Organization: MCAA

NIBCO’s Tips for Designing an Efficient Hydronic System

Designing an efficient hydronic system is no easy task. The needs of each system can vary greatly from one job to the next, although the core elements remain mostly the same. In a typical system, you will usually find a boiler, circulator pumps, an expansion tank, various heat distributors, and accessories such as vents, valves, and drains. Selecting the right components for the best installation, servicing, and control of the system and its equipment are key to the efficiency of the job.

These are things to look for when designing a modern and efficient hydronic system:

  1. Starting at the boiler, consider a manifold with integrated shutoffs and drains to simplify installation and service of the primary heating loop. This solution combines closely spaced tees with isolation valves to (1) achieve hydraulic separation for the heating loops, (2) isolate the circulator pump, and (3) purge the system. Using a manifold with the right piping kit can save an impressive 261 minutes of labor, eliminate 29 leak paths, and replace 34 individual components. For combination boilers or tankless water heaters, choose a service valve kit that combines union-threaded isolation valves for the hot-water outlet and cold-water inlet with high-flow purge drains and a port for the required pressure relief valve. The service valve kit in this installation saves 108 minutes of labor, eliminates 12 leak paths, and replaces 14 components.

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  2. For the system pumps, choose a uni-flange ball valve that connects to the circulator pump at one end and the system piping at the other. It enables the user to isolate the pump for service, allowing virtually no air into the system upon replacement. Optional features include a removable rotating flange, slotted bolt holes for high velocity pumps, a round flange for variable speed pumps, and a multifunction high-flow hose drain. Choosing this forged brass alternative to field assembly can save up to 63 minutes of labor, eliminate seven leak paths, and replace eight components.

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  3. At the expansion tank, three-way ball valves can be installed to address the various needs of the tank. These valves are designed to allow the user to easily install, isolate, drain, or replace the tank, as well as connect the system to the supply feed. It also provides a connection to an air separator, which separates and vents trapped air from the system via a unique stainless-steel coalescing medium. This single valve can save 54 minutes of labor, reduce six leak paths, and replace seven components.

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  4. Heat distribution methods can vary widely, from standard equipment such as baseboard heaters and radiators to premium installations such as in-floor heating and snowmelt systems. Use thermostatic mixing valves on any of these water distribution systems to ensure that the fluid is delivered to the device at the appropriate temperature. With eight end connections and optional union temperature gauge and isolation valves, thermostatic mixing valves can be customized for any installation.

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  5. Within the heating loops, some unique products on the market can control flow between primary and secondary zones. One such product is a valve that places a ball valve between two closely spaced tees—a configuration impossible to achieve using off-the-shelf components. For optional loops such as the snowmelt zone, look for products that assist with routine maintenance of the fluids. For the snowmelt zone, for example, the loop is outfitted with a three-way ball valve that isolates the flow between two independently actuated hose drains, allowing the user to simultaneously purge and fill the system. It saves 54 minutes of labor, eliminates six leak paths, and replaces seven components.

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  6. The remaining needs of the system can vary but mostly depend on shutoffs and drains. Combination ball/drain valves can be used anywhere the user needs to isolate and drain a portion of the system. They can save up to 45 minutes of labor, eliminate five leak paths, and replace six components. They can also be adjusted to drain from either side of the ball. For more simplified draining needs, a T-style drain can be installed anywhere a drain is needed that does not require isolation.

Hydronic systems have changed over the years. Many innovative products, such as NIBCO’s Webstone® valves, save labor, space, and leak paths. When designing your next hydronic system, consider the newest valve innovations available. In a complete installation, valve selection is essential to having a modern and efficient hydronic system. With the right products, you can expect to replace 220 components, save over 26 hours of labor, and eliminate 177 leak paths.

In a complete installation, valve selection is essential to creating a modern and efficient hydronic system.

For more information, visit www.nibco.com.

Find the Latest from Watts Water Technologies, Jay R. Smith Mfg. Co.® and More in MCAA’s Virtual Trade Show

MCAA’s Virtual Trade Show connects our contractor members with the members of MCAA’s Manufacturer/Supplier Council.

Participating companies highlight and link to new products, product lines, services, solutions or web pages of particular interest. Here are just a few of the recent additions:

Watts Water Technologies - MCAA Virtual Trade Show
Watts Water Technologies
Say hello to Pronto!™ – the brand new adjustable floor drain from Watts® that provides maximum efficiency and accuracy during installation. Designed for post-pour adjustment with flexibility in mind, Pronto! Key product features save contractors time and labor costs.

Learn More

Jay R. Smith Mfg. Co.® a Member of Morris Group International - MCAA Virtual Trade Show
Jay R. Smith Mfg. Co.® a Member of Morris Group International
Tired of taping up your strainer heads before a pour? This cover eliminates that step and protects the finish during shipping and on the job site. Discover more products that save you time on the job.

Learn More

Need Something Else?

Find many more smart solutions in MCAA’s Virtual Trade Show!

Visit the Virtual Trade Show

Speaking of Smart Solutions

Visit the Smart Solutions Case Studies area of our website to learn how other mechanical contractors found their win-win with cost-saving and productivity-enhancing applications from members of MCAA’s Manufacturer/Supplier Council.

This section of our website also includes tips and ideas to help your company save money and enhance your productivity. Don’t miss it!

VISIT SMART SOLUTIONS

Warner Mechanical Uses Aquatherm Pipe to Help Manufacturer Rebound Quickly from Roof Collapse

A roof collapse could have knocked IVP Plastics of Washington, IL, out of commission for a long time, but Warner Mechanical LLC, of Edwards, IL, used Aquatherm polypropylene pipe in the rebuild, helping the manufacturer get back to business quickly. The heat fusion process made Aquatherm piping easier and faster to install than traditional welded pipe, saving Warner Mechanical time.

From Disaster, New Opportunities

IVP Plastics was founded in 1953; today, it is a leading provider of customized plastic parts for the agricultural, heavy equipment, and automotive industries. On March 24, 2018, a late-season storm caused a portion of the roof to collapse at the IVP Plastics headquarters, a 20,000-square-foot, clear-span building. Fortunately, no one was injured. Although damage to the building itself was significant, a crane rail running the length of the ceiling spared much of the company’s manufacturing equipment from serious damage.

About two weeks after the collapse, Jeff Frieden, president of Warner Mechanical, visited the damaged manufacturing facility. “We sat down with the IVP Plastics team, the general contractor, and the insurance company, and the bottom line was that time was of the essence,” Frieden said.

The decision was made to replace the damaged building with a new one, and IVP Plastics requested that Warner Mechanical design the process piping system for the 16 machines that would be moved into the new building. The old process cooling system had used 6″ PVC pipe running overhead at the ceiling. The company said it preferred a system that would place the pipe in mechanical
trenches behind each run of machines.

Frieden knew immediately that Aquatherm would be a good choice for such a piping application, and IVP Plastics’ management agreed. Warner Mechanical used Aquatherm SDR-11 MF Blue Pipe® for the process chiller piping: 1,575′ of 4″ pipe, 247′ of 3″ pipe, and 156′ of 1 1/2″ pipe. They also used 507′ of 1″ Aquatherm Green Pipe® for clean-up water.

Plastic Pipe Eases Maintenance Concerns

The system designed by Warner Mechanical called for most of the pipe to be located in trenches under the equipment in the concrete floor of IVP Plastics’ new manufacturing facility. Fittings emerging from the trench covers allow the manufacturing machines to be hooked up easily whenever the process line is reconfigured. The company’s process chiller provides 40° F cooling water to the machines, with return water flowing through the Aquatherm pipe at up to 100° F.

“We decided to do things differently at the new facility,” explained Joe Camp, engineering manager at IVP Plastics. “We wanted to put the process plumbing in the floor, and it was Jeff’s recommendation to use the Aquatherm pipe for that. It will be nice to not have pipes sweating and dripping, which was a problem when we had the PVC overhead.

“Another nice feature of the Aquatherm pipe was that we could get longer continuous lengths of pipe, so we had fewer joints to deal with,” Camp added.

The clincher for IVP Plastics, according to Camp, was Aquatherm’s virtually leak-free performance, backed by an extensive and comprehensive 10-year warranty because it was installed by Warner Mechanical’s Aquatherm-trained technicians.

“There is definitely peace of mind that comes from investing in a product with a warranty like that,” Camp said.

Warner Mechanical found that Aquatherm polypropylene pipe was ideal for the new IVP Plastics facility, and it is easier and faster to install than traditional welded pipe, saving the contractor time and money.

Perfect Pipe for Plastics Pros

For Warner Mechanical, an undeniably interesting aspect of this project was installing Aquatherm in a plastics manufacturing facility. “As we discussed this project with IVP Plastics, the owners were very pleased to see the range of temperatures and pressure ratings that were available to them,” Frieden said. “After our initial conversations, the owners researched it themselves and were very impressed by what they saw. When you’re working with a plastics company and they’re researching plastics, you’re playing with experts.”

Once the project began, the installation of the Aquatherm pipe attracted a great deal of attention from IVP Plastics’ personnel. “The engineers were watching us put this in, and it really intrigued them—being a plastics company—that we were putting this thermoplastic piping in their building,” Frieden said.

“Once they saw the benefits of the heat-fusion welding process, they had total confidence in the durability of the product,” Frieden continued. “They could understand when it’s properly heat-fused there would be no leakage problems.”

Frieden added it was much faster and easier to heat-fuse the Aquatherm pipe and place it in the trenches than it would have been to weld metal pipe. “I think any time you’re in a process where you would typically turn to welded piping, you should look at the time savings and durability of Aquatherm pipe,” he said. “For this customer, using Aquatherm enabled us to reduce the time it took to complete the system and allow the owner to start production.”

“I also really think it’s a great choice any time you’re in a buried or constrained space,” Frieden concluded. “It’s easier to work with than metal pipe, and it offers a big advantage in peace of mind. You know you can walk away from it and when the job’s complete and not worry about leaks.”

For more information, visit aquatherm.com.

Message from William Hughes, M/SC Chair: Putting Your Money Where Your Mouth Is

In this issue of Smart Solutions, see how MCAA supplier partners are putting their products to the test by having them installed in their own buildings. Using Viega products on Viega’s new building, Braconier Mechanical and Plumbing Services reduced the manpower needed considerably. For Carrier’s new headquarters, Hill York Service Company’s expertise in installing Carrier
products helped the company achieve LEED® Platinum certification.

Taking Tech Further

Read how contractors are using new technology to improve business. Arista Air Conditioning Corporation is arming technicians with the cloud-based XOi mobile app and letting customers see what the techs see. Using Key2Act’s Connect, Harris Company gathers data from building controls and sensors to identify problems much faster than traditional troubleshooting methods.

Jackson & Blanc digitized its timekeeping process with Rhumbix Core, saving about $52,000 per year in labor costs alone. Just two years after implementing STRATUS software from GTP Services, University Mechanical Contractors, Inc. saved hundreds of thousands of dollars in packaging, spooling, and cutting costs. Complete Temperature Systems slashed office staff time by 14 hours per week using MobiliForms from iBusiness Technologies. MMC Contractors simplified its day-to-day labor management tasks with LaborChart, freeing up workers to focus on other activities.

Ease and Efficiency

Our supplier partners can make installation easier and provide you with efficient solutions. EVAPCO created an updated version of a building’s original cooling tower for the same space, making installation easier for Elliott-Lewis Corporation. To rebuild a facility after a roof collapse, Warner Mechanical LLC used Aquatherm polypropylene pipe because it was easier and faster to install than traditional welded pipe. ACCO Engineered Systems installed 138,000’ of tubing with Uponor’s Radiant Rollout™ Mats in five months—much faster than conventional PEX rails or tie-down methods would have required. Sloan’s preassembled plumbing fixtures saved AMS Mechanical Contractors installation time and helped it meet clients’ energy efficiency goals. A New Hampshire hospital upgraded to Daikin chillers, cutting energy use in half and reducing maintenance costs.

Expertise on Tap

This issue also draws on the considerable expertise of our supplier partners. Learn how Victaulic’s building information modeling saved Kruse Corporation nearly $20,000 on a renovation project. IFS offers advice on selecting the best field service management software. NIBCO describes how to design an efficient hydronic system. Jay R. Smith Mfg. Co.® provides tips for specifying a trench drain system. CNA explains what you can do to prevent deadly distracted driving. I hope you’ll find a lot to learn from Smart Solutions!

Kruse Saves Thousands Using Victaulic BIM and Products

Contractor Meets Tight Timeline for Renovation of Wichita’s Union Station

Victaulic’s building information modeling (BIM) expertise saved Kruse Corporation an estimated $15,000 to $20,000 on the renovation of Union Station in Wichita, KS, while the streamlined construction approach reduced build hours from 4,000 to 3,100, yielding an additional $40,000 in labor savings. The combination of BIM services and Victaulic products simplified coordination,
reduced risks during construction, and cut the manpower needed for this project in half.

Laying the Foundation for Project Downtown

Project Downtown is Wichita’s master plan for developing the city’s urban core to increase the community’s quality of life and encourage regional economic growth. It focuses on key stretches of the downtown area and includes both private and public investment. Union Station, a two-story train depot built in the early 1900s as a central railway station, was repurposed as a commercial office building when the city ended its passenger rail service in 1979. Today, it is central to the city’s ambitious urban renewal project.

In September 2018, Kruse was selected to renovate the hydronic piping system in Union Station. The project schedule was ambitious—even without considering the unknowns of a building more
than a century old and the fact that work would have to take place during the winter holidays. With a move-in date of April 1, 2019, for the new commercial tenants, Kruse was determined to meet the exacting schedule, so they reached out to Victaulic and laid out the requirements and timeline.

Before construction could begin, it was important to understand the workspace. Union Station’s mechanical room was in the unlit basement, which meant there was limited space. The area was only 6′ high, and the contractor knew at the outset there was insufficient space for the hydronic system. Excavation would be necessary before work could begin, so it was critical to understand the layout, potential interference from existing structures, and the proposed placement of the new system components.

Victaulic’s 3D scans streamlined design conversations with Kruse and others, because the model and the scans could be overlaid to ensure the designs were aligned with the space.

Site assessments usually begin with a sketch made from physical measurements, a process that takes a lot of time and can be flawed. Victaulic’s Virtual Design and Construction (VDC) team used a FARO 3D scanner to assess the basement instead. Using the scanner allowed the team to quickly compile measurements of the room and the existing piping network while eliminating the need
to go back to the jobsite for a missing measurement. As the project progressed, the scans streamlined design conversations, because the model and the scan could be overlaid to ensure the designs were aligned with the space. While traditional site assessment methods would have taken two to three days, the digital scan was completed in a single day.

The scan verified that the planned installation matched the room dimensions and confirmed which areas needed to be excavated. The data, made up of more than 40 scans, fed into the BIM software, ensuring the correct dimensions were used. As a result, designers from Victaulic, Kruse, and other trades were aware of any potential interference as components were assembled for the hydronic piping systems.

Coordinating in Real Time

Using Victaulic Tools for Revit®—a pipe-routing software add-in—the VDC team drew all piping sized 2.5″ and larger and submitted the drawings to Kruse. Once everything was approved, Victaulic began drawing equipment and piping schematics and shared a virtual model with the Kruse design team.

Taking advantage of Navisworks to identify clash detection, designers from both companies began piecing the system together, noting, for example, that previous electrical components posed impediments that would require piping to be routed around them. This information allowed the teams to coordinate workarounds that would permit construction to proceed without interruption,
streamlining the design and avoiding costly and time-consuming rework down the road.

Using Trimble layout software, the teams were able to see where components were placed in relation to one another. The Victaulic model was imported to the Kruse model to ensure system design was coordinated throughout the project. Kruse laid out duct work and hangers based on the piping design developed by Victaulic. Once the designs were confirmed, semi-trailer trucks excavated
47 loads of earth to prepare the space for the hydronic systems.

Expedited Construction

A nearby Victaulic facility manufactured the pipe spools for installation and shipped them to the jobsite, following the BIM assembly map provided by the design team. Because Kruse knew exactly what was coming and when, they efficiently organized and executed a systematic construction schedule. While work was being done in the Victaulic shop, Kruse was installing hangers in preparation for the pipe spool delivery. Once a spool arrived on the jobsite, it was lifted straight up into the hangers.

With piping systems being installed in a confined space, ventilation was a safety concern. Welded connections would not be feasible because of the open flames and fumes. Kruse decided the most efficient way to meet the schedule would be to use Victaulic’s grooved mechanical joining system, which would allow joints to be connected safely and easily in this space-restricted area.

Using BIM to schedule the work resulted in significant time savings, allowing installers to complete 80 percent of the basement in just a few days. Everything fit as intended, enabling accelerated installation. By using visually inspectable parts, workers could verify proper installation as the system came together, enabling work to proceed safely and delivering a reliable and robust system.

Wichita celebrated the grand re-opening of Union Station on May 16, 2019.

For more information, visit www.victaulic.com.

Elliott-Lewis Installs Resurrected EVAPCO Cooling Tower for Historic Philadelphia Residence

Recreating Discontinued Model Makes for a Smooth Installation

Downtown Philadelphia’s Benjamin Franklin House needed an HVAC overhaul but, like most historic buildings, had no room to expand. EVAPCO reached into its archives for the specs of the building’s original cooling tower and created a more powerful, up-to-date version for the same space, making the installation process easier for Elliott-Lewis Corporation.

Time for an Upgrade

The Benjamin Franklin Hotel—now known as The Franklin Residences or, simply, “The Ben”—was built in 1923. Upgrading historic sites typically comes with challenges, such as limited space. The building’s owners recognized that keeping tenants and guests comfortable during increasingly warm and humid summers would take the right systems and equipment working with minimal or no downtime.

EVAPCO recreated a discontinued cooling tower to fit the tight quarters occupied by its original unit in the historic Benjamin Franklin House, simplifying the installation process for Elliott-Lewis Corporation.

A key component of The Ben’s cooling system is the cooling tower that serves a water-sourced heat pump loop in the building. For many years, this loop met most of the building’s cooling needs. Several suites still use packaged terminal air conditioner units, but many tenants have requested the switch to heat pumps. In addition, the retail space expanded from one floor to two. These changes have increased demand on the heat pump loop.

Mike McCauley, sales engineer at Elliott-Lewis Corporation, explained yet another reason for the demand increase. “Some equipment loses efficiency as it gets older. Back when it was built, the system was designed to meet certain demands. Well, those demands have changed. We have warmer summers now, and that’s taxing on older equipment. You can have the best maintenance in the world and [the system] still won’t be as efficient as it once was.”

The increased demand did not come with increased floor space for a second cooling tower or even a new, larger one. The owners were faced with a challenge: how to get more cooling capacity using the same footprint. At the same time, the existing cooling tower, which had served the building since 1984, was reaching the end of its useful life.

“Our company maintains the cooling tower on this site,” said McCauley. “We realized that the equipment was at its end of life and told the owners that if they didn’t replace it soon, they’d be spending lots of money refurbishing it.”

Old Meets New

When the original cooling tower was built, it was not subject to certifications or ASHRAE 90.1 requirements, and building codes were different too. The building needed a new cooling
tower that met current requirements—yet had the same footprint and a greater capacity. Engineers were called in to tackle the design, and Elliott-Lewis Corporation, which has served Philadelphia for a century, was chosen to install the new cooling solution.

The original cooling tower was a discontinued EVAPCO unit, a PMTQ cooling tower. So, EVAPCO retrieved the design from their archives and built a new one to meet all the requirements for the project, including a sharply increased cooling demand, while maintaining the same footprint. EVAPCO’s solution increased the system’s cooling capacity on the heat pump loop from about 565 tons to 675 tons, without sacrificing space.

The original galvanized material was replaced by stainless steel, ensuring durability and a long lifespan. The addition of a custom fiber acoustic base for the tower ensured that the new unit was fully up to code.

Quiet and Efficient

The new tower also needed to meet or exceed current codes for thermal and acoustic performance. The building sits in a densely populated part of Philadelphia, surrounded by office buildings and residences, so noise is a concern. The new unit features EVAPCO’s super low sound fan instead of the typical centrifugal fan that would be used with a forced draft system.

In addition, the unit has four fans drawing a total of 60 horsepower, up from the original unit’s 40 horsepower. Despite this increase, which achieves a greater capacity, the unit’s performance is more energy-efficient at part loads. Each fan is driven by a variable frequency drive (VFD) designed to run at part loads rather than cycling on and off when the demand changes.

With VFDs, the unit can run all four fans at, for example, 30 percent, which is much more efficient than running one fan at 100 percent. The unit only uses the energy needed at any given load.

Overcoming Other Challenges

The heat exchanger, originally designed to meet the lower demand, would not serve the upgraded cooling tower to provide extra cooling to the building. Rather than replace the heat exchanger, the owners chose to modify the existing piece of equipment. Because there was enough room to add additional plates to increase capacity, the original heat exchanger was cleaned and expanded.

Replacing the Benjamin Franklin House’s old cooling tower with a modernized version allowed for minimal pipework, saving Elliot-Lewis time.

Replacing the old cooling tower with a modernized version allowed for minimal pipework, saving Elliot-Lewis time. “There were some piping changes,” said McCauley. “Old pipe was replaced because of its age, but other than that there was only some rerouting of pipes to accommodate the new tower dimensions.”

Controlling the cooling tower required integration of the unit’s VFD controllers into the building management system. This step proved to be a challenge at first, but since its startup, the unit has been able to meet its required performance with no complaints from the owners. With its sturdy equipment and supportive professionals, The Ben is sure to maintain its reputation for luxury for many years to come.

For more information, visit www.evapco.com.

Braconier Saves Time, Money with Obvious Choice for New Viega Headquarters

Viega MegaPress, ProPress Cut Installation Time, Minimize Fire Risk

While it is no surprise that Viega chose to put its own products into its newly constructed building, Braconier Mechanical and Plumbing Services said using Viega products was a good option for them, too. “We reduced the manpower needs on this project by using Viega. That’s a big advantage of MegaPress—we can have a smaller crew and still stay on schedule,” said Tom Stone, president of Braconier.

Viega’s new North American headquarters building takes full advantage of its own state-of-the-art products, including radiant heating, snowmelt for outdoor walkways, and touchless bathroom fittings. The ease of use of MegaPress and ProPress helped streamline installation. Efficient products like Viega’s Flushing Technology Systems will save the company money moving forward. The headquarters building, and the Colorado Seminar Center located next door, opened earlier this year in Broomfield, Colorado.

Viega’s two new buildings use ProPress fittings behind the walls to provide potable water because, as Braconier President Tom Stone said, soldered joints might leak, but ProPress joints do not.

In the two new Viega buildings, ProPress fittings behind the walls provide potable water. “With ProPress, the biggest advantage for us is there are no callbacks and no leaks,” said Stone. “With solder joints, you’re likely to get some leaks and warranty callbacks. That doesn’t happen with Viega fittings.”

By using Viega’s MegaPress and MegaPressG fittings in the predominantly wooden structure of Viega’s two new buildings, Braconier avoided having open flames and did not need to protect against the mess of welding and soldering.

MegaPress connects the fire sprinkler system, and MegaPressG fittings were used on the natural gas lines. “Especially with this being a big wooden structure (the buildings are filled with cross-laminated timber), not having open flames involved in the process of putting the pipe together is a big bonus,” Stone added. “Plus we don’t have areas to protect from the mess of welding and soldering.”

Radiant heating and cooling systems are installed in both buildings. Stone said the biggest benefits of using radiant versus traditional forced air come after installation. Radiant provides a truly even temperature no matter the location, and the efficiency leads to lower operating costs and a more comfortable setting.

Stone said the radiant system in the seminar center—which contains more than 36,000 linear feet of tubing—was the largest radiant job Braconier had ever installed. The bare concrete floors of the seminar center, as well as both the carpeted and concrete areas of the headquarters building, stay comfortable year-round with the radiant products.

The radiant system in the seminar center—which contains more than 36,000 linear feet of tubing—was the largest Braconier had ever installed. The bare concrete floors stay comfortable year-round with the radiant products.

Snowmelt systems were installed in front of both buildings, so walkways will remain clear regardless of the Colorado weather. This equates to less maintenance and no chance of icy slips or falls by employees or visitors.

The bathrooms feature Viega in-wall carriers and touchless flush plates. The Viega Flushing Technology Systems products provide a sleek, modern look and make maintenance easy. With the tank inside the wall and bowls off the floor, cleaning is simplified. Touchless flush plates help improve hygiene for users, and the choice of a small or larger-volume flush means less water is used.

“For us, the number-one reason we use Viega is because when you install, you’re done. There are no warranty callbacks, no leaks,” Stone said. “Compared to other systems, Viega seems to have the largest product line. You’re not going to be missing a type of fitting or anything like that. Definitely the performance of the system is key. You just don’t have any leaks.”

For more information, visit www.viega.us.

With Close Collaboration, Hill York Saves Time, Carrier Saves Money

Carrier’s New Global Headquarters Achieves LEED Platinum Status

Hill York Service Company worked closely with Carrier Corporation for nearly a year before construction began on Carrier’s new headquarters, and Hill York’s input saved Carrier $1 million. Moreover, Hill York introduced a novel approach to installing Carrier’s chilled induction beams that allowed the contractor to save time on the project’s tight schedule. Thanks in part to Hill York, Carrier’s new headquarters also met stringent indoor air quality (IAQ) standards and received LEED® Platinum certification.

Building a Model Facility

When Carrier was building a world-class, first-of-its-kind facility, selecting the right HVAC contractor was key. As the new global headquarters for Carrier—the inventors of modern air conditioning—the Center for Intelligent Buildings in Palm Beach Gardens, FL, required a high-caliber contractor to install and configure the HVAC equipment that Carrier designs and manufactures. Carrier chose Hill York, an EMCOR Company based in Ft. Lauderdale.

Hill York, founded in 1936, designed and installed the first air conditioning systems in Miami Beach hotels after World War II. It has since played a key role in ensuring that premiere Florida facilities achieve indoor comfort and energy efficiency. “Historically, Hill York has worked closely with Carrier to deliver the best solutions and pricing,” said Jeff Phillabaum, Hill York’s president.

Products in Action and on Display

Completed in 2018, the 224,000-square-foot building was designed to showcase new technology for customers from around the world. The building reveals the unseen, putting the most advanced integrations of Carrier’s solutions and services in action and on display.

Every product displayed is in use somewhere in the building, and visitors can see how they function in real time. The building was designed specifically to demonstrate what is possible in the building technology space. Critical building technologies—typically hidden in mechanical rooms, behind walls, or on rooftops—are openly displayed.

 

To meet the tight construction schedule for Carrier’s state-of-the-art headquarters, Hill York recommended setting Carrier’s ActivAir chilled induction beams in place before the ceiling contractor’s installation—a dramatic timesaver.
Hill York’s recommendations contributed to a $1 million savings on Carrier’s building project and included a final design that used 350 chilled induction beams.

Hill York Showcases Innovative Solutions

“The Center for Intelligent Buildings is truly iconic,” said Phillabaum. “It was one of those rare projects that, for HVAC professionals, comes along once or twice in a lifetime. It allowed us to showcase our full range of innovative solutions and craftsmanship on a world-class stage.”

Hill York’s solutions and uncompromising quality not only met the stringent technical and comfort specifications, but also substantially reduced costs. “Our recommendations helped contribute to a $1-million savings on the project and included a final design that used 350 chilled induction beams,” said Phillabaum.

But Hill York would take the chilled induction beams installation one step further.

“All the Carrier ActivAir™ units were set in place prior to the ceiling contractor’s actual installation,” commented Anthony Scalone, Hill York’s onsite project superintendent for the installation. “We worked very closely with the ceiling contractor to confirm each unit’s precise measurements and position. This proved to be a critical and successful part of the puzzle,” he noted.

Hill York “worked very closely with the ceiling contractor to confirm each unit’s precise measurements and position. This proved to be a critical and successful part of the puzzle,” said Anthony Scalone, Hill York’s onsite project superintendent for the Center for Intelligent Buildings’ installation.
To shave time off the installation timetable, Hill York prefabricated offsite many of the piping components that typically would have been done onsite for Carrier’s new headquarters.

Scalone continued, “One of the most significant challenges was the tight schedule of this project, but we knew that getting the chilled beams in position first would be a dramatic timesaver.”

To further shave time off the installation timetable and help their overall cost-reduction strategy for the building owner, Hill York prefabricated offsite many of the piping components that
typically would have been done onsite. During the construction phase, Carrier Rentals supplied five portable packaged units ducted directly into the site throughout construction.

The Center for Intelligent Buildings illustrates the value of collaboration and communication between Hill York and the in-house engineering staff. “We worked very closely with engineering, both during the construction phase and through the commissioning of the project,” said Scalone. “Furthermore, we enjoy an ongoing relationship with them.”

Taking Technology to the Next Level

Visitors to the building can use augmented reality—a technology that superimposes a computer-generated image on a user’s view of the real world—to see the airflow in the four-story entryway. Building tours are customized to the visitor, so an HVAC consulting engineer and a security professional would receive different content relevant to their areas of expertise.

In the Customer Experience Center, solutions are highlighted across all product segments so that customers see products at work in the building. A prominent residential space built to look like an actual home shows how HVAC, fire, and security products all connect. Here too, Hill York installed all of the HVAC components.

Efficiency and Productivity

The Center is designed to meet IAQ conditions found by Harvard University researchers to double occupants’ cognitive function test scores, compared with a conventional building environment. “The building owners were adamant about meeting the stringent IAQ standards, and we executed the testing to ensure that they were, indeed, met,” said Scalone.

From its inception, every component of the Center for Intelligent Buildings was developed with sustainability in mind. As a result, it is the first commercial building in Florida to earn the coveted LEED Platinum version 4 certification. The Platinum rating—the highest designation—was awarded under the stringent LEED green building program for building design and construction from the U.S. Green Building Council.

“We take great pride in knowing that Hill York’s HVAC installation in the Center for Intelligent Buildings project helped the building achieve efficiency ratings that contributed to obtaining the LEED Platinum v4 certification,” Phillabaum said. “As a testament to this, we have used the facility to host events for various professional organizations that we support, and we held our annual sales meeting there.”

Phillabaum has also used the Center as a selling tool, taking prospective clients on tours of the facility to illustrate the level of craftsmanship, skill, and expertise involved. “It’s a project that distinguishes Hill York and clearly defines who we are,” he concluded.

For more information, visit www.carrier.com/commercial.

Transform Your Field Leaders’ Perspective – Give them a Network of Peers

In their fast-paced jobs, it’s easy for field leaders to feel isolated. The Field Leaders Conference will transform their perspective by enabling them to share stories and challenges—as well as solutions— with jobsite leaders from outside of their area. By participating in discussions and interactive exercises as a team, they will develop a group of contacts they can call upon when they’re up against a tough challenge. Take it from Jeff Ranke of Smith & Oby, “I am so glad I was sent to the Philly Field Leaders Conference. I needed this. Very helpful. Great speakers. I took a lot from this. Nice to know I’m not alone.” Choose your preferred city for details – it’s the same education.

Save Time on Your Next JHA with this Guide

It’s no accident that job hazard analyses (JHA) are required by many construction owners, GCs, CMs, and government agencies. These analyses help significantly reduce the risk of workplace incidents that could result in injury or property damage, thus reducing cost. Whether you’re developing a JHA to meet a requirement, or as part of your company’s standard process, this resource gives you a head start.

Inside, you’ll find:

  • Information to help you identify the jobs that require hazard analysis
  • Guidance on developing JHAs for your projects
  • A sample JHA that uses the hazards and safe work practices outlined in the guide
  • A list of job components, along with the associated hazards and safe work practices for each, that can be easily plugged into your JHA

Using these tools and guidelines will save you time and make the JHA development process easier and more cost-effective than starting from scratch.

reEVALUATE and reESTABLISH Your Financial Health at MSCA19

This year at MSCA19, being held October 13—16 in Colorado Springs, CO, we are honing in on financial health — both personal and business.

reEVALUATE Your Personal Finance

We invite you to reEVALUATE the tenets of Personal Finance with Innovest Vice President and Certified Financial Planner® Jared Martin. Jared will outline aspects of personal finance and ways to reinforce your finances through estate planning, education planning, investing and retirement planning and will identify best practices that can maximize efficiencies for retirement. You’ll leave with tools to ensure your money is working for you!

reEVALUATE the Financial Health of Your Service Business

The key to financial health and sustainability is knowing what financial benchmarks you should be measuring and why. Join Leah Gutmann, owner of First Forward Consulting, LLC, to reESTABLISH and sustaining the financial health of your service business. Leah will share results from the 2019 MSCA Benchmark Survey and explain what these findings mean to you!

Discover the Latest from The Harris Products Group, Delta Cooling Towers, Inc. and More in MCAA’s Virtual Trade Show

MCAA’s Virtual Trade Show connects our contractor members with the members of MCAA’s Manufacturer/Supplier Council.

Participating companies highlight and link to new products, product lines, services, solutions or web pages of particular interest. Here are just a few of the recent additions:

The Harris Products Group - MCAA Virtual Trade Show
The Harris Products Group
DynaFlow® contains considerably less silver, making it an excellent cost effective alternative to 15% silver alloys. Contact Harris for a Brazing Cost Reduction Analysis. Call 800.733.4043.

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Delta Cooling Towers, Inc. - MCAA Virtual Trade Show
Delta Cooling Towers, Inc.
TM Series – capacity from 250 to 2000 cooling tons – Engineered plastic tower provides longer life – Low Maintenance – CTI Certified.

Learn More

Need Something Else?

Find many more smart solutions in MCAA’s Virtual Trade Show!

Visit the Virtual Trade Show

Speaking of Smart Solutions

Visit the Smart Solutions Case Studies area of our website to learn how other mechanical contractors found their win-win with cost-saving and productivity-enhancing applications from members of MCAA’s Manufacturer/Supplier Council.

This section of our website also includes tips and ideas to help your company save money and enhance your productivity. Don’t miss it!

VISIT SMART SOLUTIONS

Collaborative Programming Aimed at Labor-Management Success

From discussions on apprenticeship best practices, diversity, and service to an MCAA-sponsored session that lets apprentices understand the management side of the business, the 2019 UA-MCAA Labor Relations Conference: Succeeding Together will enhance your understanding of both UA and MCAA viewpoints. With mutual understanding, we can work toward continued work for UA members and profitable jobs for MCAA contractors, and that’s a win for everyone!

Help Your Field Leaders Understand Their Impact on Profitability

Many in the field may not realize how their daily job impacts the people they work with and the bottom line. At the MCAA Field Leaders Conference, your field team can benefit from the know-how of someone who has experienced it all in The Foreman’s Impact on Profitability session led by MCAA member Mark Rogers. Rogers began his career as a Steamfitter Apprentice in 1986 with Local 420 in Philadelphia, went on to start his own mechanical contracting company in 1996 and served as MCAA President in 2011. He volunteers around the country presenting his “Real Cost of a Man Hour” and has given the talk over 125 times to over 20,000 UA Members. Rogers is passionate about education for everyone in the industry and tailored his presentation at the Field Leaders Conference specifically so those in the field can better understand and appreciate their overall role and impact on a job. Register your field personnel today! This is a conference you can’t afford them to miss.

Coming Soon!

As more contractors use BIM in virtual design and construction, they are faced with many limitations, including no drawing standards, a lack of drawing content specific to manufacturers, software systems that don’t connect and no easy way to estimate shop hours versus field hours. The goal of MCAA’s WebLEM+Plus is to become a single solution to all of these challenges.

When the WebLEM+Plus is released soon, you will find a complete buildout of the Work Activity Method Labor Units (over 100,000 labor units are being added to the LEM) which allow contractors to specifically identify shop and field labor separately.

You will also find features in this release which allow each manufacturers and drawing content providers to attach their drawing content (.ITM and RFA), technical data, pictures of the product, item weight, etc. to each and every labor unit.

When the WebLEM+Plus website is released, be sure to keep coming back to the site as we work with manufacturers to get their information connected and available to you.

We’re also making it easier for software partners and all MCAA members to connect to our data by providing APIs for our software partners to use, and by making our unique data identifier available for our contractors to download and be the central data key that connects all of the software systems they use.

And, we’ve published the first ever drawing content standard to help all industry partners work together better.

MCAA contractors will soon have a single source for all of their needs and it’s the WebLEM+Plus. So, stay tuned! We’ll keep you updated!

MCAWW Service Connections Panel

MSCA Chair, Kip Bagley was a special guest at the first “Service Connections” event, hosted by the MCA of Western Washington Service Committee on July 25th. Approximately 50 people attended the event, which connected labor and management over industry trends and challenges. The panel, including Kip Bagley (MSCA Chair), held a lively discussion on topics that included recruiting, the “uberization” of the service industry, self-diagnosing equipment, training and industry growth.

The full of panelists consisted of John Payne (Auburn Mechanical), Joel Crabtree (Local 32), Duane Bjornsen (Seattle Area Pipe Trades), Matthew Barnes (MacDonald-Miller Facility Solutions) and Kip Bagley (EMCOR Services Mesa Energy Systems and MSCA Chair), held a lively discussion on topics that included recruiting, the “uberization” of the service industry, self-diagnosing equipment, training and industry growth. MCAWW’s Executive Director, Ed Kommers, served as moderator.

3M™ PROTECTA® Cobra Mobile/Manual Rope Grab AC202D Is Incorrectly Stamped

3M Fall Protection has determined that the 3MTM PROTECTA® Cobra Mobile/Manual Rope Grab AC202D is incorrectly stamped for use with 1/2 to 3/4 inch diameter rope on the exterior body of the unit. This Cobra Rope Grab is certified for use ONLY with 5/8 inch diameter polyester or polypropylene rope. All marketing information and the Instructions for Use (IFU) for this rope grab correctly identify the size of rope to be used as 5/8 inch polyester/polypropylene rope.

In the event of a fall from height, a Cobra Rope Grab used with 1/2 inch diameter rope may not arrest the fall and could result in serious injury or death to the worker. To remedy this situation, 3M is launching a Stop Use & Product Recall to replace all AC202D and related Cobra Rope Grabs that are stamped 1/2″-3/4″ Dia.

Learn More

Frank Schaetzke Receives Zurn Lifetime Achievement Award

Frank Schaetzke received the first ever Zurn Lifetime Achievement Award for his exceptional service, solid dedication, and leadership. Frank has developed and maintained strong partner relationships, including Zurn’s relationship with MCAA. Congratulations!