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Chris Watts, MARC USA/Indianapolis Public Relations
Phone:  317.638.9158	Fax:  317.632.0078
E-mail:  cwatts@marcusa.com
OR
Mike Lynam, Knauf Insulation
Phone:  800.825.4434	Fax:  317.398.3675
E-mail: mike.lynam@KnaufUSA.com

(MIAMI, Fla, June 2, 2005)  At Florida International University’s Biscayne Bay campus, faculty and students alike are anxiously awaiting a new home for FIU’s Marine Biology program.  At the edge of campus on the Bay, the 52,000 square foot, three-story laboratory complex will offer new opportunities to explore the mysteries of undersea life. 

 

To keep the new laboratory comfortable and energy-efficient, the team at TLC Engineering, the project’s specifying engineers, needed a non-fibrous, high-performance duct system that could also resist the potential corrosion of sheet metal ductwork with prolonged exposure to salt particles in the coastal air.  TLC, one of the largest engineering firms in the Southwest for nearly 50 years, prides itself on embracing leading-edge technologies, and soon found its solution – the Knauf KoolDuct system.

 

Knauf Insulation, a leading manufacturer of fiber glass insulation products, is the North American distributor for the KoolDuct system, a pre-insulated duct system originally developed in Europe.  The Knauf KoolDuct System features a CFC-free closed cell phenolic foam board faced on both sides with reinforced aluminum foil, using patented aluminum flanges to connect duct sections and assure a strong, tight closure.  The KoolDuct system offers significant advantages over sheet metal ducts in terms of weight, space, installation time, installed costs, air leakage and energy performance. KoolDuct is a UL 181 Class 1-rated system and easily meets SMACNA Leakage Class 6 while providing thermal performance of R-6.7 at 7/8ths inch thick (R-8.5 at 1 3/32nds inches). 

 

TLC was familiar with the KoolDuct system from previous projects and knew it would be a perfect fit for the FIU marine biology project.  They won quick agreement from Spillas Candella, the project’s architectural firm and another enthusiastic advocate of the system.

 

“We initially proposed stainless steel ductwork for FIU to combat corrosion, but that just wasn’t economical,” said Tom Farmer, Project Engineer for TLC.  “The KoolDuct system was a cost-effective alternative; although it’s fairly new in our market, it’s clearly a quality system.  From an engineering standpoint, the UL 181 and SMACNA Class 6 ratings mean that KoolDuct is a high-performance system that will deliver the installed performance we need, as good or better than metal ductwork.  We were happy to specify KoolDuct as an alternative system.

 

“We’ve been very pleased with the progress so far.  Joe Vincenti (Knauf’s KoolDuct Business Development Manager) has been very responsive in answering questions about the product, and everyone is happy with the installation – it’s very clean and looks great.  The speed of installation and the flexibility of the system are also a huge plus.”

 

Centex, the general contractor on the Florida International lab, joined TLC and Spillas Candella in embracing the KoolDuct system.  Allen Messer, Senior Estimator for Centex, recognized the system’s advantages in cost, jobsite productivity and installed performance.

 

“I’ve been a fan of the KoolDuct system ever since Joe Vincenti presented it to me on one of his first trips to Florida,” said Messer.  “With the rising cost of sheet metal, KoolDuct is a great value and offers several unique advantages over metal as well.  Its lightweight construction makes it easier and faster to install and that saves significant time and effort on the jobsite.  The installed performance is excellent and the finished appearance, in my opinion, is better than wrapped ductwork or bare sheet metal…”

 

This confidence in the KoolDuct system is paying off on the jobsite, where the system has helped Thermal Concepts, the air conditioning contractors on the job, stay productive and respond quickly to unforeseen installation issues.

 

For more than 20 years, Thermal Concepts has built a reputation as one of the top ‘Class A’ air conditioning contractors in southern Florida.  Having used the Knauf KoolDuct system on previous projects, Thermal Concept’s management knew that the product would save time and resources on the Marine Biology project.

 

“As a pre-insulated duct system, KoolDuct eliminates the need for two trades on the job site,” said Larry Maurer, co-owner of Thermal Concepts.  “Instead of installing a section of sheet metal duct, having it inspected, then calling in another crew to wrap insulation, KoolDuct is installed and done.  The FIU project is on a fast track, and we knew the KoolDuct system would help us meet our schedules.”

 

To help meet the demanding construction schedule, the Thermal Concepts team decided to create a makeshift fabrication shop on the jobsite, using two empty containers with a covered work area between them. 

 

“Fabricating KoolDuct is easy,” said Gary Becraft, manager of Thermal Concepts’ duct fabrication shop.  “The panel handles and cuts well, and Knauf supplies a full line of tools and flanges for assembly, plus training for our guys.  That made the on-site fabrication possible, and it’s made a world of difference.”

 

With multiple duct sizes ranging from  60”x30” down to 8”x8” over three floors and several trades working on the job simultaneously, on-site fabrication also means that the KoolDuct system is adaptable to changing circumstances on the job.

 

“Everybody knows that things are never exactly the same in the real world as they are in the blueprints,” said Becraft.  “If you fabricate a piece of metal ductwork off-site, then during installation you learn there’s a pipe in the way – well, you’re stuck.  KoolDuct is a lot more flexible than metal, and fabricating on-site helps us stay on schedule when conflicts crop up.”

 

Brian Becraft, Gary’s son and the foreman in charge of the FIU crew, also sings Knauf KoolDuct’s praises.  Becraft supervises a crew of six, including two fabricators, two KoolDuct installers, and two employees focused on cleanup and the installation of metal exhaust ducts.  But KoolDuct makes Becraft miss his days as a full-time installer.

 

“I’m a metal guy, always have been,” said Becraft.  “But this stuff [KoolDuct] makes me want to just install all day.  It’s fast, clean, you don’t cut yourself…the fabrication is easy, but it’s the installation where you really see the fruits of your labors.”

 

A driving factor behind the KoolDuct system’s quick installation is the lightweight nature of the product; as a pre-insulated foam panel, KoolDuct is just 15% the weight of sheet metal on average.  This allows easy handling and streamlined processes – for example, the ability to use a ladder rather than a lift to raise a 13’ section of KoolDuct.  During the FIU project, an unexpected construction hurdle brought the advantages of a lightweight product to the forefront.

 

“The masonry work on the stairs between floors had run into delays, so we had no access to the second and third floors except ladders,” recalled Becraft.  “With KoolDuct, we could just hand big sections right up the ladders, no problem – there’s no way we could have done that with sheet metal.”

Although Knauf KoolDuct’s phenolic foam construction makes it easy to handle, it’s a heavyweight when it comes to withstanding wear and tear, according to Becraft. 

 

“KoolDuct is also really easy to repair.  We’ve had pieces bumped by a lift and damaged – you just cut out the affected piece, replace it, seal it and you’re ready to go…I’ve seen this system save us so much time and so many resources – I’d say it’s reduced our installation labor costs by two-thirds, maybe more.  You can’t help but be out front with this stuff.”

 

Through two rounds of air leakage testing, KoolDuct installed to date has yielded exceptional readings of 0.4% and 0.6% air loss – an indication of the outstanding installed performance that will keep the FIU Marine Biology lab comfortable and energy-efficient, with an aluminum-faced airstream surface that offers cleanability and indoor air quality assurance.

 

After the opening of the Florida International University Marine Biology building, professors and students likely won’t spend much time thinking about the building’s air handling system.  But nonetheless, their cutting-edge research environment will be supported by a cutting-edge product – the Knauf KoolDuct system.

Photography:
There are several photographs available to accompany this case study, as described below.  Please request these phtotos electronically using the contact information provided above (cwatts@marcusa.com). 

Photo 1: (File: koolduct)
Knauf Insulation introduces the KoolDuct system, a high-performance, pre-insulated duct system for the commercial and industrial markets.

Photo 2: (File: installation)
Brian Becraft of Thermal Concepts installs a section of KoolDuct at the Florida International University marine biology lab site.

Photo 3: (File: bldg exterior)
Florida International University’s marine biology laboratory complex will offer comfort and energy-efficiency, thanks to the Knauf KoolDuct system.