challenges to going green in manufacturing/distribution

Challenges To Going Green In Manufacturing/Distribution FacilitiesTrack 4 Session 5

Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS

Director of Sustainable ConstructionClayco

[email protected]

Paul Todd Merrill, PE, LEED AP

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mailto:[email protected]


Abstract

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The US Green Building Council's LEED Green Building Rating System is the international standard for defining a new or existing green building however, large manufacturing and distribution facilities can struggle to meet the LEED metrics much of the time. These building types present a significant impact on the environment and many are self-defined as green, but few have been able to gain the official designation of LEED Certified. The presentation will focus on an overview of the LEED Green Building Rating Systems and specific examples of project challenges to obtaining LEED certification. In addition, the presentation will include a discussion of practical and economical energy saving ideas to incorporate into your facility to increase LEED credit potential, improve operational cost and reduce impact on the planet. Also provided will be an Energy Consumption Calculator to help you compare the effect of design choices.


Agenda

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Green Building Progress to DateOverview of the USGBC - LEED Assessment System and new changesChallenges with USGBC - LEED and Manufacturing/DistributionRecommendationsEnergy Consumption Calculator Demonstration


Clayco Green Building Progress

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Platinum Certified: 1 ProjectGold Certified: 5 ProjectsSilver Certified: 4 ProjectsCertified Level: 16 Projects


Starting Points

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Presentation with new construction focusRegional approaches/attitudes and capabilities differ across the country Heated/ventilated vs. conditioned spaceProcess loads are unique to each projectWe represent one contractor’s opinionEach client/project is uniqueNot here to preach why this is a good thing


Starting Points

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Environmental Impact of Manufacturing/Distribution Facilities

Energy use/water use Waste generation/packagingTransportation impactMaterial quantitiesSite impact and land use


What We See and Hear in the Manufacturing/Distribution Marketplace…

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Increased commitment to going green75 – 90 % of recent opportunities consider LEED certification or Sustainable MeasuresClients are becoming more educated Industry wants to be GREEN just not sure how to do it!Green practices in place – but just not touted as suchStill a lot of misconceptions


What We See and Hear in the Manufacturing/Distribution Marketplace…

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“We have implemented high efficiency process equipment, but get no LEED credits!”“Not going green” is the exceptionEnergy savings results from a business case perspectiveResults = Better, Higher Quality BuildingsOthers will follow your sustainable lead!


Overview - USGBC LEED Rating Systems

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Internationally recognized green building certification system using third-party verification that a project was designed and built using strategies aimed at improving performance across all the metrics that matter most:

Energy savingsWater efficiencyCO2 emissions reductionImproved indoor environmental qualityStewardship of resources and sensitivity to their impacts.


USGBC LEED Progress to Date

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19,957 USGBC member organizations2,476 commercial LEED certified projects19,524 commercial LEED registered projects91 countries with LEED projects4.2 billion square feet in process81,155 LEED accredited professionals



LEED BD&C – Building design and construction (old LEED NC)LEED EBOM - Existing buildings: operations & maintenanceLEED ID&C – Interior design and construction (old LEED CI)LEED core and shell, LEED for schools

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LEED v3.0 – LEED 2009 newest versionEach system includes prerequisites and credits 100 point system + 10 bonus points4 certification levels

Certified - 40 PointsSilver - 50 PointsGold - 60 PointsPlatinum - 80 Points

You Don’t Have to Do Everything!


LEED Credit Categories

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Sustainable Sites – 26 points possibleWater Efficiency – 10 points possibleEnergy & Atmosphere – 35 points possibleMaterials & Resources – 14 points possibleIndoor Environmental Quality – 10 points possibleInnovation in Design – 6 points possibleRegional Priority – 4 points possible


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LEED Recent Changes –LEED v3.0

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Weighting of priorities of creditsEmphasis on sustainable sites and urban developments – 26% of creditsIncreased water conservation efforts – 10% of creditsIncreased energy efficiency and carbon production reductions – 35% of creditsRegional priority credits


Easier LEED Points For Manufacturing/Distribution

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Sustainable construction activitiesErosion and sediment control measuresAir quality management and cleanlinessConstruction waste management and diversion

Site logistics and storm water issues – except vegetative “green” roofs


Easier LEED Points For Manufacturing/Distribution

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Reduced parking capacity and preferred parkingReduced heat island effect - roofDomestic water use reduction measures –landscaping and plumbing fixturesUse of regional and recycled content materialsMaterials and finish selections


Challenging LEED Points For Manufacturing/Distribution

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Site and location challenges – urban vs. ruralAlternative transportation measures – bike racks & showers, public transportation accessMaximize open spaceRestoration of native vegetationReduced heat island effect, non – roof hard surfaces



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Use of on-site renewable energy sourcesEnhanced building systems controls for tracking and monitoring of energy use and outdoor air monitoringUse of salvaged (used) building materialsUse of rapidly renewable and certified wood materials



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Enhanced HVAC Systems and refrigerantsOccupant controllability of lighting/thermal comfort accessible controlsNatural illumination to meet creditsInnovation in design credit limitations –limited to 6 total; 1 for LEED AP on Project; only 3 points allowed for exemplary performance



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Energy use and process load challengesCan be low energy users to begin withProcess loads can be trickyEnergy loads must be “modeled”

Up to 19 points can be “available” in this LEED categoryEnergy modeling rules and the building type make this challenging



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Energy use credits – regulated modelingDetermine baseline energy use from ASHRAE 90.1-2007 standardsDetermine actual design energy use from selection of envelope, HVAC, Lighting, domestic water heating and process loadsPercent cost savings from actual design to baseline determines available LEED points


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02000400060008000

1000012000140001600018000

Basecase Proposed Design

Ener

gy U

se 1

0^6

Btu

/yr

Project X Energy USE Pumps

Motor Loads

Cooling Systems

Lighting Systems

Power Devices

Heating Systems

Process Loads



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Larger buildings (over 150,000SF) are required to be modeled with more efficient baseline performance systems per ASHRAE appendix GAll “conditioned spaces” in the proposed design shall be simulated as being both heated and cooled, even if none is to be installed.



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“Conditioned Spaces” are defined as cooled space, heated space, etc. Heated space in a building is considered if the output capacity of the system relative to the floor area is greater or equal to:Heating Output (Btu/Hr*SF) Climate Zone

5 1&210 315 4&520 6&725 8


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ASHRAE 90.1-2007 Climate Zones



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“Process Loads” must be identical for both baseline and actual design. HOWEVER, Exceptional Calculation Method (ECM) can be used to document measures that reduce process loads.Exceptional Calculation Method can be used when no simulation program is available that adequately models a design, material, or device.



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Documentation must include listing of assumptions for both baseline and actual design and theoretical or empirical information supporting the assumptions.ASHRAE 90.1-2007 appendix G2.5 is the reference standard


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Recommendations for LEED Points…Or Just Good Practices

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Implement energy efficiency improvements – envelope, HVAC systems, lighting systemsASHRAE Advanced Energy Design Guideline for Warehouses is a great resourceCreative approach to the exceptional calculation methods – past data collection; work with equipment suppliers; documented process load efficiencies



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Energy Efficient HVAC SystemsVFD controlled exhaust ventilation systemsHigher efficiency MAU and RTU equipment, chiller plant, drive unitsPassive Ventilation and CoolingHeat Recovery from process loadsEnergy recovery unitsThermostatically controlled exhaust systems



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Energy Efficient HVAC Systems



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Energy Efficient Lighting SystemsT-8 or T-5 fluorescent lighting systemsMotion controlled lightingDaylight Harvesting SystemsFoot-candle levels which do not exceed task requirementsCentralized controlsLED lamp sourcesReflective interior surfacesUse task lighting where appropriate



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Energy Efficient Lighting Systems



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Energy Efficiency Building EnvelopesDock SealsReflective Roofing Materials



Innovation in design credit ideas:Transportation/rail emission reduction measuresShipping/delivery reduction measuresReduced packaging efforts - waste stream reductionsSupply chain perspective – upstream and downstreamEstablish green cleaning policiesEstablish A green education plan

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Transportation/rail emission reduction measures

Smarter TravelBetter VehiclesBetter FuelsImprove the efficiency of operations

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Reduced packaging efforts - waste stream reductions

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Establish green cleaning policies

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Consider alternate green building assessment tools

Green globes, energy starEmbrace self – defined certification!


Energy Consumption Calculator

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Excel spreadsheet toolEstimate of power consumption comparison for 2 scenariosInput data tabs - storage, pallet conveyor, case conveyor, sortation, automated vehicles, manual vehicles, picking/palletizers, lifts, building utilitiesCost savings or KWHR savings results


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Project Examples -Manufacturing/Distribution Facilities

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Anixter, Inc. Distribution Warehouse Alsip, IL

450,000 SF Logistics Distribution Warehouse19,000 SF Office Area$16.5 M Construction CostLEED NC CertifiedDesign / “Actual” Construction Duration = 8-9 Months



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Villa LightingSt. Louis, MO

222,000SF Distribution CenterUrban SettingLEED NC v2.2 Registered



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USPS - Troy, MI and Greenville, SCBulk Mail Processing CentersLEED NC v2.2 Registered ProjectsTroy, MI – 150,000SF RenovationGreenville, SC – 200,000SF Addition; 58,000SF Renovation



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General MillsSocial Circle, GA

1,500,000SF Distribution CenterLEED NC v2.2 Registered


Key Takeaways

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General overview of the LEED rating system and new changesSustainable measures may already be in placeLEED challenges to manufacturing/distribution facilitiesCertification can be challenging but can be done!


References

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www.usgbc.org – Further Understanding of the LEED Rating System and Case Studieswww.energystar.gov – Great tools and resources for existing and new buildingswww.ashrae.org/publications/page/1604 -Advanced Energy Design Guide for WarehousesManufactures Websites

http://www.usgbc.org/

http://www.energystar.gov/

http://www.ashrae.org/publications/page/1604


Questions?Questions?

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challenges to going green in manufacturing/distribution

Documents

hk systems

leed metrics

leed projects4

leed credits

usgbc leed progress

usgbc leed assessmentsystem

leed credit potential

schools12 supply chain