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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At Controlled Air, Inc., we eliminate those friction points through our Design-Build delivery. By integrating engineering, custom fabrication, and installation into a single-source solution, we take full responsibility for your facility’s climate and energy future. Not only does it save time, but it saves cost as well, by eliminating the need for a separate engineer and/or construction manager.  

Design-Build vs. Traditional Plan-Spec 

Why Single-Source Responsibility Wins 

1. The “No Finger-Pointing” Guarantee 

In a typical project, if a control sequence fails or a unit doesn’t fit the roof curb, the contractor blames the engineer, and the engineer blames the installer. With Controlled Air, that conflict is eliminated. Because we are the engineer and the installer, we own the outcome. If a challenge arises, we solve it internally without the multiple change orders. 

2. Accelerated “Speed to Market” 

Time is the greatest cost of construction. Our Design-Build model allows us to overlap phases. We can begin site preparation, equipment procurement (critical for long-lead items), and in-house duct fabrication while the final engineering stamps are being applied. This typically reduces project schedules by 10–30%. 

3. In-House Precision 

Our Branford facility houses specialized sheet metal fabrication and piping departments. Unlike firms that outsource these critical components, we manufacture to the exact specifications of our design team. This ensures that what is drawn in CAD is exactly what is installed in the field. 

The Specialized Advantage: Efficiency-Driven Design 

While the Design-Build model provides the structure, our specialty in energy efficiency provides the value. We don’t just build systems that work; we build systems that pay you back.

• Our Energy Specialty: Because energy efficiency is our core focus, it makes for a better Design-Build process. We use advanced modeling to “right-size” equipment, ensuring you aren’t paying for excess capacity that wastes energy and increases maintenance costs. 
• Integrated Controls: We design the mechanical hardware and the Building Automation System (BAS) simultaneously. This ensures “native” communication between systems, preventing the energy-wasting “fighting” between heating and cooling cycles common in piecemeal installs. 
• Futureproofing: Our designs account for 2026 sustainability standards and ROI-driven technologies like Gas Heat Pumps and Cogeneration (CHP) from the very first sketch. 

Long-Term Facility Value 

An HVAC system is a 20-year investment. A Design-Build project with Controlled Air focuses on the Total Cost of Ownership, not just the initial bid. 

• Serviceability by Design: Because we also provide 24/7 service, our engineers design systems that are actually maintainable. We don’t bury components in inaccessible corners; we design for a lifetime of easy access and lower repair costs. 
• Enhanced Asset Value: A high-efficiency, well-documented Design-Build system increases a building’s “Green” rating and marketability, protecting the owner’s equity against rising utility costs. 

Partner with Controlled Air, Inc. 

Since 1980, we have been the premier Design-Build partner for general contractors, architects, and facility owners across Connecticut and Rhode Island. Let us take the complexity out of your next mechanical project. 

The post The Design-Build HVAC Advantage: Streamlining Complexity, Increasing Efficiency appeared first on Controlled Air.

Controlled Air, Inc, a leader in HVAC/Building Automation design build sales and service, seeks construction and service professionals to join our sheet metal organization.  From seasoned mechanics to apprentices, we are looking for hard working individuals who strive for excellence and seek a long and lasting work career with a company who cares.

• SM2 license with HVAC sheet metal experience or sheet metal apprentice
• Valid driver’s license
• US citizen or valid permanent worker

• Competitive salary based on experience
• Medical insurance paid 100% (including family)
• Paid sick, holiday and vacation time.
• Annual profit sharing retirement plan
• Low cost employee paid dental, vision, disability, vision, and life insurance
• Pretax flexible benefits plan
• Apprentice schooling reimbursement
• Company supplied vehicle, gas card, phone and tablet/computer if qualified
•  

Join us and become a visionary and leader in environmental solutions, efficiency, and optimal performance. We would love for you to be a part of our family-like environment, which fosters seamless collaboration and innovation. We are constantly starting conversations around how to create the most intelligently designed and constructed systems, focusing on high performance, energy efficiency, and customer satisfaction. Every day provides an opportunity to participate in hands on experiences, and become immersed in the industry. Working for Controlled Air, Inc. will not only offer you an edge in developing state of the art strategies and an insight to the most cutting-edge technologies, but will offer a thoughtful community whose mission is to contribute to a more sustainable future.

Controlled Air, Inc. offers professional growth opportunities, and benefits. Come join our growing team!

Controlled Air Inc. is an Equal Opportunity Employer

CLICK HERE TO APPLY ONLINE

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What does this mean for you?

If you make $150,000 in HVAC system upgrades you could potentially receive a $52,200 reduction in taxes rather than having to take the 39-year depreciation which only gets you a $1300 deduction. This does vary by situation but this change can give a business a large deduction in a single year. The deduction must be taken in the year that the equipment was installed.

What properties are qualified?

• The taxpayer or its predecessor didn’t use the property at any time before acquiring it.
• The taxpayer didn’t acquire the property from a related party.
• The taxpayer didn’t acquire the property from a component member of a controlled group of corporations.
• The taxpayer’s basis of the used property is not figured in whole or in part by reference to the adjusted basis of the property in the hands of the seller or transferor.
• The taxpayer’s basis of the used property is not figured under the provision for deciding basis of property acquired from a decedent.
• Also, the cost of the used property eligible for bonus depreciation doesn’t include the basis of property determined by reference to the basis of other property held at any time by the taxpayer (for example, in a like-kind exchange or involuntary conversion).

So in summary, if you acquired a new property that was in need of upgrades you can use the new tax benefits to offset the cost of the upgrades now, rather than spreading it over 39 years. Now is the time to make the investment and maximize your tax benefits. As always, be sure to consult with your tax professional for your best tax benefit.

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The variable refrigerant flow (VRF) heat recovery system serves the parking level, ground floor, 2nd floor and 3rd floor. The installed system includes 10 VRF Heat Recovery outdoor condenser units; 34 Med Static ducted indoor units;  and 108 indoor Cassettes varying in size between 2×2 and 3×3 with a compact 360-degree airflow design for uniform air distribution.

Additionally we installed two (2) Aaon RN 25 rooftop units with heat wheel defrost, digital compressor, high turndown natural gas heat section with stainless steel heat exchanger, variable speed condenser fans with head pressure control, modulating hot gas reheat and nonfused disconnect switch. The AAON units supply the required fresh air to the indoor VRF units and recovers the energy from the exhaust air.

Our in house controls department will install a  Johnson Controls system with a FX-80 web-based user interface supervisory front-end controller. The system will control the two AAON rooftop dedicated outdoor air units and monitor the temperature in the areas served by the four ductless splits. Additionally the BMS will monitor the VRF system, and act as a gateway for remote connection, monitoring and trouble shooting.

The post VRF Installation, Shelton CT | Office Building appeared first on Controlled Air.

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Even new high efficiency boilers need maintenance. Many would think that if you have brand new equipment that you have a few years to wait until maintenance is required. Unfortunately, that is not the case, especially with high efficiency boilers.

Here is an example:

Last winter we received a call for service due to no heat. The customer had a high efficiency boiler which was just over a year old. They had not had any preventative maintenance performed, since its installation earlier in the year. Upon arrival our service tech discovered that components of the boiler had literally melted (see photo above). Upon further inspection it was discovered that the ignitor had failed and someone in the customer’s organization was repeatedly resetting the boiler to try and keep it lit. The repeated process caused over-heating and melting of some of the components.

With a preventative maintenance contract this issue could have been avoided, saving money for the organization in the long run. Ignitors and flame rods are replaced yearly during maintenance which would have prevented the occurrence.

During a typical service, we flush the system using a cleaner that removes any build up in the system such as calcification from the condensation.  We also brush the system to further remove any build up that will lead to poor heat exchange or blockages of the fins. The fins in the boiler are checked to make sure they are clean and a tool is run between each fin to remove any build up. Plugged fins can lead to poor heat transfer and hot spots in the boiler heat exchanger.

Even if you have a brand new high efficiency boiler it is important to schedule preventative maintenance. Not only can things breakdown or melt, but a high efficiency boiler that is not properly maintained can be running far lower than the 95% efficiency you expected. The heating season is fast approaching. Having preventative maintenance performed in advance will help to ensure that your equipment is running safely and efficiently.

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Just to give you an idea of the enormity of this project, it required over 58,000 ft. of ductwork with a combination of insulted and non-insulated. A brief overview of just some of the HVAC equipment we installed includes:

• Seven AAON units with humidity control, return air bypass, energy efficient dehumidification and economizers; one AAON units with a premium efficiency motor, economizer with power exhaust and a VFD; one AAON unit with an Energy Recovery wheel, premium efficiency motor, and 2 motors on 2 VFDs; and two 25 Ton High Efficiency Lennox RTUs with variable volume air flow and economizers. All new RTU’s installed use R-410A refrigerant per the EPA requirements.
• We also installed six (6) Sterling Linear Radiant Hydronic Ceiling Panels. Radiant Panel ceiling systems are an energy and cost saving method of heating. They provide distributed heating radiantly rather than by forced air providing a “draftless” environment.
• 2 PK Gas fired condensing boilers with Axiom Condensate Neutralization Tank and Nuro touch-screen control system.
• 8 Nortec Humidifiers, The industry’s most precise humidifier. An isothermal system that produces mineral free, odorless, sterile steam from any water type.
• Ceiling Grid System by Titus which allows for the building of critical environment spaces with flexibility. Each system is custom engineered to meet the requirements of codes and guidelines, such as ASHRAE Standard 170 and the Facility Guidelines Institute (FGI) ‘Guidelines for Design and construction of Hospitals and Outpatient Facilities.’

The Expected completion date is 10/31/2018.

What is always challenging about medical facilities and pharmacies, are the extensive regulations for air changes, filtration, as well as humidity and temperature controls. Unlike office buildings where the building requires consistent settings throughout the building, medical facilities can have different requirements per area. Surgical rooms and pharmacies, have different settings from the offices and also from each other. It take extensive controls and programming to make sure each area functions as required.

The post HVAC and VRF, Rocky Hill CT | Surgery and Medical Center appeared first on Controlled Air.

RTU’s need regular system maintenance to function at peak efficiency. The roof exposes your unit to extreme weather. It is colder and/or hotter up there depending on the weather. Unlike other types of heating and air conditioning systems that are either inside the building or outside on the ground, the RTU is exposed to much more extreme temperatures and more pollutants. Ambient temperatures on the roof of a building can reach 120 degrees on hot summer days. Pollutants collect on the components of the unit causing it to lose efficiency and even degrade. Excessive heat causes the unit to work harder to produce comfortable conditions in your building.

Regular system inspections prevent inconvenient system breakdowns, increase the life of your system and will reduce utility bills. HVAC systems have over 100 components and many common component issues increase energy usage. You can see more on this chart of the Building efficiency initiative that describes in detail the greatest energy impacts with the various components.

“Portland Energy Conservation Inc. found that building operation and maintenance programs specifically designed to enhance the operating efficiency of HVAC and lighting systems decreased energy bills 5 to 20 percent in commercial buildings, without significant capital investment.^“

Controlled Air, Inc. offers custom service and maintenance packages. Below is a list of items typically done during a maintenance appointment.

• Changing filters to keep dirt and debris out of the ductwork and the system components
• Checking blowers for proper airflow
• Checking the electrical system, fuses, thermostats, and contactors
• Checking belts and replacing if necessary
• Cleaning dirt, soot and mold from the condenser coil, including measuring before and after temperatures to verify effectiveness
• Inspecting evaporator coils and clean as needed
• Checking refrigerant charge and fix any leaks
• Checking cabinet integrity for air leaks caused by cracks, missing screws, loose latches and faulty gaskets

The post Consequences of Ignoring HVAC Maintenance appeared first on Controlled Air.

Hurricane straps are designed to secure a rooftop unit to a roof curb. By doing this, the rooftop unit is more likely to withstand high wind gusts, thereby reducing the chance of the unit separating from the roof curb and causing damage to other equipment, people or the building itself.

The strap/clip requirements are determined by a combination of codes: Section 301.15 of the 2012 International Mechanical Code require “equipment and supports that are exposed to wind shall be designed to resist the wind pressures in accordance with the IBC.” The 2012 IBC chapters 15 and 16 make determinations about roof securement with specific wind load requirements in section 1609.

In 2015, the Insurance Institute for Business & Home Safety (IBHS) gave Connecticut one of the highest scores for state building codes among hurricane-prone coastal states. Connecticut scored 88 out of 100 points, up from a score of 81 in 2012, the first year IBHS ranked state building codes. The higher score is the result of the state’s intent to adopt an updated code from the International Code Council. The updated code has more stringent requirements for roof tie-downs. As of today, the 2012 IBC codes have been adopted but it is up to the individual inspectors interpretation of the law to determine if the attachment to the roof are acceptable.

Over the last few years, Controlled Air, Inc. has made it a policy to install hurricane straps/clips on all new rooftop unit installations. Installed roof top units are secured to curbs using sheet metal clips made in-house by our sheet metal shop. Make sure your rooftop unit is prepped for this storm season with hurricane straps.

Contact Our Service Department

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