Chal l enges To Goi ng Gr een I n

Manuf ac t ur i ng/Di st r i but i on
Fac i l i t i es
Track 4 Session 5
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Director of Sustainable Construction
Clayco
merrillp@claycorp.com
314.429.5100
Paul Todd Merrill, PE, LEED AP
2
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Abst r ac t
3
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.
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Agenda
4
Green Building Progress to Date
Overview of the USGBC - LEED Assessment
System and new changes
Challenges with USGBC - LEED and
Manufacturing/Distribution
Recommendations
Energy Consumption Calculator
Demonstration
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Cl ayc o Gr een Bui l di ng Pr ogr ess
5
Platinum Certified: 1 Project
Gold Certified: 5 Projects
Silver Certified: 4 Projects
Certified Level: 16 Projects
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
St ar t i ng Poi nt s
6
Presentation with new construction
focus
Regional approaches/attitudes and
capabilities differ across the country
Heated/ventilated vs. conditioned
space
Process loads are unique to each
project
We represent one contractor’s
opinion
Each client/project is unique
Not here to preach why this is a good thing
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
St ar t i ng Poi nt s
7
Environmental Impact of
Manufacturing/Distribution Facilities
Energy use/water use
Waste generation/packaging
Transportation impact
Material quantities
Site impact and land use
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
What We See and Hear i n t he
Manuf ac t ur i ng/Di st r i but i on
Mar ket pl ac e…
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Increased commitment to going green
75 – 90 % of recent opportunities consider
LEED certification or Sustainable Measures
Clients 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 such
Still a lot of misconceptions
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
What We See and Hear i n t he
Manuf ac t ur i ng/Di st r i but i on
Mar ket pl ac e…
9
“ We have implemented high efficiency
process equipment, but get no LEED credits!”
“ Not going green” is the exception
Energy savings results from a business case
perspective
Results = Better, Higher Quality Buildings
Others will follow your sustainable lead!
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Over vi ew - USGBC LEED Rat i ng
Syst ems
10
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 savings
Water efficiency
CO
2
emissions reduction
Improved indoor environmental quality
Stewardship of resources and sensitivity to
their impacts.
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
USGBC LEED Pr ogr ess t o Dat e
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19,957 USGBC member organizations
2,476 commercial LEED certified projects
19,524 commercial LEED registered projects
91 countries with LEED projects
4.2 billion square feet in process
81,155 LEED accredited professionals
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Over vi ew - USGBC LEED Rat i ng
Syst ems
LEED BD&C – Building design and
construction (old LEED NC)
LEED EBOM - Existing buildings: operations &
maintenance
LEED ID&C – Interior design and construction
(old LEED CI)
LEED core and shell, LEED for schools
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Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Over vi ew - USGBC LEED Rat i ng
Syst ems
13
LEED v3.0 – LEED 2009 newest version
Each system includes prerequisites and
credits
100 point system + 10 bonus points
4 certification levels
Certified - 40 Points
Silver - 50 Points
Gold - 60 Points
Platinum - 80 Points
You Don’t Have to Do Everything!
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LEED Cr edi t Cat egor i es
14
Sustainable Sites – 26 points possible
Water Efficiency – 10 points possible
Energy & Atmosphere – 35 points possible
Materials & Resources – 14 points possible
Indoor Environmental Quality – 10 points
possible
Innovation in Design – 6 points possible
Regional Priority – 4 points
possible
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
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Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
16
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
LEED Rec ent Changes –
LEED v3.0
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Weighting of priorities of credits
Emphasis on sustainable sites and urban
developments – 26% of credits
Increased water conservation efforts – 10% of
credits
Increased energy efficiency and carbon
production reductions – 35% of credits
Regional priority credits
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Easi er LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
18
Sustainable construction activities
Erosion and sediment control measures
Air quality management and cleanliness
Construction waste management and diversion
Site logistics and storm water issues – except
vegetative “ green” roofs
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Easi er LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
19
Reduced parking capacity and preferred
parking
Reduced heat island effect - roof
Domestic water use reduction measures –
landscaping and plumbing fixtures
Use of regional and recycled content materials
Materials and finish selections
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Chal l engi ng LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
20
Site and location challenges – urban vs. rural
Alternative transportation measures – bike
racks & showers, public transportation access
Maximize open space
Restoration of native vegetation
Reduced heat island effect, non – roof hard
surfaces
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Chal l engi ng LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
21
Use of on-site renewable energy sources
Enhanced building systems controls for
tracking and monitoring of energy use and
outdoor air monitoring
Use of salvaged (used) building materials
Use of rapidly renewable and certified wood
materials
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Chal l engi ng LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
22
Enhanced HVAC Systems and refrigerants
Occupant controllability of lighting/thermal
comfort accessible controls
Natural illumination to meet credits
Innovation in design credit limitations –
limited to 6 total; 1 for LEED AP on Project;
only 3 points allowed for exemplary
performance
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Chal l engi ng LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
23
Energy use and process load challenges
Can be low energy users to begin with
Process loads can be tricky
Energy loads must be “ modeled”
Up to 19 points can be “ available” in this
LEED category
Energy modeling rules and the building type
make this challenging
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Chal l engi ng LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
24
Energy use credits – regulated modeling
Determine baseline energy use from ASHRAE
90.1-2007 standards
Determine actual design energy use from
selection of envelope, HVAC, Lighting,
domestic water heating and process loads
Percent cost savings from actual design to
baseline determines available LEED points
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
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Chal l engi ng LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
Basecase Proposed Design
E
n
e
r
g
y

U
s
e

1
0
^
6

B
t
u
/
y
r
Proj ect X Energy USE
Pumps
Motor Loads
Cooling Systems
Lighting Systems
Power Devices
Heating Systems
Process Loads
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Chal l engi ng LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
26
Larger buildings (over 150,000SF) are required
to be modeled with more efficient baseline
performance systems per ASHRAE
appendix G
All “ conditioned spaces” in the proposed
design shall be simulated as being both
heated and cooled, even if none is to be
installed.
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Chal l engi ng LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
27
“ 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&2
10 3
15 4&5
20 6&7
25 8
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
28 28
ASHRAE 90.1-2007 Cl i mat e
Zones
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Chal l engi ng LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
29
“ 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.
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Chal l engi ng LEED Poi nt s For
Manuf ac t ur i ng/Di st r i but i on
30
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
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
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Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
32
Implement energy efficiency
improvements – envelope, HVAC
systems, lighting systems
ASHRAE Advanced Energy
Design Guideline for
Warehouses is a great resource
Creative approach to the
exceptional calculation methods
– past data collection; work with
equipment suppliers;
documented process load
efficiencies
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
33
Energy Efficient HVAC Systems
VFD controlled exhaust ventilation systems
Higher efficiency MAU and RTU equipment,
chiller plant, drive units
Passive Ventilation and Cooling
Heat Recovery from process loads
Energy recovery units
Thermostatically controlled exhaust systems
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
34
Energy Efficient HVAC Systems
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
35
Energy Efficient Lighting Systems
T-8 or T-5 fluorescent lighting systems
Motion controlled lighting
Daylight Harvesting Systems
Foot-candle levels which do not exceed task
requirements
Centralized controls
LED lamp sources
Reflective interior surfaces
Use task lighting where appropriate
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
36
Energy Efficient Lighting Systems
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
37
Energy Efficiency Building Envelopes
Dock Seals
Reflective Roofing Materials
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
Innovation in design credit ideas:
Transportation/rail emission reduction
measures
Shipping/delivery reduction measures
Reduced packaging efforts - waste stream
reductions
Supply chain perspective – upstream and
downstream
Establish green cleaning policies
Establish A green education plan
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Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
Transportation/rail
emission reduction
measures
Smarter Travel
Better Vehicles
Better Fuels
Improve the
efficiency of
operations
39
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
Reduced packaging efforts - waste stream
reductions
40
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
Establish green cleaning policies
41
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Rec ommendat i ons f or LEED
Poi nt s…Or Just Good Pr ac t i c es
42
Consider alternate green building assessment
tools
Green globes, energy star
Embrace self – defined certification!
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Ener gy Consumpt i on Cal c ul at or
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Excel spreadsheet tool
Estimate of power consumption comparison
for 2 scenarios
Input data tabs - storage, pallet conveyor, case
conveyor, sortation, automated vehicles,
manual vehicles, picking/palletizers, lifts,
building utilities
Cost savings or KWHR savings results
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
44 44
Ener gy Consumpt i on Cal c ul at or
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
45 45
Ener gy Consumpt i on Cal c ul at or
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
46 46
Ener gy Consumpt i on Cal c ul at or
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Pr oj ec t Ex ampl es -
Manuf ac t ur i ng/Di st r i but i on
Fac i l i t i es
47
Anixter, Inc. Distribution Warehouse
Alsip, IL
450,000 SF Logistics Distribution Warehouse
19,000 SF Office Area
$16.5 M Construction Cost
LEED NC Certified
Design / “ Actual” Construction Duration = 8-9 Months
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Pr oj ec t Ex ampl es -
Manuf ac t ur i ng/Di st r i but i on
Fac i l i t i es
48
Villa Lighting
St. Louis, MO
222,000SF Distribution Center
Urban Setting
LEED NC v2.2 Registered
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Pr oj ec t Ex ampl es -
Manuf ac t ur i ng/Di st r i but i on
Fac i l i t i es
49
USPS - Troy, MI and Greenville, SC
Bulk Mail Processing Centers
LEED NC v2.2 Registered Projects
Troy, MI – 150,000SF Renovation
Greenville, SC – 200,000SF Addition; 58,000SF
Renovation
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Pr oj ec t Ex ampl es -
Manuf ac t ur i ng/Di st r i but i on
Fac i l i t i es
50
General Mills
Social Circle, GA
1,500,000SF Distribution Center
LEED NC v2.2 Registered
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Key Takeaways
51
General overview of the LEED rating system
and new changes
Sustainable measures may already be in place
LEED challenges to
manufacturing/distribution facilities
Certification can be challenging but can be
done!
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Ref er enc es
52
www.usgbc.org – Further Understanding of
the LEED Rating System and Case Studies
www.energystar.gov – Great tools and
resources for existing and new buildings
www.ashrae.org/publications/page/1604 -
Advanced Energy Design Guide for
Warehouses
Manufactures Websites
Supply Chain Forward. 2009 MATERIAL HANDLING & LOGISTICS CONFERENCE | SPONSORED BY HK SYSTEMS
Quest i ons? Quest i ons?
53