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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BAUSCH Advanced Technology Group has over 60 years in engineering and manufacturing. Bausch has divisions located here in the USA, Germany, Brazil, and Switzerland. They offering table top units for small batches up to high speed fully automatic production lines for Syringes, Cartridges, Vials, Bottles, Ampoules, Bags and various other containers. Cleanrooms are used in industries and manufacturing processes where small particles can adversely affect the outcome. Cleanrooms can vary in size and complexity based on an individual companies’ needs. A cleanroom is a contained space where there is reduced particulate contamination and extensive control other environmental parameters such as temperature, humidity and pressure. One of the main components is the High Efficiency Particulate Air (HEPA) filter that is used to trap particles that are 0.3 micron and larger in size.

The clean room installed at Bausch Advanced Technology was manufactured by PortaFab. The PortaFab cleanroom is a series 300 fire and sound proof modular cleanroom. The Series 300 wall system is often used for creating standalone units like this ISO 7 cleanroom for medical device manufacturing. The load-bearing roof supports HVAC equipment, provides easy maintenance access, and is anti-static which is ideal in manufacturing situations. You can read more them here.

Furthermore, Controlled Air Inc. designed, and installed the complete HVAC system. The installation included an AAON air handling unit with modulating hot gas reheat, digital compressors with 2 lead stages and variable speed compressor fan head pressure control. We also designed and installed a custom duct air distribution system to supply the fan powered HEPA supply terminals along with the air return system. Controlled Air Inc. engineered and installed a Johnson Controls system with a FX-80 Supervisory controller, Web based user interface, room pressure sensors for the cleanroom, AHU control, 8 VAV boxes.

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PCC Structurals Wax Room Chiller – An aging process chiller put the production capabilities of PCC Structurals at risk so they turned to Controlled Air, Inc. to design and build a new process cooling system. Controlled Air, Inc. recommended installing a new chiller on the roof so a steel support system was designed and installed. A new Carrier chiller controlled by a Johnson Control Metasys energy management system provides both process and comfort cooling. PCC Structurals now enjoys a reliable and energy efficient system.

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