HVAC Ductwork Insulation | Banks Industrial Group

Commercial HVAC Ductwork Insulation Case Study: Replacing Compromised Ductwork Insulation to Improve Performance and Reduce Energy Costs

Building Specs:

Multi-Floor Commercial Facility Owned by The Pennsylvania Housing Finance Agency (PHFA)

Pain Point:

Damaged HVAC System Due to Poorly Insulated Ductwork

Pennsylvania Housing Finance Agency’s Vision:

On behalf of the Pennsylvania legislature, the PHFA provides affordable homes and apartments for older persons, adults of modest means, and those with special housing needs.

Pennsylvania Housing Finance Agency’s Challenge:

The rooftop HVAC system installed in PHFA’s multi-floor main office became compromised due to environmental conditions and poor insulation. Five years after installation, the system became rusted, water-logged, and infested with mold and mildew.

The Challenge’s Impact on PHFA’s Day-to-Day Work:

The damaged HVAC system threatened the health of PHFA’s workers and increased energy costs. The mold and mildew within the ductwork had the potential to create hazardous air problems throughout the entire building. The HVAC system’s poorly insulated duct joints also led to higher energy bills for the agency, driving up operating costs.

To protect workers' health and keep operating costs manageable, PHFA needed a quick solution to their ductwork problem.

Banks Industrial Group’s PHFA Solution: Techna-Duc® HVAC Ductwork Insulation

Banks Industrial Group solved PHFA’s challenge by replacing their failed insulation system with a new system from Techna-Duc®. The Techna-Duc® system was the perfect long-term solution for PHFA’s problem due to its:

R-16 installed thermal value (166% higher than R-6)
Mold- and mildew-resistant properties
Triple-sealed, water-tight interlocking joint system
Minimal maintenance needs

Techna-Duc® systems are pre-manufactured insulated panel systems. All of the panels are constructed with polyisocyanurate insulation to prevent the growth of mold and mildew. The panels’ water-tight qualities also prevent the ingress of water and water vapor, practically eliminating air quality problems.

By replacing PHFA’s compromised ductwork with a Techna-Duc® system, BIG helped PHFA:

Protect the health of its employees by eradicating air quality problems
Eliminate maintenance needs
Save tens of thousands of dollars in yearly operating costs
Reduce necessary system cooling time

See the chart below for an in-depth look at how the Techna-Duc® system is saving PHFA substantial money year-after-year:

Initial Cost Difference to Install Techna-Duc	$37,678
Estimated Savings after Installation	$30,000/yr
Return on Investment in Years	1.3 Years
Savings Over 20 Year Limited Warranty	$599,920
Annual Tax Base Not Required due to Energy Savings	$299,957
20 Years of Tax Base Not Required	$5,999,140
20 Years of $0 Maintenance ($5,000 / year)	$100,000
4 Replacements of Original System ($110,000 each)	$440,000
Total Savings Over 20 Years	$7,139,060

Techna-Duc® Multi-Floor Commercial Building Case Study

Industrial HVAC Ductwork Insulation Case Study: Replacing Water-Logged Ductwork Insulation to Resume Manufacturing Facility Operations

Building Specs:

Large Manufacturing Facility

Pain Point:

Damaged Rooftop Exterior Ductwork

Manufacturing Facility’s Vision:

Maximize operational productivity day-in and day-out

Manufacturing Facility’s Challenge:

The facility’s fiberglass-insulated aluminum rooftop ductwork was failing due to excessive moisture and construction defects.

The facility operators installed the ductwork four years before contacting BIG. The operators initially considered installing a Techna-Duc® system but opted for a fiberglass-insulated aluminum system instead to save $5000.

Within a year of installation, facility workers discovered that rainwater was leaking through the system’s jacketing seams and protrusions. The leaks reduced the insulation's performance value, increasing the facility’s energy costs. By this point, the wet insulation caused the system to operate worse than if there was no insulation at all.

Unfortunately, budget constraints prevented the facility from removing and replacing the water-clogged ductwork until the problem couldn’t be ignored any longer.

The Challenge’s Impact on the Manufacturing Facility’s Day-to-Day Work:

Four years after the aluminum ductwork was installed, the HVAC unit shut down due to excessive moisture in the air system. The resulting downtime cost the facility $80,000 per day in lost production.

Banks Industrial Group’s Manufacturing Facility Solution: Techna-Duc® HVAC Ductwork Insulation

BIG ended the facility’s extended downtime period by removing the water-logged insulation and replacing it with a water-tight Techna-Duc® system. With 12,600 square feet of Techna-Duc® installed, the facility was able to resume operations and experience the following energy savings:

105,000 kW/hrs saved monthly
At $0.11/kwh = $11,500 monthly
Annual savings = $136,000
20 Year ROI = $2.72 million projected

For a visual breakdown of the facility’s monthly energy savings, see the chart to the side.

In addition to reducing energy needs, the facility experienced additional savings by:

Decreasing HVAC unit runtime
Preventing HVAC unit shutdowns
Eliminating maintenance and equipment replacement costs

Looking forward, the facility’s Techna-Duc® system is also protected by a 20-year limited warranty, ensuring that the facility won’t require another system replacement for at least two more decades.

Techna-Duc HVAC Ductwork Insulation Case Studies: Commercial and Industrial Facilities

Replacing Failed Commercial/Industrial HVAC Ductwork Insulation Improves Energy Efficiency and Reduces Usage Hours

Commercial HVAC Ductwork Insulation Case Study: Replacing Compromised Ductwork Insulation to Improve Performance and Reduce Energy Costs

Industrial HVAC Ductwork Insulation Case Study: Replacing Water-Logged Ductwork Insulation to Resume Manufacturing Facility Operations

ASSOCIATIONS, CERTIFICATIONS & AWARDS