When a long-term client in East Hartford, Connecticut expanded their manufacturing facility, they faced a challenge: their existing 100% air recirculation and filtration system could not keep up with their dust control needs.

Here is how Controlled Air designed and installed a custom solution to eliminate the dust, support their facility expansion, and ensure precise climate control.

The Challenge: When AIR Recirculation Isn’t Enough

For years, the client relied on standard air recirculation with high-efficiency filtration. While this setup works for many applications, the high volume of particulates from their manufacturing processes left lingering dust in the air.

With a major facility expansion underway, the client needed a solution. They required a system that could handle heavy-duty dust collection across multiple stations. To solve the dust problem for good, we needed to move away from recirculation and shift to a single-pass, high-volume air strategy.

The Solution: 100% Outside Air and Precision Engineering

Our engineering and installation teams transitioned the facility to a 100% outside air system. Instead of trapping and filtering the same air repeatedly, the new system draws fresh air from outdoors, filters it, circulates it through the plant, and filters it again and then exhausts the filtered air through the roof.

• Custom Spiral Round Galvanized Ductwork
  • Industrial dust collection requires high velocity to keep particles moving without settling inside the ribs of the system. We reworked the existing ductwork and fabricated new, heavy-duty spiral round galvanized steel ducts. Round ductwork minimizes friction loss and prevents dead zones where dust can accumulate, ensuring optimal airflow.
• 8,000 CFM Direct-Fired Make-Up Air Unit (MAU)
  • Bringing in 100% outside air means you inherit the outdoor weather. To maintain a stable indoor temperature during cold Connecticut winters, we installed an Direct-Fired Heated Make-Up Air Unit. This system automatically triggers and heats incoming air whenever outdoor temperatures drop below a specific set point, preserving worker comfort without driving up energy bills.
• Single-Source Design-Build Execution
  • As a design-build contractor, Controlled Air managed every phase of this complex industrial retrofit:
    • Structural Integrity: We secured an engineer’s stamp for a full structural review and installed weld-free bar joist clamp kits for structural steel bracing.
    • Rigging & Logistics: We coordinated the crane services to lift and place the heavy MAU and roof curbs.
    • Turnkey Controls: Our team handled all power and control wiring, integrating a programmable time clock and disconnect switches for easy operation.
    • Committed Craftsmanship: We connected the new system to existing gas piping, painted the lines safety yellow, and partnered with a certified roofer to guarantee leak-free roof penetrations and flashing.

The Results: Cleaner Air, Better Value

By testing, balancing, and commissioning the total CFM of the new MAU, our technicians ensured the building stays properly pressurized. The benefits for our East Hartford client were immediate:

• Zero Dust Recirculation: The single-pass system exhausts particulates immediately, drastically improving indoor air quality.
• Seamless Integration: The new layout fits perfectly within the expanded manufacturing footprint.
• Energy-Efficient Heating: The direct-fired MAU applies heat only when necessary, keeping operational costs low.

If your industrial manufacturing company is facing air quality issues, reach out to Controlled Air about how we can engineer a better solution for your company.

The post Enhancing Air Quality and Efficiency: A Case Study in Industrial Dust Control appeared first on Controlled Air.

Controlled Air recently solved this seasonal challenge for a local medical service building. To prevent any disruption to patient care, our team coordinated all trades and performed the entire installation after hours. Here is a look at why precision humidity control matters, and how our design-build team executed the solution.

The Why: The Hidden Risks of Dry Air in Operating Rooms

Hospital operating rooms must meet strict environmental standards to remain compliant and safe. ASHRAE Standard 170 governs ventilation for healthcare facilities. It requires operating rooms to maintain relative humidity (RH) between 20% and 60%.

However, maintaining compliance requires looking closer at your medical gear. Most equipment manufacturers specify a narrower target range of 30% to 60% in their instructions for use. When humidity drops below this 30% threshold, risks escalate.

The primary threat is electrostatic discharge (ESD), or static electricity. Dry air allows static charges to build up on surfaces and clothing. A sudden static spark can cause sensitive electromedical devices to malfunction or fail during a procedure. Data from the FDA confirms that static discharge causes real-world equipment failures in surgical suites.

The What: Precision Engineering and Smart Installation

To stabilize the facility’s climate, Controlled Air furnished and installed two Nortec EL series steam humidifiers. We selected a 50-pound unit and a 75-pound unit to handle the building’s specific load requirements.

Our team mounted the units on the third floor below the ceiling, close to existing drainage access point. We placed the first unit on the Pre-OP inside corner wall and the second unit above the single handwash sink in the operating room corridor. A closet will be built around these units to keep them out of sight.

Key technical highlights of the installation include:

• High-Efficiency Piping: We ran steam piping from the humidifiers directly to the main rooftop unit (RTU) supply ducts. We wrapped all copper lines in high-grade insulation to reduce heat loss and lower energy waste.
• Rapid Absorption: We installed short absorption duct distributors. These components ensure that steam absorbs into the moving air stream instantly, preventing moisture from pooling inside the ductwork.
• System Protection: The Nortec units feature a built-in quench mechanism. This system cools excess steam condensate before it enters the building drainage lines, protecting your pipes from thermal damage.
• Safety Controls: We installed airflow switches, high-limit switches, and dedicated manufacturer humidity sensors within the operating rooms to guarantee precise, automated regulation.
• Smart Monitoring: We wired the controls for standalone operation, but the entire setup is ready for building automation system (BMS) integration. Our project partners at ABS are currently finalizing the digital BMS graphics for remote facility monitoring.

Low Maintenance, Long-Term Value

We choose equipment that protects your bottom line over time. The Nortec EL series features replaceable canisters. When the system requires service, technicians can swap the canisters out quickly. This design reduces maintenance hours and minimizes facility downtime.

Looking Ahead to Summer

Controlling a medical environment requires year-round vigilance. Now that we have secured the building against winter dryness, Controlled Air is preparing for the next seasonal shift. Our team is already designing the dehumidification strategy for this summer to ensure the facility stays compliant, dry, and efficient when the outdoor humidity spikes.

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Controlled Air is currently tackling this exact challenge at the historic Capitol Theatre, transforming its cooling infrastructure to meet modern standards.

The Challenge: Replacing a Century-Old hvac Concept

Every historic building has a story, and the Capitol Theatre is no exception. The venue’s original cooling system dated back to the 1920s. In those days, state-of-the-art climate control meant placing massive blocks of ice in front of large industrial fans to push cool air through the auditorium.

While that primitive system was a marvel a century ago, today’s packed houses require precise, reliable, and energy-efficient cooling. To protect the venue’s reputation and ensure patron comfort, the ownership team partnered with Controlled Air to replace the aging infrastructure with a high-performance modern chiller plant.

The Solution: A Two-Phase Modernized hvac system

With the purchase order authorized, our team transitioned from planning straight into the active installation phase. The scope of work focuses purely on a complete HVAC chiller plant upgrade, designed to deliver 44°F supply chilled water with a 10°F temperature differential.

To minimize disruption and maintain project clarity, the workflow was structured into two distinct phases:

• Phase 1 (Design & Coordination): This initial phase involved site verification, equipment selection confirmation, and creating detailed HVAC design drawings to clear the way for local permitting.
• Phase 2 (Construction & Installation): With permits cleared, we are actively executing the physical installation, which includes cutting and capping the old 4-inch piping, rigging the new equipment onto the roof, and integrating the system controls.

High-Performance HVAC Equipment Lineup

To deliver the reliability and quiet operation an active theater environment demands, we selected a 115.9-ton YORK air-cooled scroll chiller utilizing eco-friendly R-454B refrigerant and low-sound variable speed drive (VSD) condenser fans. Circulating the water are two Grundfos inline chilled water pumps with built-in variable frequency drives, installed discreetly inside the attic space next to the existing 5-foot by 8-foot chilled water coil. The entire system is supported by heavy-duty infrastructure, including a Bell & Gossett air and dirt separator, Wessels and Amtrol ASME-rated tanks, and an Axiom glycol feeder system to ensure reliable fluid management and freeze protection.

The new chiller modules will be securely mounted on specialized 12-foot structural equipment support rails on the roof adjacent to the old unit, keeping the rooftop organized and secure.

Streamlining Complexity: Serving as the Owner’s Representative

Large-scale mechanical upgrades in historic properties are rarely simple HVAC jobs. They require careful choreography between multiple trades. To alleviate the logistical burden on the theater’s executive team, Controlled Air is stepping into an expanded role, representing the ownership team as the primary Owner’s Representative.

In this role, we are directly coordinating and engaging all specialized contractors on-site, including:

• General Contracting
• Asbestos Abatement
• Structural Steel Fabrication
• Electrical Infrastructure
• HVAC Installation and Controls

By serving as the central point of contact, we ensure that the structural, electrical, and architectural modifications handled by external New York licensed professionals align perfectly with our mechanical timeline. This turnkey approach keeps the project moving smoothly toward completion without draining the theater’s internal management resources.

Looking Ahead

This project stands as a prime example of Controlled Air’s full project management capabilities. We don’t just drop equipment on a roof. We engineer, design, price, and manage complex mechanical overhauls from conception to final commissioning.

We will share more updates and photos as the Capitol Theatre project progresses toward its final startup and testing phases. Stay tuned to see how we blend 21st-century comfort with 20th-century charm.

BEFORE PHOTOS: AFTERS COMING SOON!

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Controlled Air was asked to review the current equipment and provide options to: 

• Bring operating room air changes into compliance with current code requirements 

• Resolve persistent humidity issues 

• Improve temperature and comfort control for surgical staff 

HVAC Engineering Assessment 

A comprehensive evaluation by Controlled Air’s in‑house engineering team determined that the existing systems were originally designed in the early 1990s and no longer met modern operating room requirements. 

Key HVAC System deficiencies identified included: 

• Air handling equipment undersized for effective dehumidification 

• Insufficient reheat capacity to maintain staff comfort 

• Inability of the central chilled water system to deliver the low water temperatures required for proper latent moisture removal during summer conditions 

• Operating room airflow levels substantially below the current minimum requirement of 20 air changes per hour 

These conditions contributed to challenges in maintaining temperature, relative humidity, and airflow compliance within the surgical suites. 

Controlled Air’s Design/Build Solution 

Recognizing the urgency and regulatory importance of these issues, the hospital elected to move forward with Controlled Air’s design/build solution. 

The proposed system retrofit includes: 

• A new dedicated air handling unit capable of delivering code‑mandated airflow rates 

• A chilled water coil selected to achieve the desired leaving air temperature at increased airflow, ensuring proper dehumidification 

• A new air‑cooled chiller engineered to supply lower chilled water temperatures independent of the existing central plant 

To enhance system reliability, the design incorporates a remote evaporator configuration that eliminates the need for glycol antifreeze. This approach allows a direct tie‑in to the hospital’s existing chilled water system, providing redundancy in the event of air‑cooled chiller downtime. 

Project Status and Next Steps 

The project is currently under contract, with completion scheduled for the end of this year. 

A parallel phase of work will add reheat coils and upgraded controls in surgery support areas, further improving occupant comfort while maintaining precise relative humidity control within the operating suites. 

Why It Matters 

By addressing airflow deficiencies, improving dehumidification, and adding system redundancy, the Hospital will gain: 

• Safer surgical environments with consistent temperature and humidity control 

• Improved staff comfort and performance during long procedures 

• Reduced regulatory and accreditation risk through code compliant design 

• Greater system resilience, minimizing downtime and operational disruption 

• A HVAC System ready for increasing standards and regulations.  

A well-designed operating room HVAC system is not just a facilities upgrade, it is a direct investment in patient care quality, clinical efficiency, and long-term operational reliability. 

Check out our before pictures below and watch out for updates and completed photos last this year!

BEFORE

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Overview 

When an existing commercial utility facility required a complete mechanical refresh of its heating and cooling systems, the project team—working from a plan-and-spec design—turned to Controlled Air, Inc. to execute the installation. What followed was a coordinated effort that replaced aging, inefficient boilers with a new high efficiency boiler, upgraded the chilled water plant with a larger, quieter Trane air cooled chiller, and uncovered a hidden piping leak that had been quietly wasting water and driving up utility costs for years. 

The Result

projected energy savings of 20–30%, improved system capacity, reduced noise impact on the surrounding property, and a facility that is better positioned for future expansion. 

Boiler Replacement: Switching to Lochinvar for Faster Delivery and Higher Efficiency 

The Challenge 

The existing heating plant relied on standard atmospheric boilers that, at their best, operated at approximately 75% thermal efficiency. As the equipment aged, performance degraded further, meaning a significant portion of every energy dollar spent on natural gas was going straight up the flue. The client had a completion deadline, and lead times on the originally specified equipment threatened to push the project well past that window. 

The Solution 

Working within the plan-and-spec framework, the installation team pivoted to Lochinvar’s FTXL850 high-efficiency condensing boiler—a decision driven by two factors: superior availability and significantly better performance. The Lochinvar FTXL850 operates on natural gas at 97% thermal efficiency, representing a dramatic improvement over the legacy equipment. 

To keep the project on the client’s accelerated schedule, Controlled Air’s mobile boiler was brought online during the transition period, allowing the building to maintain heat while the permanent equipment was installed. This approach kept the project moving without sacrificing occupant comfort. 

Scope of Work 

The boiler replacement involved more than just swapping equipment. The full scope included: 

• Installation of the new Lochinvar FTXL850 natural gas condensing boiler (97% AFUE) 

• Decommissioning and closure of the existing flue system 

• Design and installation of a new flue and exhaust configuration appropriate for high-efficiency condensing operation 

• Temporary mobile boiler deployment to maintain heating continuity during construction 

Efficiency Impact 

The jump from roughly 75% efficiency (legacy boilers) to 97%+ (Lochinvar FTXL850) is not a marginal gain—it is a fundamental transformation of how the building uses energy. For every unit of gas consumed, the new system extracts substantially more usable heat. Over the course of a heating season, that difference adds up to measurable reductions in fuel consumption and utility costs. 

Trane Air Cooled Chiller: Expanded Capacity, R-454B Refrigerant, and Quieter Operation 

The Upgrade 

The chilled water system received an equally significant overhaul with the installation of a new Trane high-efficiency air cooled chiller. The replacement unit was intentionally sized larger than the original equipment—a forward-thinking decision that gives the facility the capacity to accommodate an additional chilled water coil as the building’s cooling needs growth. 

Refrigerant: R-454B 

The new Trane unit operates on R-454B refrigerant, a lower global warming potential (GWP) alternative that aligns with evolving environmental regulations and positions the facility for long-term compliance. As HFC phase-down requirements continue to take effect, buildings with updated refrigerants will face fewer regulatory hurdles and potentially lower service costs. 

Noise Reduction: A Quiet Package for Community Compatibility 

One of the specification requirements for this project was minimizing the acoustic impact of the new outdoor condensing unit. The Trane unit was selected and configured with a quiet package designed to reduce sound levels at the property line—an increasingly important consideration as municipalities across Connecticut and Rhode Island continue to strengthen noise ordinance enforcement. 

For facilities in mixed-use areas, near residential zones, or in communities with active noise regulations, specifying a quiet-package condensing unit is a straightforward way to prevent compliance issues before they arise. Engineers and general contractors should consider acoustic performance alongside energy efficiency when selecting outdoor HVAC equipment. 

Projected Savings 

Taken together, the boiler and condensing unit upgrades are projected to deliver 20–30% savings in overall energy consumption compared to the previous system. Factors driving those savings include: 

• Higher thermal efficiency from condensing boiler technology (75% → 97%+) 

• Modern compressor and refrigerant circuit efficiency in the new Trane unit 

• Elimination of standby losses associated with aging equipment 

• Right-sized cooling capacity that reduces short-cycling and improves system runtime efficiency 

Bonus Find: Repairing a Hidden Piping Leak 

During the course of the project, the installation team identified a leak in the piping connecting the air cooled chiller to the building’s chilled water system. The leak, located at the exterior connection point, had gone undetected and was causing the system to consume excess makeup water—an ongoing operational cost that the facility’s management team likely did not realize they were carrying. 

Repairing the leak was incorporated into the project scope, stopping the waste and restoring the system to proper operating condition. It is a straightforward example of the value that an experienced installation team brings to a project: the ability to recognize when something is wrong, communicate it clearly, and fix it—rather than simply completing the contracted scope and moving on. 

Key Takeaways

This project illustrates several principles that are worth carrying into future mechanical retrofits and new construction specifications: 

• Equipment availability matters. When lead times threaten a project schedule, there are often high-performance alternatives that meet or exceed the original specification. Flexibility in the procurement process—without sacrificing efficiency targets—can keep projects on track. 

• Condensing boiler technology delivers real returns. The efficiency gap between standard boilers and modern condensing units is substantial. For any project where natural gas heating is part of the design, condensing boilers should be the baseline specification, not an upgrade. 

• Refrigerant selection has long-term implications. Specifying R-454B and similar next-generation refrigerants now avoids costly retrofits as HFC regulations tighten in the coming years. 

• Acoustic performance is a specification item. In municipalities with noise ordinances—and their number is growing—quiet-package equipment is not a luxury; it is a risk management tool. 

• Site observation has value. Scheduled walkthroughs and attentive installation teams catch problems—like the piping leak on this project—that save clients money and prevent larger failures downstream. 

The post High-Efficiency HVAC Upgrade: Boiler Replacement and Condensing Unit Modernization Deliver 20–30% Energy Savings  appeared first on Controlled Air.

We are proud to announce the successful completion of a massive HVAC integration for the Yanmar Tractor and Parts Warehouses. For this project, Controlled Air served as the lead organizer and turnkey provider, delivering a seamless “design-to-execution” experience that modernized the climate control for two massive industrial spaces.

Here is a look behind the scenes at how Controlled Air managed this complex infrastructure project.

The Scope: Total Project Management

This was not a simple “swap and drop” equipment changeout. This was a comprehensive facility upgrade. 

Beyond the mechanical installation, our team managed the critical logistics to keep the project running smoothly:

• Structural & Architectural: We handled the structural reviews and the installation of pre-engineered deck support systems to safely hold the new heavy-duty equipment.
• Roofing & Rigging: From crane rentals and rigging to the necessary roofing repairs and curb installations, we ensured the building envelope remained secure.
• Utilities & Safety: We managed the complete gas piping infrastructure, electrical connections, and fire alarm tie-ins (including duct smoke detectors).

The Technology: High-Efficiency Synergy

One of the most exciting aspects of this project was the equipment selection. We paired high-performance air handling with Yanmar’s own cutting-edge engine technology.

To condition this massive space, we furnished and installed a robust system designed for longevity and efficiency:

• Air Handling: Seven (7) Aaon 30-ton Rooftop AHUs, fully equipped with VFD blowers for energy efficiency and a high-grade filtration system using MERV 8 and MERV 13 filters.
• Heating & Cooling: These units are powered by fourteen (14) Yanmar 14-ton Gas Heat Pumps (GHP). This 2-pipe natural gas system utilizes Yanmar’s engine technology to provide efficient heating and cooling with reduced electrical demand.
• Reliability: The system includes custom 14″ roof curbs, stainless steel drain pans, and vibration isolation to ensure quiet, long-term operation.

2. The Parts Warehouse

Similar to the tractor facility, the parts warehouse received a top-tier upgrade:

• Three (3) Aaon 30-ton Rooftop AHUs paired with six (6) Yanmar 14-ton GHPs.
• This setup ensures that valuable inventory is kept at consistent temperatures while maintaining high air quality standards through double-wall cabinets and advanced filtration.

Intelligent Controls

Controlled Air furnished and installed a complete Johnson Controls ecosystem to tie the entire facility together.

We deployed panel-mounted controllers across both warehouses, complete with all necessary sensors, relays, and current switches. For the Parts Warehouse, we installed a Johnson Controls Supervisory front-end controller. This web-based user interface allows facility managers to monitor the system remotely, ensuring peak performance and immediate diagnostics.

The Controlled Air Difference

By handling everything from the certified air balancing and start-up testing to the permits and gas meter coordination, Controlled Air ensured that Yanmar could focus on their business while we handled their building.

We are thrilled to hand over a facility that is energy-efficient, structurally sound, and controlled by the latest in building automation technology.

Do you have a complex commercial or industrial HVAC project? Contact Controlled Air today to see how we can organize your next project from start to finish.

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