Up to 20% of the U.S. population gets the seasonal flu annually. More than 200,000 are hospitalized with flu-related complications, and 36,000 people in this country die from flu-related causes.

This year, the emergence of the H1N1 influenza virus—which has caused the first influenza pandemic (global outbreak of disease) in more than 40 years—may cause this flu season to be worse than a regular flu season. It is thought that a lot more people will get sick, be hospitalized, and die than during a typical flu season. As of October 25, there have been more than 440,000 confirmed cases of H1N1 and 5,700+ deaths worldwide, according to the World Health Organization, which cautions that the actual number of cases (ie, milder, unreported cases) is likely significantly higher.

While flu outbreaks can happen before the winter months set in, most of the time influenza activity peaks in January or later. This year, the 2009 H1N1 virus caused illnesses, hospitalizations, and deaths in the U.S. even during the summer months, when influenza is very uncommon.

The uncertain severity and timing of this year’s seasonal-plus-H1N1 flu activity means that schools, businesses, and workplaces need to prepare for higher absenteeism rates, along with cases of presenteeism—when someone goes to work or school while sick—leading to productivity declines and the possibility of spreading illness to others.

Fortunately, there are several things facility managers can do to help prepare their employers and occupants of their buildings for the upcoming flu season and to respond if an outbreak occurs in their facilities. Even seemingly simple strategies like facility sanitation and giving occupants the tools they need for proper personal hygiene can help reduce the spread of germs during flu season and other times of the year.

Influenza 101
Some people may confuse the symptoms of the common cold with those of the flu. Both viruses enter the body through the mucous membranes of the nose, eyes or mouth. Cold symptoms are less severe than flu symptoms and typically begin with a sore throat, which usually goes away after a day or two. Nasal symptoms, runny nose, and congestion follow, along with a cough by the fourth and fifth days. Fever is uncommon in adults. Cold symptoms usually last for about a week with the contagious period being the first three days.

The flu is a contagious respiratory illness caused by influenza viruses. It can cause mild to severe illness, and at times it can lead to death. Some people—including older people, young children, pregnant women, and people with certain health problems such as asthma, diabetes, or heart disease—are at increased risk for serious complications from the flu. These may include bacterial pneumonia, ear infections, sinus infections, dehydration, and worsening of chronic medical conditions.

Someone infected with the flu may be able to infect others beginning one day before symptoms develop and up to seven or more days after becoming sick. Symptoms of seasonal flu include:

• Fever (often high)
• Headache
• Extreme tiredness
• Dry cough
• Sore throat
• Runny or stuffy nose
• Muscle aches
• Stomach symptoms such as nausea, vomiting, diarrhea (particularly associated with H1N1 flu)

Flu viruses spread mainly from person to person through coughing or sneezing. Sometimes, people may become infected by touching something with flu viruses on it and then touching their mouth or nose. In fact, some germs can live for two hours or more on surfaces like doorknobs, desks, and tables.

Preventing the Spread of Flu: Education
There are several steps facility managers can take to help prevent the spread of influenza and other germs in their buildings. Education is critical; people not only need to know how to spot the signs of flu (as outlined above) so they can care for themselves appropriately, they also need to know how to avoid getting sick in the first place and how to avoid spreading germs to others.

Consider instituting a Healthy Tips campaign with letters to building occupants and posters in prominent locations detailing recommendations from health experts like the Centers for Disease Control and Prevention, which advocates the following tips to help stop the spread of germs:

• Cover your mouth and nose when you sneeze or cough. It’s best to cough or sneeze into a tissue, which should be thrown away after it is used, or into one’s sleeve. If you sneeze or cough into your hands, be sure to clean your hands afterward—every time you cough or sneeze.
• Clean your hands often. When possible, use soap and warm water and rub hands vigorously together for 15 to 20 seconds, scrubbing all surfaces of the hands to help dislodge and remove germs. When soap and water are not available, alcohol-based disposable hand wipes or gel sanitizers may be used. If using a gel, rub the gel in your hands until they are dry.
• Avoid touching your eyes, nose, or mouth. Germs are often spread when a person touches something that is contaminated with germs and then touches his or her eyes, nose, or mouth.
• Stay home when you are sick (and for at least 24 hours after fever is gone) and check with a health care provider when needed. Keeping your distance from others may protect them from getting sick.

The CDC offers free, downloadable posters and other materials to help you get started at these links: www.cdc.gov/germstopper/work.htm and www.cdc.gov/flu. In addition, the World Health Organization posts a visual, step-by-step guide for proper handwashing here. Consider posting this guide in every restroom in the building as well as by hand sinks in break areas.

Preventing the Spread of Flu: Facility Issues
Educating yourself and building occupants about how to prevent the spread of flu is only one step. You’ll also need to make sure you have the right infection control tools for the job. That means stocking workstations and public areas with plenty of facial tissue. Anti-viral facial tissue is now available for this purpose. In addition, you should install wall-mounted dispensers for alcohol gel hand sanitizers throughout your facility. It’s also important to make sure restrooms don’t run out of hand soap and paper towels, and that sufficient numbers of no-touch disposal receptacles are provided for used hand towels and used facial tissue. Keeping surfaces spot-sanitized throughout the day is another good idea.

When stockpiling items like hand soaps and cleaning supplies, the Occupational Safety & Health Administration recommends being aware of each product’s shelf life and storage conditions (e.g., avoid areas that are damp or have temperature extremes) and incorporating product rotation (e.g., consume oldest supplies first) into your stockpile management program.

One area of particular concern when stepping up facility sanitation efforts is the restroom—an area where microorganisms can flourish. Lavatory surfaces that are touched frequently may serve as reservoirs of microbial contamination. In fact, research from Dr. Charles Gerba of the University of Arizona discovered high amounts of bacteria on restroom surfaces:

• The average toilet paper dispenser has more than 150 times the amount of bacteria than the average toilet seat.
• Paper towel dispensers were found to have more than 50 times more bacteria on average than a typical public restroom toilet seat.

Facility managers looking to minimize the potential spread of germs can install touchless restroom dispensing systems. The electronic revolution that has taken place in the washroom in recent years has greatly enhanced restroom hygiene by eliminating the need to touch dispensers, faucets and toilet handles during use. These systems can help make the task of using as well as maintaining the restroom easier, more efficient and more cost-effective.

Not all touchless systems are electronic, however. There are also mechanical no-touch towel dispensers, for example, with no levers to pull, that provide the same hygienic benefits as sensor-activated dispensers. Continue the no-touch theme by providing no-touch disposal receptacles for used towels and installing doorless entryways so that freshly washed hands don’t have to grab a dirty door handle on the way out of the restroom.

Remember that nothing says unhygienic more than a restroom without an adequate supply of toilet paper, hand soap, and paper towels. Highcapacity systems help ensure adequate supply as well as ease maintenance headaches and reduce costs and waste.

Not All Disinfection Methods Are Equal
While germs are common on certain surfaces in the restroom, they can also flourish throughout a building. To prevent the spread of flu, the CDC recommends that routine cleaning of commonly touched surfaces be performed regularly. Use the cleaning agents that are usually used in these areas, and follow directions on the label.

In the case of a flu outbreak, facility managers may choose to increase their surface sanitation efforts. If that happens, it is important for janitorial staff to minimize contamination of the cleaning solution and cleaning tools used for these efforts. Keep in mind that bucket solutions become contaminated almost immediately during cleaning, and continued use of the solution transfers increasing numbers of microorganisms to each subsequent surface to be cleaned. Another source of contamination in the cleaning process is the cleaning cloth, especially if left soaking in dirty cleaning solution. This is why the choice of wiping materials is important.

Indeed, it may be surprising to learn that common systems, such as using a cotton rag or cellulose-based wiper to apply common disinfectants such as bleach to surfaces, deliver less-than-ideal concentrations of disinfectants to the surface. However, a non-woven wiper designed specifically to be compatible with bleach (and used in a closed-bucket system) can keep the active bleach ingredients stable for 72 hours, allowing a much higher concentration of active ingredients to reach the surface being cleaned, according to recent studies.

An enclosed system, with pre-saturated wipes dispensed from a port in the top of the closed bucket, helps avoid contamination of the wipes and cleaning solution while reducing exposure to chemical vapors and splashes, an advantage for janitorial staff.

According to the CDC, businesses and employers, in general, can play a key role in protecting employees’ health and safety, as well as in limiting the negative impact of influenza outbreaks on the individual, the community, and the nation’s economy. Facility managers should be on the front lines in the war against the flu and other germs in their facility. A combination of education and effective flu-prevention tools and practices will put facilities and their occupants in a good position to avoid the brunt of the flu this season.

Additional Resources
The CDC has published a number of Guidance documents to help different groups and facilities decrease the spread of flu:

• CDC Guidance for Businesses and Employers to Plan and Respond to the 2009-2010 Influenza Season
• CDC Guidance for Responses to Influenza for Institutions of Higher Education during the 2009-2010 Academic Year
• CDC Guidance for State and Local Public Health Officials and School Administrators for School (K-12) Responses to Influenza during the 2009-2010 School Year

This Web Exclusive article comes from Jeff Razwick, vice president of business development for Technical Glass Products (TGP).

Do life jackets really need labels? All life jackets offer users some degree of flotation, but improperly fitted vests can fail to keep people afloat in times of need. Labels help prevent improper use by quickly pointing users to the jacket’s size, weight and type.

In the same way, building industry professionals rely on fire-rated building material labels to help select and inspect appropriate products—which is critical for protecting building occupants and valuables from the spread of flames and smoke. Of the various fire-rated building materials available, fire-rated glazing is one product class whose label is essential to understand for effective use. Such labels are mandatory, and are required to be compliant with current codes.

An example of a fire-rated glass label

A Look At The Basics
Fire-rated glass labels include basic product information, such as product name, characteristics (e.g., tempered, laminated), and whether it is listed by an independent testing agency like Underwriters Laboratories (UL). Labels compliant with the 2006 International Building Code (IBC) also include four easy to decipher marking categories (example label at right):

• suitability per testing requirements for use in doors, openings or walls;
• conformance with the hose stream test;
• conformance with any temperature rise door criteria; and
• fire-rating in minutes.

Suitability per testing requirements
The label includes one or more specific designations that describe where the system may be appropriate for use based on applicable testing standards:

• “D” indicates Doors (doors, sidelites, and transoms meeting NFPA 252)
• “O” indicates Openings (window openings meeting NFPA 257)
• “W” indicates Walls (fire-resistant glazing meeting ASTM E119)

Products marked with a “D” or “O” are designed to remain intact during a fire as a door or opening for the specified number of minutes in the fire rating. A “W” marking is for products tested as wall assemblies that are intended to block the spread of smoke and flames, as well as provide a barrier to radiant heat. Such fire-rated walls may be suitable for areas where people can be trapped for extended periods of time, such as exit corridors and stairwells.

The hose stream test
Performance on a required hose stream test is indicated on the label by:

• “H” indicates glazing meets the NFPA HOSE STREAM test standards (required for all windows and door assemblies with ratings of 45 minutes or more)
• “NH” indicates glazing does NOT meet HOSE STREAM test standards (an NH marking is only appropriate for some 20-minute fire-rated door assemblies)

The hose stream test is an essential part of fire-rated glass testing. It addresses the “cooling, impact, and erosion effects” of a stream of water and is designed to eliminate “inadequate materials or constructions.” Products that fail the test may be at risk for breaking or shattering if heated in a fire and cooled by water from fire hoses or sprinklers.

Temperature rise door criteria
Similarly, conformance with temperature rise criteria is shown on the label with:

• “T” indicates glazing meets TEMPERATURE RISE door criteria per codes
• “NT” indicates glazing does NOT meet TEMPERATURE RISE criteria

Fire rating in minutes
The final marking is a two- or three-digit number showing the fire rating in minutes. Fire-rated glass can earn anywhere from a 20-minute to a 3-hour rating, depending on how long it can be expected to perform in a fire.

Safety Is Key
Correctly installed fire-rated glazing materials can buy individuals more time to escape burning buildings before firefighters arrive, as well as help reduce building damage. By taking the time to understand labeling systems, building industry professionals can decipher which materials are suited for use in various applications.

This Web Exclusive article is by Bruce Lang, vice president of marketing & business development at Southwall Technologies, Inc.

Initial revisions to the Department of Energy (DOE)’s Energy Star® window performance standards, which will be effective January 1, 2010, should make clear that generic low-e glass no longer represents a level of energy efficiency required to “transform the market,” a key charter of the agency’s Energy Star program.

Because generic low-e glass provides insulating performance of about R-4 in a world in which R-19 insulated walls are the norm, there’s a dramatic performance gap between what low-e glass provides and what green building practices promise in saving energy and reducing carbon emissions.

Despite heavily insulated walls and ceilings and the popularity of low-e glass, 25% to 35% of the energy used in buildings is wasted due to inefficient glass. So, it should come as no surprise that glass is responsible for >10% of the total carbon emissions in the U.S. annually.

The truth is that low-e glass thermal performance has reached practical limits. A low-e coating reflects heat, reducing heat transfer between panes of glass, and thereby improving insulation performance. The “e” in low-e stands for emissivity—the ability of a surface to radiate energy. Low-e coatings are rated for the amount of heat they radiate—the lower the number, the less heat is radiated and the better the insulation performance of the glass.

This triple film, four cavity window construction provides insulating performance of R-20.

Coated glass is commonly available today with emissivity ratings below 0.03, and lowering emissivity from 0.03 to 0.00 will have a negligible incremental improvement on window performance. Clearly, further improvements in glass thermal performance will not come from improvements in low-e coatings. Low-e coated glass has become a minimum performance baseline and no longer represents a path to improved energy performance.

Generic low-e insulating glass, consisting of two pieces of coated glass separated by a sealed, gas filled air space (or cavity), achieves a maximum thermal insulation value of R-4. With further advances in glass coating technology expected to provide minimal performance improvement, the focus has now shifted from coatings to cavities. Just as the introduction of single cavity insulated glass provided a breakthrough in performance beyond monolithic glass, the introduction of multi-cavity constructions, consisting of two, or even three, insulating cavities, is providing the next performance breakthrough for insulating glass.

Two alternatives to generic low-e insulating glass are currently available that can meet Energy Star’s proposed Phase2 window performance standards scheduled to debut as early as 2013. One is triple pane glass, consisting of three panes of glass and two low-e coatings. By using a third pane of glass to create a second insulating cavity, triple pane low-e glass improves generic low-e insulating glass performance from R- 4 to R-9. The bad news is that triple pane glass is 50% heavier than standard insulating glass, requiring stronger window framing and increasing cost accordingly.

Southwall Heat Mirror insulating glass has been used at the Audubon Association Headquarters in New York City.

An alternative consists of suspending a low emissivity and solar reflective film inside of an insulating glass unit. Without the weight disadvantages of a third pane of glass, film can create two, three, or even four insulating cavities that maximize light transmission and provide conservation performance ranging from R-6 up to R-20.

Such internally mounted film does not replace low-e glass. It leverages the benefits of film based and glass based technologies to create a lightweight, multi-cavity insulating glass that offers a new level of performance. Most units fabricated today use low-e coated glass to minimize solar heat gain, while using film to maximize insulation performance, block UV radiation, reduce noise, and increase occupant comfort more effectively than low-e glass alone.

Film based, multi-cavity insulating glass has been saving energy in such landmark buildings as the Audubon Association headquarters in New York City, the Rotch Library at MIT, the Hoover Dam Visitor Center, and the Museum of Flight in Seattle.

This Web Exclusive comes from Gina Tsiropoulos, Market Manager, Kimberly-Clark Filtration.

Virtually everyone has been learning to cope with tough economic conditions. For individuals, the loss of jobs and cuts in pay mean tighter budgeting at home: forgoing vacations, dinners out, and luxury purchases. For companies, reduced income and profits often means taking a hard look at line item expenses in an attempt to boost the bottom line.

One line item that may come under scrutiny among facility managers (fms) looking to reduce maintenance expenses is the HVAC system. It may seem perfectly logical, for example, to save hundreds or even thousands of dollars per year in purchasing costs by reducing the frequency of air filter change-outs or by downgrading to a lower-priced filter.

Smart fms should realize the small amount of money saved by reducing or eliminating air filter purchases or by purchasing lower priced (and lower efficiency) filters pales in comparison to the energy and operating costs that can be saved by maintaining a robust air filtration maintenance and upgrade program.

The Role of Air Filtration
Effective air filtration provides the primary defense for building occupants and HVAC equipment against pollutants generated within a building as well as pollutants from air drawn into a building from the HVAC system. It affects the quality of indoor air, which can be two to five times as polluted as outdoor air.

Poor indoor air quality (IAQ) is more than just a nuisance. The cost of poor IAQ to the overall U.S. economy is in the neighborhood of $160 billion in terms of healthcare costs and reduced productivity among workers. Moreover, studies have shown that when indoor environments are improved, businesses can realize up to a 20% improvement in productivity—another strong incentive to pay close attention to enhancing IAQ through proper air filtration.

While air filters play a key role in a building’s IAQ, they also play a major part in the energy consumed to operate the building’s HVAC system. This makes air filtration a wise target for cost reductions as long as the right strategies are followed.

HVAC Expenditures: Myths vs. Facts
There are a number of ways that facilities may try to save money and reduce their HVAC system budgets. For example, facilities may try to delay filter change-outs or upgrades, or they may want to downgrade from high efficiency pleated filters to lower efficiency and lower priced panel filters. These strategies may be short sighted and contrary to cost saving goals; especially when one considers that the U.S. Department of Energy suggests enhancing operating efficiency of HVAC systems can reduce energy bills by up to 20% without significant capital investment.

Myth: Delaying filter maintenance (i.e., change-outs) will help save money.
Fact: While it is true that purchasing fewer filters reduces initial expenses, delaying filter change-outs also causes the filter to run more days at peak energy usage. It doesn’t take long for peak usage cost to offset any savings in the filter price. (See chart below.) That’s because energy use is the largest operating cost involved in air filtration. A filter’s energy consumption accounts for a full 80% of its total life cycle costs. Moreover, the cost of the energy used to operate the filter can be more than eight times the initial purchase price of the filter itself.

It comes down to physics; the energy used to operate filters is directly proportional to the airflow resistance of the filters. The more resistance (due to clogged filters that aren’t changed out as frequently as needed), the more energy is needed to push air through the filter. Resistance typically increases as filters remove more and more contaminants from the air. This filtration is essential for air quality and protection of HVAC equipment, but it comes at an extremely high cost when filter change-outs are delayed.

Delaying filter maintenance not only increases energy consumption, it also increases CO2 emissions; the extra energy consumed by dirty filters drives up energy production and greenhouse gas emissions. According to the U.S. Environmental Information Administration, 1.354 pounds of CO2 are released into the atmosphere for every 1 kWh of electricity produced, making delayed filter maintenance extremely costly to the environment. Plus, because America generates close to 50% of its energy by burning coal, reducing HVAC energy consumption also helps conserve natural resources.

Myth: There is little economic incentive to upgrade a building’s air filtration system.
Fact: Some commercial and institutional buildings in the United States are still using pre-WWII technology in their air filtration system—panel filters. Sometimes called “throw-away” filters, they are constructed in much the same way they were made 75 years ago and are among the lowest priced filters in use today.

For years, it was believed that panel filters provided adequate filtration to keep HVAC systems running cleanly and efficiently. However, a recent study found that panel filters do not provide adequate protection to HVAC equipment, allowing for particle deposits to build on fans and heating/cooling coils, a problem known as “fouling.” Fouling greatly reduces airflow through the HVAC system and prevents heat transfer in the coils, all of which can add up to a significant increase in energy costs. Fouling also leads to expensive and time consuming fan and coil cleaning.

Myth: Air filtration is not in the budget.
Fact: One of the biggest traps that commercial facilities fall into regarding budgeting for air filtration is the NIMB (Not in My Budget) factor. In many cases, one department (and budget) is responsible for purchasing air filters and filter service contracts while another is responsible for energy expenditures. The problem inherent in this system is that the filter purchaser can easily and quite innocently make a costly decision for the enterprise by choosing to buy filters without considering the energy consumption and system operating implications described above.

Reducing HVAC-Related Costs
It is important to remember that filters will only support good IAQ and perform as specified when they are maintained correctly. There are three important factors for proper air filter maintenance and reduced operating and energy costs: following the proper filter change-out frequency and installation steps; upgrading from panel filters to pleated filters; and choosing a filter with a lower resistance to airflow.

Proper filter maintenance is crucial to keeping HVAC ductwork clean. If dirt accumulates in the ductwork and if the relative humidity reaches the dewpoint so condensation occurs, then it can become a breeding ground for bacteria and mold.

For all of these reasons and more, it is important to establish the appropriate filter change-out frequency. However, filters should be changed immediately if they become wet, if microbial growth on the filter media is visible, or when the filters collapse or become damaged to the extent that air bypasses the media.

It is crucial to pay close attention to filter installation during change-outs. The goal is to avoid bypass air (air that does not go through the filter) which occurs when filter media is not properly sealed in the filter frame, when filters are not properly installed and gasketed in filter racks, or when air handler doors and ducts are not properly sealed. Bypass air can cause contamination in housings, coils, fans, and ducts and can increase system operating costs; fouled heat exchangers have diminished heat transfer performance and increased pressure drop, leading to increased energy use and decreased heating and cooling performance. Bypass air can also decrease a filter’s performance and negatively affect IAQ.

Keep in mind that bypass air tends to have a larger effect on high performance filters. A 1mm gap causes a MERV 15 filter to perform as a MERV 14 filter, while a 10mm gap causes a MERV 15 filter to perform as a MERV 8 filter.

One way to lessen the frequency of and purchase costs related to filter change-outs is to choose a high-capacity pleated filter which typically has an extended filter life along with a low resistance to airflow Pleated filters certainly offer advantages over “throw-away” panel filters.

First, while panel filters typically yield performance only in the MERV 1 to 4 range, pleated filters are available with performance up to MERV 13, allowing improved efficiency in capturing both large and small particles. Second, upgrading from panel filters to pleated filters provides cost savings advantages, thanks to decreased routine maintenance and energy costs. Because panel filters allow HVAC system components to become dirty, operating efficiency decreases and energy costs to operate the inefficient system can increase. The small amount of money saved by purchasing a lower priced panel filter can be substantially offset by even a slight reduction in the operating efficiency of the system.

One of the easiest ways to realize HVAC related energy costs savings is to switch to a filter with a lower resistance to airflow. When filters have a lower resistance to airflow, the HVAC system motor needs to overcome less resistance to deliver the required air flow, thus reducing the motor’s energy consumption.

Airflow resistance is calculated with a pressure gauge, which indicates Water Gauge (WG), the measure of the pressure required to lift a 4C-degree column of water a certain distance in the air. For example, a 0.05” WG reduction in a filter’s initial pressure drop (also known as airflow resistance) can reduce energy costs by up to 3.5% or about $7 per filter, while a 0.20” WG reduction in a filter’s initial pressure drop can reduce energy costs by up to 10% or about $28 per filter. While an energy cost savings of $28 per year may not sound like a lot, those cost savings are per filter, not for an entire HVAC system.

Skimping on air filtration during a tough economy has the potential to put facilities even deeper in financial trouble. It can negatively impact IAQ which can increase costs relating to worker health and productivity. It can also increase HVAC system operating and energy costs. While reducing the frequency of filter change-outs or downgrading to a lower-priced (and lower performance) filter may seem like good ways to reduce expenditures, they are not true cost-savings strategies. Because energy costs are the largest component of an air filter’s total life cycle cost, it is imperative for facilities to look beyond the line item purchase price of filters when seeking to reduce their overall costs and instead look at the initial and sustained pressure drops of different filters.