Kilbarrack Fire Station Gymnasium Construction Project Green Plan© Dublin Fire Brigade To purpose build a self sufficient gymnasium that would use forward thinking, continuous insulation and renewable technology combined with behavioral change to satisfy the physical training needs of a fully operational Fire Station

2013

Fire Fighter Neil McCabe Green Plan© Manager Dublin Fire Brigade

3/4/2013

Copyright© Neil McCabe, 2013.

The moral right of the author has been asserted.

All rights reserved. Without limiting the rights under copyright reserved above, no part of this publication may

be reproduced, stored in or introduced to a retrieval system or transmitted in any form or by any means

(electronic, mechanical, photocopying, recording or otherwise), without the prior written permission of the

copyright owner.

Building type: Detached brick and block built single storey unit measuring 207m3 with no attic space.

Completion Date: 01/08/2012

Location: Kilbarrack Fire Station, Kilbarrack, Dublin 5.

Project Designer: FF Neil McCabe

Project Supervisor FF Neil McCabe

Project Manager Design Phase: Rory Walsh

Project manager Construct Phase: Stephen Brady

Drawings: FF Neil McCabe

Mechanical & Electrical: Dublin City Council, Public Lighting

Builder: Dublin City Council, Housing Department

Note: all works on site have been built in accordance with build regulations and best practice

including part L of the Building Regulations 2007. All Materials supplied have been installed in

accordance with manufacturer’s specifications and encompassed the values of the Green Plan© for

both the Fire Station and the whole of Dublin Fire Brigade. This includes The Natural Step (TNS) as

my definition of Sustainability; TNS is listed and defined in both the Green Plan© and the DCC

Sustainability Report 2010, signed off by Dublin City Council. Energy Conservation, Heat Loss and Air

Tightness are the core values of this project and have been adhered to at all times. All materials have

been disposed only when prevented as much as was possible first, recycled and / re-used as much as

possible and have met the above criteria.

Project Overview

The Concept of the Green Plan©

Innovation

The concept of the Green Plan© is to embrace an innovative sustainable approach that will use best

practice, forward collective thinking and new technologies to:

Significantly reduce energy and water consumption

Prevent and reduce the volume of domestic waste created

Save money by reducing the energy running costs by up to 80%

Deliver community focused services that engage staff and our local community

Support Fire Stations to meet the 2020 targets of 33% energy reduction

The Green Plan© History

The Green Plan© started off four years ago as a holistic approach to tackle the needs of a 40 year

old full time Fire Station in the heart of Dublin. To bring it up to date with modern forward thinking

renewable technologies and to ambitiously make Kilbarrack Fire Station, Carbon Neutral and Off

Grid. The technology installed would produce ring-fenced savings that would then be ploughed back

into the Fire Station to invest on our other environmental wish list projects. The Seven Themes of

the Green Plan© are Energy; Water; waste; Biodiversity; Transport; Society and Procurement.

To take our aims and turn them into Actual Actions, I wrote the Green Plan for Dublin Fire Brigade

and placed Kilbarrack Fire Station as the Flagship retro fit Project. Once the Green Plan worked in

Kilbarrack and showed financial viability from a reduction in kWh, then the Green Plan would be

rolled out across the whole of our Fire Brigade. There are over 300 completed retro fit and

environmental projects finished to date in the flagship Fire Station. Running costs have been

reduced by more than €50,000 per annum since the retro fit project began. The next step was to

take the verified energy reduction in kWh carrying a monitory value and to reinvest it in the

construction of the Gymnasium. Thus using the Money saved on the Energy theme to benefit the

Society Theme of the Green Plan©.

Materials, Equipment and Acronyms

PIR Boards: Polyisocyanurate Insulation Rigid Boards

ASHP: Air Source Heat Pump

Fan coil unit: Unit used to disperse heat

HVAC: Heat Ventilation Air Conditioning

Probes: A device that measures physical quantities and converts them into signals

Cat 5 cables: Communication Cables

Current: Electrical charge through and Electric Conductor

Voltage: Unit used to measure Volts (V)

Ohms: Unit used to measure resistance (r)

Amps: Unit used to measure current (I)

GGBS: Ground Granulated Blast furnace slag

RCD: Residual Current Device

RCCB: Residual Current Circuit Breaker

Watts: Electrical power is measured in Watts

kWh: A Kilowatt is a 1000 Watts

Jambs: The vertical section of a door frame

Sills: The horizontal member of a window

Reveals: The surround of a door or window

Sensors: A device that measures physical quantities and converts them into signals

LEDs: Light Emitting Diode

SMD: Surface Mounted Device

COB: Chip on Board

Stats: A device that measures physical quantities and converts them into signals

Meters: A device that measures quantity

ELCB: Earth Leakage Circuit Breaker

PMDP: Project manager Design Phase

PMCP: Project Manager Construct Phase

TGL: Technical Guide lines

Part L: Part L of the TGL in the building Regulations

U Value: The thermal resistance of a material

CAD: Computer Aided Design

Active considerations:

1) How to provide continuous mould insulation

2) What products and cost performance including Green Plan 3 pillars system

3) Renewable techs and new green thinking

4) Building orientation

5) Ensuring symmetry and design with the Fire Station and to have a pleasant finish to the eye

6) Non use of uPVC and Aluminium and The Natural Step (TNS)

7) Recycling availability for new products and old ones – such as windows eventually.

8) Educating on the use of renewables to support local employment in the Green Economy

The Four Watches, Kilbarrack Fire Station.

A Watch B Watch

C Watch D Watch

History and Scope of Works carried out in the construction of Kilbarrack Fire Station Gymnasium

Site preparation

Check for site services

Break concrete and remove slab existing approx 150mm thick

Foundations

Excavate trench to receive foundation

Dispose of excavated material in the agreed area on site – this soil and rubble mix to be

reused as in fill for the rain water pond area

Prepare excavated foundations to receive insulation – (lean mix if necessary)

Supply and lay insulation 150mm thick.

Supply and lay 36 N – 10 concrete foundations, Reinforced with an A393 mesh

Supply and lay 150mm insulation to spec below

External wall : 100mm wide brick outer leaf, form 150mm wide Cavity with stainless steel

ties 4.5no m2 ; Inner leaf 215mm wide, 5 N block work.

DPC as per build regulations

The building rests on a pre mixed layer of GGBS Cement. This is an insulated raft foundation

that sits upon Super Grund 300mm Aero Board polystyrene insulation with a U Value of

0.1w/m2.

There are no load bearing internal walls so structural grade board was not considered.

Passively reducing the thermal bridge to the ground and creating a better internal climate

were key factors.

There is also a radon membrane and a vapour control layer.

Ground floor slab

225mm thick hardcore compacted

in 100mm layers

50 mm sand blinding

Waterproof membrane radon

barrier as per building regs

150mm high density polyiso

insulation

150mm thick 35N –ten reinforced

concrete slab with A142 mesh,

with raft toe detail to perimeter

Steel trowel finish

Floor

The floor has been insulated to the following Specification:

25mm screed of GGBS premixed cement resting on top of 100mm of Xtratherm XT/HYF.

On top of the PIR Board is counter battening and on top of this sits Reclaimed 45mm

Maplewood hardwood flooring.

The flooring has been refurbished, sprung and re-used. The flooring had previously been

used in a basket ball arena in Dublin and had reached the end of its working life.

Wall and floor junction with insulation under screed Xtratherm XT/HYF and Xtratherm

Perimeter strip XT/STR

Jambs: All jambs have a proprietary cavity closer directly connected to an Xtratherm Cavity

Therm XT/PIR 100mm -0.12Wm2k

External walls

Outer leaf brick work External wall 100mm thick brick outer leaf form 150mm wide Cavity

with stainless steel ties 4.5no per m2.

Inner leaf 215mm thick 5 N block work.

DPC and cavity closures as per build regs

Precast concrete window sills and lintels sized appropriately Internal walls insulation:

150mm Xtratherm PIR board XT/Thin R; XT/TL _0.022Wm2k

Cavities: All building has continuous insulation: this includes opes; jambs; with internal

cavities filled with Xtratherm Cavity Therm CT/PIR.

This is followed by Lycene sealant spray around all joints to guarantee no air leaks.

Air tightness, it is imperative that the building be constructed to achieve a tight seal. This

building is intended to use almost no energy to provide heat. An air tightness test will be

commissioned after construction to provide test analysis of the project.

Roof structure

All roof timbers are soft wood and treated and FSC certified

Roof members to be sized and constructed in accordance with current building regulations

Roof finishes

600 mm x 300 mm tegral or similar roof tile on 50mm x 38 mm treated soft wood batons on

breathable roof membrane, minimum lap 150mm

Eaves, ridge and valley details in accordance with building regulations and best building

practice

Velux supply and install in accordance with manufacturer specifications and note*: glass will

be replaced with AA Rated low emmisvissity, Argon filled, K Glass. To provide thermal

conductivity and allow for solar gain. *Please note that this was before Velux were able to provide DFB with .62

Glazing.

Supply and install uPVC facia and soffit with ventilation as per building regulations.

Supply and install uPVC gutters and downpipes as required.

These downpipes and drains run off to the rain water harvesting system tha services the

pond with fresh water

Roof Insulation:

Joist insulation of 150mm Xtratherm PIR Board XT/PR - underneath and 100mm between

each Rafter.

12.5mm Gyproc plaster board and a skimmed plaster finish.

All voids (if any) have been filled.

Internally SIGA Majpell 5 Vapour Control layer is used before the Xtratherm CT/PIR-

0.021W/m2k

The roof is finished with natural black Slate tiles mounted externally on a ventilated cavity

with battens and counter battens on a SIGA Majocat Vapour Control Layer, (VCL).

Inter walls

Nil

Internal wall completion

nil

Wall finishes

Mechanically fixed 90 mm high density polyiso insulation mechanically fixed to block work.

Floor finishes

50mm high density insulation to ground floor slab and install previously salvaged Cherry

wood floor in accordance with best practice. This floor has already been sourced by DCC

Joinery Dept.

Ceiling finishes

150mm thick insulation between rafters including Vapour Barrier

Composite insulated ply line board 90 mm fixed to rafters in accordance with Manufactures

details: Skim ditto

Three coats emulsion paint

75mm x 50 mm PAO treated soft wood false rafters @ 400 centres

Air tightness, it is imperative that the building be constructed to achieve a tight seal. This

building is intended to use almost no energy to provide heat. An air tightness test will be

commissioned after construction to provide test analysis of the project.

Joinery

Skirting 125mm high soft wood painted

25mm thick MDF Window board, bull nosed and painted

Throughout the project triple glazed, argon filled timber windows with low emmisvisity

coatings have been used.

The wood used has been sourced in Ireland and includes FSC Certification.

This is to reduce the miles travelled by the timber and to reduce associated carbon.

There are a total of 14 Nr windows in the build. The 8 windows are set into the walls and

doors of the build. They have a U Value of .81.

There are 6 no S06 standard windows as roof lights, supplied by Velux with a U Value of .62.

Xtratherm perimeter strip XT/STR has been used at all Jambs.

Mechanical installations

To be designed in accordance with building regulations and encompass the values the Green

Plan: see below

Contractor will be required to install a water fountain

Water supply to be provided from existing main at agreed location as necessary

Electrical installations

All works to be carried out with current build regs and best practice

Layout to be agreed with contractor, note it is envisaged that a dado trunking will be used

through out to allow for flexibility and versatility

Lighting layout to be agreed and issued at a later date prior to internal finishes commencing

Fire alarm system to be supplied and fitted

Emergency turnout alarm notification system to be supplied and installed

All mains connection from existing building

Contractor to supply and install a sub metering system

Contractor to supply and install external lighting to building regulations and encompass the

values the Green Plan

Drainage

Manhole 1. Supply and lay surface water drainage in accordance with Building Regulations

layout to be confirmed and contractor to include for design for approval.

Contractor to include for connection to manhole 1

See rain water harvesting below

Site works

Contractor to make good all works disturbed externally

Concrete yard to be re instated as required

Contractor to construct wheel chair access ramp with building regulations and provide a

galvanised mild steel handrail and grab rails all in accordance with building regulations,

painted as necessary

Walls

The interior of the walls has been dry lined using Xtratherm Thin-R Plus Partial Fill Cavity Plus

XT/CWP _0.12W/m2K.

This includes pre formed corners thus avoiding default factor heat loss and thermal bridging

at joints. All Jambs have been sealed with Proprietary Cavity closers: Xtratherm perimeter

strip XT/STR

External windows and doors to be supplied by nominated supplier DCC, in accordance

previously submitted performance specification. This includes the thermal conductivity .8 U

Value calculations and will involve tinted glass with the architectural character of the Fire

Station.

Green thinking and the use of Renewables

Green Thinking

“A key challenge in moving to a green, energy intelligent European economy is capacity building,

which means not only increasing the skills of the existing workforce, but also increasing the numbers

of skilled people working in the sector because both are needed to drive new business and to exploit

the potential markets”

Patrick Lambert EU Director for Competitiveness and Innovation

I would like to think that as much as is possible I have tried to directly

link the Gymnasium project to the above statement. From inception

to design through to completion, I have designed and over seen the

Gymnasiums construction, which has at most times presented

educational experiences for all parties concerned. Kilbarrack Fire

Station is a test bed for new and innovative technologies and best

practice energy management projects for all of Dublin Fire Brigade,

thanks to its Green Plan©. However the Gymnasium project has

really pushed the boundaries for forward planning involving thermal

conductivity and energy conservation.

The Gym is positioned in a South West orientation. This includes a large triple glazed AA+ wooden

feature window. The window is designed to maximise the solar gain in the day and evening and to

increase the thermal mass heat stored in the floor and north side gable wall. This reduces the need

for mechanical heating. The windows to the rear of the building are north facing and horizontal.

They are relatively small but are positioned to take advantage of morning solar gain. Shading has

been negated. It is only in summer evening that solar shading would be an issue. The Fire Stations

Engine Bay blocks the last of the evening sun and allows for the HVAC system to fulfil its function

more efficiently.

The Gym is in situ in a working full time Fire Station. Therefore in the day time (most of the time) the

Gym will not be in use. For this reason Solar Shading is not an issue.

The shutter foundation is heavily insulated and of solid poured GGBS premixed concrete. It is

intended for thermal mass to be stored in the foundation gained from the window mentioned

above.

The concrete shutter is GGBS Concrete from ecocem ltd.

The horizontal and vertical windows do not open. This is to ensure that the HVAC heat recovery

system is not interfered with. However mechanical provisions have been made for future works

should windows require opening. This includes Electric points and spurs already installed at each

ope. When opened the windows would transmit a message to the HVAC system that would begin

shutting them off until the windows are closed again.

The six Velux windows in the Gym roof are purposefully included so as to benefit from solar gain

though out the day as the sun journeys from east to west. They also provide plenty light and give the

Gym a pleasant feel. The average daylight factor levels are achieved with the combined array of

windows.

All door Jambs, Opes, Cavities, Joists and Rafters have been continuously insulated throughout the

entire build. Specialised PIR Boards that include corner joints have been used. All lintels have been

precast steel construction that includes interior and exterior blown insulation.

The Xtratherm internal insulation Thin R PIR boards have been mounted while ensuring a continuous

ribbon top and bottom around all openings to provide fire stops and maintain the predicted U

Values.

All electrical cables are run from the ELCB to the sockets and lights. The cables are running behind

large trunking. This allows for future re positioning of sockets and switches should the Gym lay out

change over the years.

On site in the Fire Station an array of 40 micro wind turbines are in situ. The turbines produce a

theoretical peak of 6.4 kWh to the fire station. A sub meter is installed and shows the power

delivered to the Gym from the turbines and the kWh consumed by the Gym. The electric energy

back up is the national grid.

Apart from being FSC timber, sourced in Ireland, the doors are of a robust design and should offer a

good LCC and lengthy return. This includes key pads to reduce key and lock replacement. All glass is

triple glazed E glass.

Waste management was established from the very start of the project. An onsite recovery and

segregation of all recyclables took place in the Fire Stations recycle bay in situ. All left over timber

was re-used on other projects as part of the Society Theme of the Green Plan©. This included bird

boxes and bat roosts for local schools in the community. The remaining waste was collected and

recovered in bring centres or removed and certified as waste. 20% went to landfill.

Rain water harvesting system

The roof space of the Gym is 625m2 using the Dublin Airport

Authority (DAA) mean figures for rainfall the current roof space can

collect an estimated 20.5mm of rain water per day approx. This water

is collected via guttering at the facade and rear that are connected to

Nr 2 downpipes. The downpipes connect to a collecting pipe that

sends the water to the 3m3 harvesting tank, stored above ground. The

tank is reinforced insulated plastic.

The water is used for supplying the Fire Stations pond with regular fresh water. The pond is to have

Fresh Water Mussels, Fish and Plants by June 2013, once the filtration system is established. The

overflow of the harvesting system and the pond is sent to the storm drains and is currently not

recycled.

Space Heating

The main source of heat for the Gym is a Kingspan Aeromax 8kw Plus Air source Heat Pump. This has

an amp at start point of 20 amps. The pump sends its heat to an exposed horizontal fan coil unit FP-

85 4.42/8.47Kw, that blows hot air into Gym. The unit has a user interface control that is connected

to stats.

Ventilation

There is also a Ventaxia HR500X HVAC Unit. This unit can recover over 153l/s of heat and can extract

over 250 l/s of air and is efficient at 550m3/h. The system is fitted with CAT 5 communication cables.

As warm air set to the desired temperature is blown from the north facing side gable wall though the

ASHP and into the Fan coil unit; the air is then picked up on the south facing gable wall and entered

into the HVAC system. The stale air is then stored and used to heat fresh air entering the building.

The fresh air is then blown back across the Gym in the direction of the fan coil unit. The room stats

and probes then engage the system to shut off to prevent overheating.

Reuse of materials

1) The surface of the floor has been covered in reclaimed, refurbished Maplewood Hardwood

flooring.

2) The slate roof tiles used were recycled and brand new.

3) All timber used was to FSC standard and has originated in Ireland

4) All subsoil from the foundation was retained to be used as in fill for the construction of the

pond; for rainwater recycling

Wind Turbines

The Gymnasium is directly tied to the electric energy coming from the 40 Micro Wind Turbines

located on the Hand Ball Alley in the Fire Station. A meter has been installed in the gym that records

the actual energy in kWhrs directly providing energy. The National Grid is the Fire Stations backup

energy provider. The Micro Turbines are part of a Green Plan© strategy to R&D new technologies

for Dublin Fire Brigade and are specific to a Green Public Procurement guidance project and are not

readily available on the Market.

LEDs

The Gymnasium is fitted with 6 Nr twin T8 LEDs. The lights take direct current and have no ballast.

They consume 17W of energy per fitting. This represents an energy reduction of at least 70% when

compared with traditional equivalent T8 lamps.

Renewables used

LEDs Twin T8 equivalents

HVAC

ASHP and Fan coil unit

Micro wind turbines and grid tie connection

Original Concept Drawings of the Gymnasium

Appendix

Contents:

Useful Links

Cavity Closer details

Fire alarm and Electric schedule

Drawings

Window and door schedule

Ventaxia HVAC system

Useful links

http://www.ecocem.ie/downloads/Technical_Data_Sheet.pdf

http://www.vent-axia.com/range/hr500-hr500x.html

http://www.kingspansolar.ie/pdf/Aeromax%20Plus.pdf

http://www.xtratherm.com/wp-content/uploads/2012/01/Xtra_IAB_03_0183_Pitched_Roof.pdf

http://www.siga.ch/en/product-overview/majpell-detail.html

http://www.uvalue.ie/uploads/files/Roofshield.pdf

http://www.xtratherm.com/resources/videos/xtratherm-pitched-roof-vented-insulation

Proprietary Cavity Closer

Window Head

Proprietary Cavity Closer

Window Cill

Proprietary Cavity Closer

At Jamb

Proprietary Cavity Closer

At Jamb Reveal

Perimeter Strip

At Slab

Junction Insulation

At Screed

Wall Ceiling Junction

At Eaves

The External Corner

Fire Alarm Schedule

Acknowledgments:

I would like to thank John Carbery electrician of DCC Public Lights.

Mark O Mahoney of DCC Housing and Maintenance.

Brendan McCabe DCC Housing Area Management Officer.

Pat McGrory Forman DCC Joinery.

DCC H&S.

Velux Ltd.

Supply and Erect Scaffold Co Ltd.

Xtratherm for the use of their drawings and products.

TO John Keogh and the four Watches in Kilbarrack Fire Station

Window and Door Schedule

Notes: