As most of the readers know KoolDuct is made up of a sandwich of foam between two layers of aluminum. The foam’s R-value is widely advertised and tested as exceeding the R6 and R8 required by most energy codes. What is never discussed is the possible effectiveness of the aluminum skin as radiant barrier!?

http://www.ornl.gov/sci/roofs+walls/radiant/rb_01.html

Here is the thought the foam insulation is designed to combat conductive heat (heat by physical contact) and convective heat (forced air) but the unthought-of form of heat flow is RADIATION.

To date I do not know of anyone who has consider the reflective benefits of KoolDuct on top of the convective and conductive properties of the foam. This snippet was just a starter for further discussion.

1. Prioritize Fittings List
   1. Instead of importing with the .PNL file; Use the “Edit Parts List” and set the priority settings. Keep them in clusters (i.e. have fittings 1-3 as priory 1, next 2-6 priority 2, so on and so forth). Then auto nest.

1. Use Different Nesting Strategies
   1. Don’t just use the auto nest (green button) for the best utilization. Use the yellow auto nest button right next to it. Try different strategies and compare the performance.

1. Use Tip 1 & 2 In Conjunction With Each Other.

1. Leave the Computer
   1. Leave the computer while it is performing nesting calculations. Go do other value-added work.

1. Minimize Part Removal Labor
   1. Move pieces nested with a “score cut” along the boards edge to the very edge thus utilizing the board edge.

1. Use Scrap and Nest From Previous Jobs
   1. Using the “Reports” feature to identify all the pieces of the last nest. Save all the pieces from the last sheet of the job (assuming it’s a partial nest) and re-nest it at the beginning of the next job – before importing the new job. Import and using the yellow auto-nest button menu. On the “begin nesting on” drop down menu select "First Nest". This will start the current job nesting on the waste from the last job.

Tiger closures are great for the assembling of KoolDuct and allow you not to use the glue. The problem is its almost impossible to bend the tiger closure in a true 90 degree angle. To combat this, bend the tiger as normal then use a dead blow hammer to set the closure. Doing so will bend the tiger over 90 degrees. The duct will be more robust and considerably squarer. Also, the tape will cover the tiger flawlessly.

Let me strengthen my argument by first illuminating my bias. I like the product KoolDuct and think everyone renovating or under new construction should be using it. In the following I would like to show you why. The US releases more CO2 than any country in the world (See Figure 1). U.S., homes account for 21% of all CO2 emissions¹ and business account for business account for 17% of the total². Of this release, businesses and residents use a combined total 38% or 2242 million metric tons (in 2001) (see Figure 2)³. The vast majority of energy used in a home is for heating and cooling. According to the DOE, Energy Information Administration's 2001 Residential Energy Consumption Survey anywhere from 38% to 70% of homes energy consumption is spent on heating and cooling⁴. Businesses data on the energy consumption is estimated to be similar. That leaves between 852 – 1569.4 million metric tons of CO2 being released through heating and cooling. Typical duct systems lose 25 to 40 percent of the heating or cooling energy⁵. That equates to 213 – 627.6 million metric tons of CO2 leaking out into the environment. Keep in mind that that number is pure waste! This translates in to about 806.68 billion kWh of electrical power per year using the DOE calculator (http://www.epa.gov/grnpower/pubs/calcmeth.htm)⁶.

1. U.S. Green Building Council Doubles Local LEED for Homes Network: Press Release. http://www.usgbc.org/News/PressReleaseDetails.aspx?ID=3585. Retrieved 03-31-08
2. See Energy Information Administration, http://www.eia.doe.gov/oiaf/1605/ggrpt/carbon.html
3. See Energy Information Administration, http://www.eia.doe.gov/oiaf/1605/ggrpt/carbon.html
4. U.S. Department of Energy, Energy Information Administration, “Energy Information Administration, 2001 Residential Energy Consumption Survey,” 2001
5. US Department of Energy. (1999). Improving the efficiency of your duct system.
6. (http://www.epa.gov/grnpower/pubs/calcmeth.htm)

The environmental impact of fabrication of HVAC ductwork, although small in comparison to many industries, it is a significant contributor to air pollution.  If you might doubt this, visit any sheet metal shop and wipe your hand across the floor...even if the shop has a ventilation system, you will likely have a hand covered with glass fibers and soot.  Burning contributes to most processes used for cutting metal and hence, much of the environmental issues stem from this process.  New cleaner cutting methods, such as water jets, are available, but the costs associated with these low pollution methods are very costly and out of reach for almost all contractors in the HVAC industry.  

Another impact is energy from utility.  Sheet metal fabrication contributes to this in two ways; one being the energy consumed by the machinery used in the fabrication of metal and two, the costs associated with heating the space required to house a sheet metal shop.  Both the process...and the space required for the process, require energy.  KoolDuct and IFP (Insulated Foam Panel) fabrication methods do not require nearly as much energy to fabricate and the space for the processes required for production of the product is much less, hence, energy savings.  

Attached I have included (2) studies relating to experiences at Commercial Comfort Systems, Inc. in Maumee, Ohio.  In these studies, it becomes apparent why KoolDuct or IFP fabrication process are advantageous.  Reducing environmental impacts...can and does have an impact on your bottom line.  Koolduct provides advantages for the environment, your customer and your own sustainability. (SEE .pdf files below photos.)

Sheet Metal Shop Costs.pdf (113.24 kb)

 KoolDuct Shop Costs.pdf (125.32 kb)

Being a KoolDuct contractor is an environmentally conscience thing to do.  KoolDuct addresses almost all green issues…green house gas emissions, zero ozone depletion, very high R-value (exceeding the 2006 IECC energy codes), extremely air tight, low or virtually non-existent carbon footprint, and outstanding Indoor Air Quality.  A great deal of energy is required to make steel and fiberglass…as the production of these materials require heat generated by the burning of fossil fuels...prompting the question: Is there a better way? 

Not only is KoolDuct itself  "green" from it's manufacturing standpoint...but the use of it promotes considerably lower energy consumption over any air distribution system available...making it an excellent "high efficiency" product in the HVAC field. KoolDuct is truly a product that your customer is asking for as they are being better educated about global issues and rising energy costs.  If you are not using it...why?

Let me introduce myself; I am David W. Mueller Chief Operations Officer here at GoMech, Ltd. For you new to this blog, we are a provider of infrastructure for the construction of insulated foam panels. These panels are sold under name such as KoolDuct, P3 and PIR.

As with many companies, we have a mission statement that outlines our purpose for existence. Our mission statement reads as follows, “Partner with our colleagues in meeting the demand for insulated foam panel products in the HVAC industry.” In the spirit of our mission, I have initiated this blog to provide an exchange of information.

The background for this blog stems from all the information, or lack there of, surrounding insulated foam panels. What does exist is hearsay or, if you are lucky, information contained solely in the minds of experts but not traceable. That is, it’s anecdotal (not backed by empirical evidence) and not public domain. As with any poker hand every hands a winner and every hand maybe a loser. When using you are using IFP’s you are dealt a winning hand. This blog should be the information center of preserving your winning hand.

The vision for this blog is to amass a collection of IFP information, tools and best practices in relation to the use of insulated foam panels. We at GoMech want you, our partners in meeting the need for insulated foam panels, to help us construct a body of knowledge on topics surrounding IFP.