Wall Wisdom
In its original condition and based on 2006 fuel prices, the annual cost to heat Building 3 was estimated to be $350,000. The challenges of the renovation were not only to bring the structure up to current building and safety standards, but also to make it as efficient as possible while maintaining the original architectural character and craftsmanship.
The solution was to add insulation to the walls and roof, as well as retrofit the south-facing walls using an outer layer of metal wall panels that capture the heat from the sun to pre-heat ventilation air. A total of 11,670 square feet of 0.032 aluminum wall panels with a black KYNAR 500 PVDF- or HYLAR 5000 PVDF-based paint system were used in the installation.
The solar collector panels are perforated and installed several inches from the waterproof wall of the building, creating an air space between them. During cold months, the system is designed to provide pre-heated fresh air for the building by collecting the heat from the sun, generated when the suns rays warm the air at the surface of the dark colored panels. Ventilation fans mounted inside the building draw the solar-heated air through the perforations, into the wall cavity and then into the building’s interior through conventional ductwork.
The wall system also provides passive cooling in the summer by using a bypass damper that is opened at night to draw in cool air via the ventilation fans. The air then is distributed inside the building using ductwork. Because Cigas Machine’s production area is not equipped with air conditioning, this feature provides a more comfortable environment for employees as they start their workday. In extreme weather conditions, a thermal economizer air turnover unit is installed to supplement the system during days when there is weak sunlight and cold temperatures.
Because ceilings in the building are more than 65-feet high and there is limited clearance between overhead cranes and structural ironwork, destratification fans were installed to further achieve optimal air circulation.
More to the Eye
Further renovations to Building 3 include replacing the roof deck and roofing with a cool metal roof that reflects solar heat back into the atmosphere, reducing the building’s cooling needs during summer months.
Skylights were installed throughout the building, and fluorescent fixtures using T5HO lamps were installed where additional lighting was needed. Lights are on preset schedules and connected to lighting sensors that continuously evaluate information to determine light levels in various parts of the building. In addition, rainwater from the roof is captured in a 78,000-gallon barrel and used for process and sanitary purposes on the property.
With a little TLC, a building that played a role in creating our nation’s icons once again is contributing to our economy.