Retrofit Construction

AirBoss “SmartAir”

Big Box Facility Air Distribution System

Retrofit Construction Projects

Heating, Ventilation and Air-Conditioning Capital Cost Analysis

AirBoss “Smart Design” ® (patent pending design technology)

compared to Conventional designs with 4-way diffuser air distribution

AirBoss “SmartAir” designs utilize ASHRAE load calculations with HVAC system reductions due to the impact of continuous air flow (patent pending design). AirBoss systems are being utilized in big box facilities, including critical inventory distribution centers such as pharma, food and electronics. More than 3000 AirBoss units are installed and are distributing heated and cooled air in more than 100 million sf of facility space in Kentucky and Indiana. This is significant in that over 3 billion cubic feet of interior space are successfully being managed by AirBoss “SmartAir” systems. The net effect of this is the owners and operators of facilities with AirBoss systems, on average realize a $.26 per square foot of utility savings for heat/cool systems or $.17 per square foot for heat only system, annually.

AirBoss “SmartAir” system operating concept:

Cooling

Typically, interior temperature is managed by a system of thermostats. When the temperature near a thermostat varies by 2° to 3° F, the system begins to operate. HVAC units draw air from the interior near the ceiling, pass it over cold coils and return it to the interior, about 20° F cooler. For example, assume a ‘hot’ day and an inside set temperature of 75° F. The air that is near the roof is typically 10° to 15° F hotter at the roof than at the thermostat. That being the case, the air that enters the HVAC system, with returns at the ceiling, is 10° to 15° hotter because of the differential between the floor and the ceiling temperatures. All legacy design systems with 4-way diffusers, for air circulation, create this condition, referred to as ‘heat stratification’. The AirBoss system prevents stratification and thus maintains a uniform floor to ceiling equilibrium. When equilibrium is achieved, an HVAC system does not require as many system units or tons to maintain the required temperature. It is more efficient to cool air that is 2° to 3° F from set point, vs air that is 10° to 15° F from set point. Bottom line here, AirBoss system efficiency will allow for a substantial reduction in HVAC tons and at the same time improve interior comfort for occupants, due to continuous air circulation.

Heating

The AirBoss heating solution offers significant cost-effective benefits. With its constant interior air circulation, in the heating season, an AirBoss system takes advantage of all internal heat loads which minimizes the need for additional heat from gas or electric heaters. A big advantage for AirBoss is continuous interior air circulation which eliminates the need to continuously run big hp RTU fans or supplemental ceiling fan systems. This is true for all seasons. Ventilation: A unique ventilation design strategy can be incorporated in the design that measurably improves warm weather ventilation when air conditioning is not in the design. Flexibility: If there is a possibility that air-conditioning might be added to the system in the future, AirBoss is a very economical solution, with only the need to add cooling units to the already installed heating system. AirBoss provides a cost effective alternative to conventional hearing designs.

AirBoss system highlights:

For retrofit projects, AirBoss works extremely well. 1- AirBoss designs required fewer (15 to 30%) HVAC units which means the excess roof penetrations will need to be shuttered or possibly converted to skylights. 2- AirBoss units can easily be located in proximity to existing roof penetrations (HVAC units) in the building so that the performance of the HVAC system will be maximized.

Typical distribution center (actual FedEx Supply Chain facility housing medical products), 585,000 sf X 36’ ceiling height, 68° – 70° in summer and winter. Heating therm savings = $.17 sf and Cooling = $.09 sf for a total annual savings of $154,000, when compared to legacy designs. Qualified for $101,000 Vectren natural gas rebate.

System air throw – forward direction, approx. 300’ and sides 150’ each direction. When operating 24/7 AirBoss systems provide a continuous flow of air, eliminating air temperature stratification. This AirFlow design provides improved comfort and eliminates the need to continuously run big hp RTU fans or supplemental air circulation devices including ceiling fans

Maximizes the efficiencies of all roof top unit (RTU) HVAC systems allowing for 15 to 30% HVAC tonnage reduction.

Reduces first cost for heat-cool solutions and quick payback for heat only designs (less than one year for heat only solutions when compared to 80/20 systems).

Dramatic enhancement of corporate sustainability programs.

Lower maintenance due to fewer units to service and repair, 15 to 30%

Reduces equipment replacement cost at end of HVAC system life cycle.

How a building is subdivided for tenants or owner functionality is not usually an issue with Airboss designs. With an AirBoss design there are no restrictions on where walls may be placed or how big or small a tenant space may be. Conversely, for example, should a 200,000 sf building that has two 80/20 units needs to be subdivided into four 50,000 sf spaces, two additional units will be required along with the costly roof penetrations.

TPO roof systems with AirBoss technology for air distribution do not experience excessive positive interior pressure. Excessive positive pressure is frequently an issue with 80/20 systems and systems with greater outside air intake. This condition can cause roof ballooning which can lead to a moisture buildup between the membrane roof material and the insulation. Trapped moisture can lead to mold and mildew which can also cause the TPO roof warranty to be voided.

Capital cost estimates for various new construction design scenarios: NEED VENTILATION COSTING

Heat only design comparisons (retrofit construction), note: The only condition where the day one capital savings is not significant is the heat only design. In an estimate of a 200,000 sf facility, the day one capital is approximately $.19 per sf higher for the AirBoss design. However, there is, on average, a one-year payback, after which there will be a $38,000 per year net utility savings. As a bonus you get lower humidity in the summer and year-round circulation, which means the comfort level is dramatically better in the AirBoss design.
Heat, air conditioning and 24/7 circulation comparisons (new construction)

Design conditions for all scenarios:

Warehouse or distribution center application,

Tilt-up open ceiling box design construction

200,000 sf w/30 ft ceiling height

Location: Louisville, KY

Design temperature: 95° F summer, 0° F winter

Electric cost: $.094/kwh and gas cost: $9.04/mcf

Upgrading an AirBoss – AirFlow Heat and 24/7 Circulation Only Design to an AirBoss Heat, Air-conditioning Design and 24/7 Circulation

(Retrofit Construction)

Design – Upgrade an AirBoss – AirFlow heat only design to an AirBoss – AirFlow heat, air-conditioning and 24/7 circulation design temperature to 78° F, (6 months heat and 6 months cool with 24/7 circulation)

6 ea, 25 -ton Rooftop units

6 ea, duct drops

2 ea, AirBoss ER-142 units

Materials:

Labor:

Manlift:

Forklift:

Crane:

Total System cost: $115,495.00 $.58 per sf

Upgrading a Legacy Heat and Air-Conditioning Design to an AirBoss – AirFlow Heat, Air-Conditioning and 24/7 Circulation Design

(Retrofit Construction)

Design – Upgrade a legacy heat and air-conditioning design to an AirBoss – AirFlow heat, air-conditioning and 24/7 circulation design

*Retain 150-tons (6 units) of existing 25-ton RTU equipment

New equipment:

3 ea, AirBoss ER-242 units

3 ea, AirBoss ER142 units

Materials:

Labor:

Manlift:

Forklift:

Total system cost: $57,361.00 $.29 Per sf