Presented by Paul Groves of Khansaheb Industries LLC · 2019. 5. 11. · Estidama/Pearl, Dubai Municipality, BREEAM, LEED and Green Star environmental assessment and rating programmes

Because there’s no future in the past…...

Presented by

Paul Groves of Khansaheb Industries LLC

Suitable for all applications -

internal and external

Silver foil faced

www.spiraliteductwork.com innovative – versatile – light - robust – planet aware

Khansaheb Industries LLC

Silver foil facedwww.spiraliteductwork.com innovative – versatile – light - robust – planet aware

Since 1935 the Khansaheb Group has a

strong heritage of pioneering innovation and

development in the UAE and GCC.

Khansaheb Industries LLC was established

with a mission to introduce the latest

innovative energy efficient products and

technologies into the local and regional

markets. As a start, we acquired the Global

Intellectual Property Rights of Spiralite non-

metallic ductwork. In addition to several

prestigious projects in the UAE, Spiralite has

been installed in the international markets

in U.K., Ireland, Spain, Singapore and Oman,

to name a few.

The Product

Spiralite is an innovative and

unique circular and flat oval non-

metallic insulated air duct that has

numerous advantages over

traditional GI (metal) and PI ducts.

Its lightweight, robustness,

optimal airflow, and thermal

performance offer numerous

benefits in weight, space, time,

cost and energy consumption.

These benefits provide unrivalled

whole-of-life cost advantages.


The Product

Spiralite ductwork is approved for use by major MEP consultants and is

compliant with all the relevant building codes and local authority

regulations. Due to its environmental and sustainability credentials, it

was adopted by Masdar, included in The Future Build portal, secured

the ADQCC Trustmark certification and received a Two Tick certification

from the Singapore Green Building Council. Its use can therefore play a

role in optimising performance standards and credit awards under the

Estidama/Pearl, Dubai Municipality, BREEAM, LEED and Green Star

environmental assessment and rating programmes.

“Benefits to everyone

involved in sustainable

development”


The Product

• Circular and flat oval non-metal insulated ductwork

• Suitable for all commercial, industrial and domestic HVAC

applications

• Uses standard fittings, supports and connections to inline

plant

• Over 80% lighter than GI (metal) ducting and insulation

• Saves space, time and costs

• 25-40% more energy efficient due to

• Rounded shape = optimal airflow efficiency

• Pressure resistant up to at least 7,667 Pa

• Completely airtight – Class C at 2,500 Pa

• Smooth internal surface = lower friction losses

• Lowest lambda values = optimal thermal efficiency

• No thermal bridge = minimal condensation

• Additional weatherproof laminate for external applications

• Additional coloured laminate for internal aesthetics

“It’s a combination of the shape, internal

laminate and phenolic insulation that make it

unique and so special”


Fabrication

“It’s a combination of the shape, internal laminate and

phenolic insulation that make it unique and so special”


Easy Connection

1 2

3

Insert male coupling Line up and insert tiger clips

Tape securely applied to a dry and clean surface

3 simple steps – no protrusions, no thermal bridge, airtight


Easy Connection


Why Phenolic?

Phenolic is widely regarded as the highest quality standard

insulation material and offers:

• Lowest possible Lambda values, a measure of thermal efficiency:

0.022 W/m.K at 10-19°C (BS EN 12667); 0.018 W/m.K at 10°C

(ASTM C-518)

• Best fire and smoke performance properties:

• UK Class O EuroClass 1 Class 0 (BS476-6); EuroClass B, s1-d0

(BS EN 13501-1)

• Listed as Class 1 to Standard for Safety UL181

• Optimal performance for combustibility, surface spread of

flame, smoke and toxicity and formation of droplets

• Optimal density (55-60 kg/m3) and compressive strength (200 kPa

(EN 826))

• Minimal degradation from moisture - non-porous and

minimum 90% closed cell (ISO 4590)


Spiralite Green Credentials

Unrivalled Sustainability, Energy & Environmental Benefits

Product and Installation:

o CFC/HCFC and HFC free; zero VOC’s

o Zero Ozone Depletion Potential (ODP)

o Low Global Warming Potential (GWP)

o Full BREEAM/LEED/ESTIDAMA/Green Star accreditation

o Optimal use of recycled raw materials in production process

o Ductwork re-usable and recyclable

o Close to zero wastage on site

o Very low carbon footprint – a fraction of the 1,330kg’s for galvanized steel insulated

o Thermoset process in the production of phenolic uses far less water than with steel production

Efficiency in Performance:

o Class C leakage rating, rounded shapes and extremely low internal frictional resistance lead to greater

airflow efficiency - as much as 48% lower energy usage when compared to galvanized steel ductwork and

insulation, reducing energy costs and carbon footprint of any building

o Internal connection system, so no thermal bridges, resulting in minimal risk of condensation and thermal

losses and resistant to mould growth

o Pressure resistant and minimal leakage at up to 7.667 pa

o Ongoing HVAC operational cost savings – energy, maintenance and repairs, cleaning


Spiralite MEP Consultant Approvals

Spiralite has been approved and/or specified for use by many MEP, Design

and Cost Consultants from the US through to Singapore, including:


• AE7

• AECOM

• Arcadis

• Arif & Bintoak

• Arkiteknik

• ARUP

• Atkins

• Buro Happold

• CH2M Hill

• Chapman BDSP

• CHSS

• CKR

• Cundall

• Faithful & Gould

• Gardiner & Theobald

• Godwin Austen Johnson

• Hilson Moran

• Hoare Lea

• Hurley Palmer Flatt

• KEO

• Mario Associates

• Mott MacDonald

• Proleed

• Ramboll

• SSH

• Ted Jacob EG

• Turner & Townsend

• TUV SUD

• WME

• WSP

Benefits to Property Owners

& Occupiers

Spiralite offers many benefits to property owners and occupiers:

• CAPEX and OPEX savings through design optimisation

• Better quality air at the right temperature, volume and humidity = better cooling and

comfort with no condensation

• Energy savings and lower carbon footprint

• Greater robustness and longevity

• Less HVAC system noise; saves space, weight and time

• Reduced cleaning requirements and costs

• Faster/easier repairs and maintenance leading to reduced ongoing operational costs


Many Prestigious Installations

WAFI Tower Dubai

Serenia Residences, The Palm

Mirdif 35 Community Centre



MIRDIF 35 Mall

National Theatre, London

Google Innovation Centre, LondonWestfield Shopping Centre, Olympic Village, London

Brent Civic CentreLords CC Media Centre



MIRDIF 35 Mall

National Theatre, London

Westfield Shopping Centre, Olympic Village, London

Brent Civic CentreLords CC Media Centre

Centre for Sustainable Chemistry, Nottingham Uni

Clemenceau Medical Centre, Dubai

Guys’ & St Thomas’ Hospital, London

Palma de Mallorca Airport






Open-to-view aesthetics


Different colours and finishes

Black foil faced



Black foil faced



WAFI Gourmet Terrace


Sterile environments – hospitals,

labs, clean rooms, etc

Cleanroom at Sultan Qaboos University Hospital

Optimal cleanliness and sterility:

• Smooth internal laminate has inherent anti-mould and

anti-microbial properties

• Together with rounded shape gives less accumulation

and less adherence of foreign particles

• Quicker and easier to clean

• Special anti-microbial laminate for advance sterility

Aseptic Pharmacy at Attenbrookes Hospital


Sterile environments – hospitals,

labs, clean rooms, etc

Cleanroom at Sultan Qaboos University Hospital

Aseptic Pharmacy at Attenbrookes Hospital


Project examples include:• Sultan Qaboos University Hospital, Oman

• Clemenceau Medical Centre, Dubai

• Sheffield Hospital Blood Laboratory

• Wedgewood HO, Stoke-on-Trent

• Sheffield Hospital Blood Testing Laboratory

• Rolex Headquarters, Kent

• Astra Zeneca Laboratory, Cambridge

• Glaxo SmithKline Sycamore House, Stevenage

• Johnson Matthey TC1 and TC2 Labs, Cambridge

• GlaxoSmithKline Carbon Neutral Laboratory for Sustainable Chemistry

• Almac Pharmaceuticals, Northern Ireland

• Meira GTx Cleanroom, London

• Allied Bakeries, West Bromwich

• Nestle HQ, York

• Guys’ and St Thomas’ Hospital Cancer Care Centre, London

• One Ashworth Hospital, Kent

• Addenbrookes Hospital Aseptic Pharmacy, Cambridge

• Queen Mary’s University of London’s Institute of Cell and Molecular Science

• Charalambides Christis Dairy, Limassol, Cyprus

• Johnson & Johnson production facility, Athens

Almac Pharmaceuticals, Northern Ireland

Retail applications – mainly open-to-

view exposed ductwork

Black foil facedSpiralite ductwork is particularly well suited for use in shopping

malls and retail applications for a number of reasons, including

ease and speed of installation, enhanced aesthetics in open-to-

view environments, the energy savings that are generated and the

ongoing operational cost savings.

Spiralite ductwork has been specified for many prestigious

retail developments worldwide, including:

• Mirdif 35 Mall, Dubai

• WAFI Gourmet Terrace

• Stratford City (Olympic) Shopping Centre, London

• WAFI Mall extension and hotel, Dubai

• White City Shopping Centre, London

• Selfridges Flagship store, London

• Harrods Flagship store, London

• Bluewater Shopping Centre, Kent

• El Corte Inglés, Madrid

• WAFI Gourmet Terrace


Retail applications include many

global brand names

Black foil faced• Lefties (part of the Inditex Group, the world’s biggest fashion retailers)

• Marks & Spencer

• Selfridges

• Sainsbury’s

• Tesco

• ASDA

• H&M

• Ocado

• KFC

• Wickes

• Wilkinson

• Leon

• Dodd's

• Sunglasses Hut

• Nando's


Better aesthetics enhances the

shopping experience…….

Black foil faced


Better aesthetics enhances the

occupiers enjoyment of the space

Black foil faced


Saving space, saving time, saving

weight, saving money

Black foil faced


External Applications

Becomes a 4-in-1 application with the ductwork, the

insulation, the weatherproofing and the cladding all

installed in one fit, saving time and money






External Applications – before & after


Leisure Centres and Pool Halls

Spiralite is ideally suited to installations in moist or

chemically hostile environment, such as is found in

swimming pool halls and leisure centres, or in marine

environments:

• Impervious to damage from moisture

• Chlorine and sodium chloride resistant – no corrosion or

other staining

• Only jointing system needs treating

• Chemical resistant coloured finishes (laminates) available

• No product deterioration over time

• No untreated galvanized fittings to corrode


• Visually pleasing finish – both in natural state

and with additional laminates

• Virtually maintenance free

• ≥ 90% closed cell structure and non-porous

• Research has shown that 1% moisture content by

volume in mineral fibre can increase the thermal

conductivity by 36-107% (i.e. increases the U

values or thermal losses)


Projects include:


• Sol Pilates Studio, Mirdif 35

• Chilton College Pool

• Wolverton Pool

• Glenrothes Leisure Centre

• Kirkcaldy Leisure Centre

• Royal Commonwealth Pool, Edinburgh

• Redcar Heart Leisure Centre

• Falcon Sports Centre

• Weybridge Pool

• Huddersfield Sports Centre

• Devon Cliff Pool Hall

• Bridlington Leisure World

• Tenby Leisure Centre

• Bulmershe Sports Pavilion, Uni Reading

• Nottingham University Sports Centre

• Newry Leisure Centre

• Down Leisure Centre

• Perdiswell Leisure Centre

• Pool halls in more than 15 private mansions

Flat oval ductwork with lime

green laminate for Down

Leisure Centre Pool Hall

Flat oval ductwork with lime

green laminate for Down

Leisure Centre Pool Hall



Universities and Schools

Specific advantages include:

• Quicker installation and less disruption to working

environments

• Lower system noise, that has a significant impact on

learning abilities

• Lower energy and other operating costs

Centre for Sustainable Chemistry, Nottingham University

Ruskin School of Art, Oxford University


Universities and Schools

Interior and exterior of School for Special Needs, Valencia, Spain

MALS School, Stevenage, UK


Industrial applications and steel

structures

Existing Projects include:

• Maas Aviation Aircraft Spraybooth, Maastricht

• Amazon Logistics Warehouse, East Midlands

• THG Distribution Warehouse, Warrington

• RLG Precision Engineering Factory, Northern

Ireland

• Wedgewood Factory and Visitors Centre, Stoke-

on-Trent

• Panasonic Production Facility, Wales

• Johnson & Johnson Production Centre, Athens

• Allied Bakeries Plant, West Bromwich

• Jaguar Land Rover Advanced Engineering Facility

Spiralite is ideally suited to properties with steel

structures large production and processing

facilities, factories, warehouses and logistic centres


Industrial applications and steel

structures

Specific Project Benefits Include:

• Increased robustness, thermal

performance and airflow efficiency with

meaningful cost advantages for large (up

to 2,500mm dia) high level insulated

ductwork

• Weight (up to 85% lighter than metal (GI)

plus insulation), space and time savings

allow quick and easy delivery and

installation and

• Spiralite can generate other cost savings

such as reduced steel support structures

• Cost effective cladding

• Spiralite does not corrode, stain or

deteriorate in quality from exposure to

solvents, chemicals, moisture, chlorine or

sodium chloride and is suitable for long-

term use in hostile atmospheres


Large ductwork at high levels


Large ductwork at high levels


Residential & Accommodation


LEED Green Building Platinum Award - Accommodation in Jabal Ali, Dubai

Residential & Accommodation


Passivhaus Standards retrofit – Wilmcote House, Portsmouth, UK

Off-site modules & prefabrication


Off-site modules & prefabrication

Benefits include:

• Weight saving – can

become lightest

component

• Space saving – minimal

extra space for insulation

• Quick installation – only

one fit

• Easy connection

Silver foil faced


Energy Saving refurbishments

and retrofits

• Benefits include:

• Weight savings - up to 85% lighter than GI plus insulation

• Space savings – ideal for narrow ceiling voids

• Time saving – easy and quick installations for complex arrangements

• Flexibility – can be installed everywhere - ideal for getting around existing structures and services

• Energy savings – optimal thermal performance and airflow efficiencies


Environmental Credentials


Spiralite and the future


Spiralite and the future

Spiralite was

identified as the ONLY

known ductwork

product that could

add value to this

process


Square vs circular ductingSquare ducting:

P = 4 x A

S = P x L = 4 x A x L

A

L L L L

Dech D=A D=A

Circular Ducting:

P = π x Dech

Dech = 1.093 x A

S= P x L = π x 1.093 x A x L

Circular Ducting:

P = π x D

D = A

S= P x L = π x A x L

Saving materials, carbon, energy and

costs


Rectangular vs flat oval ductingRectangular Ducting:

P = 2xa + 2xb

S = P x L

A A A

B B B

L L L

Savings between 9.5% to 20% depending on the A/B (aspect) ratio


costs


Case Study: Emirates International School – GAJ*AHU Supply & Fresh Air:• External Ductwork• Risers (Roof to Ground Floor)• Corridors & Ceilings

Original Design in GI Ductwork:• Pressure drop: 89.12 Pa (ductwork only)• Total square meters: 275 sqm

Redesign in Spiralite Ductwork (equivalent sizes):• Pressure drop: 49.17 Pa (ductwork only)• Total square meters: 250 sqm• Savings: 10%

Redesign in Spiralite Ductwork (smaller sizes):• Pressure drop: 49.17 Pa to 89.12 Pa

(ductwork only)• Total square meters: 250 sqm to 225 sqm• Savings: 10% to 22.3%

* Calculation was made only for the highlighted run , from the AHU to the most remote grille in the groun d floor area


costs


VE Options - Saving materials, carbon,

energy and costs

Arising from greater airflow and thermal efficiencies, the

following VE Options are available through design optimization:

1. Either reduce the size of the ductwork and save material costs – CAPEX

savings

OR

2. Reduce the fan capacity/power of the AHU and save:

• Plant costs – CAPEX savings

• Operating costs – OPEX savings

In both cases there will also be further ongoing OPEX cost savings – less

frequent and quicker cleaning; quicker and easier R&M



energy and costs


Design Calculated ESP

for 1 FAHU (Pa)

Calculated ESP

for 3 FAHU (Pa)

Selected

FAHU Motor

KW

Cost (in AED

approx.)

Conventional

Ductwork

2,000 6,000 94.3 650,000.00

Spiralite

Ductwork

790 2,370 68.8 620,000.00

CAPEX Saving 30,000.00

Project – Proposed B+G+4 Commercial and Residential Building

Nadd al Shiba 1st

Equipment Under Study – 3 nos. FAHU

CAPEX & OPEX savings through reduced fan power:

Original design pressure drops per FAHU SA – 1,000 Pa & EA – 1,000 Pa

Spiralite calculated pressure drops per FAHU SA - 365 Pa & EA – 425 Pa

CAPEX Saving:

FAHU selection for fan power:


energy and costs


Design Description Particulars

Saving in power consumption of

3 Nos. of FAHU Fan Motor

94.3KW – 68.8KW 25.5 KW

Considering Plant operation for

24 hrs for 365 days

25.5KW x 24hrs x 365 days 223,380KWh

DEWA Power Tariff including Fuel

Surcharge

0.44 AED/KWh

Energy Saving Cost per year 223,380 KW/h x 0.44 AED/KWh AED 98,287.20

Total Energy Saving Cost for 15

years

AED 98,287.20 x 15 years AED 1,474,308.00

Project – Proposed B+G+4 Comm. & Residential Building, Nadd al Shiba first

Equipment Under Study – 3 nos. FAHU

OPEX Saving:

(Pressure drop calculations, FAHU selection and DEWA tariff tables follow)


energy and costs


Since 1935Investment Payback Period

OPEX cost saving – energy consumption only – 27% (approx.)

CAPEX cost saving – reduced FAHU capacity – 5% (approx.)

CAPEX Saving:

FAHU purchasing cost Saving : AED 30,000.00 (approx.)

OPEX Saving:

Savings over a period of 15 years : AED 1,474,308.00 (approx.)

(Excludes further OPEX savings from reduced cleaning

and maintenance costs)

Total Saving:

Savings over a period of 15 years : AED

1,504,308.00 (approx.)

BENEFIT: Pay for the FAHU from 6.4 years of energy savings


energy and costs


Since 1935

Example: Original Design Pressure Drops


energy and costs


Since 1935Example: Spiralite Pressure Drops…..1


energy and costs


Since 1935Example: Spiralite Pressure Drops……2


energy and costs


Since 1935

Example: AHU Selection


energy and costs


Since 1935

Example: DEWA Tariffs


costs

Example of OPEX and CAPEX savings through reduced fan power:

Original design pressure drops 750 Pa

Spiralite calculated pressure drops 460 Pa

AHU selection for fan power:

• 15KW for 750 Pa pressure drops (AED 43,000)

• 9.3KW for 460 Pa pressure drops (AED 40,000)

Both fans are connected to VFD (Variable Frequency Drive)

By reducing the frequency of the fan the differential of 5.7KW will be maintained (15KW – 9.3 KW)

The AHU is serving a Cath Cardio area and is operational 24/7

The annual difference in power consumption is:

5.7KW x 24 hours x 360 days = 49,248 KWh

From the DEWA tariff table the annual cost saving is:

49,248 x 0.38 AED/KWh = AED18,714

The previous full costs would have been 15KW x 24 x 360 x 0.38 = AED49,248

Diagrams, pressure drop tables, AHU selection and electricity tariff tables available on request

OPEX cost saving – energy consumption only – 38%

CAPEX cost saving - reduced AHU capacity – 7%

Pay for the AHU from 2.13 years of energy savings


Spiralite optimal performance

• Lower capital costs

• Efficient operation and maintenance

• Significant energy savings

• No thermal transfers, condensation

• Air leaving AHU is similar temperature to that arriving in

refrigeration units

• Estimated 58% energy saving


Spiralite optimal performance

Optimal Energy Efficiency: Case Study 1 - M&S Stratford City

Internal Ductwork

• M&S requested identical galvanised and Spiralite ductwork systems

• Installed cost of Spiralite was 5% less than galvanised ductwork plus insulation

• Installation time of Spiralite was 35% quicker

• Measured energy saving from the operation of the Spiralite system was 32%

• Spiralite assisted client with “Plan A” and EPC obligations

Optimal Energy Efficiency: Case Study 2 - M&S Lincoln

External Ductwork

• 5-sided galvanised ductwork (with 50mm insulation, PIB and alu-clad) as replaced

due to air leakages and no thermal performance

• Installed cost of Spiralite plus weatherproof laminate was 32% less than galvanised

ductwork plus insulation

• Installation time was reduced from 12 weeks to under 4 weeks


Optimal Energy Efficiency: Case Study 3 – Tesco Loughborough

Refrigeration Ductwork

• A new system developed to replace motors in chiller cabinets with large external units

was failing due to a circa 7% drop in temperature over 90 metres and excessive

condensation

• The use of Spiralite resulted in an average temperature loss of 0.1% and no

condensation


• The new refrigeration system won a major national environmental award


Spiralite other installation benefits

Examples of additional benefits and savings:

• Use in offsite fabrication and installation in modular

units. Saved circa £1.0m scaffolding costs at Guys

and St Thomas’s hospital

• Significant weight savings allow reduction in

secondary support structures. Saved circa €60k at

RLC Globalpoint precision engineering production

facility

• Can be dismantled and re-installed multiple times.

This has been done several times with the Chanel

Travelling Pavilion

• Saves significant costs and installation time for large

high level installations. Saved circa 30% on ductwork

cost at the new THG distribution centre


All shapes and sizes


Robust yet lightweight


Light and easy to work with


Documents

Presented by Paul Groves of Khansaheb Industries LLC · 2019. 5. 11. · Estidama/Pearl, Dubai Municipality, BREEAM, LEED and Green Star environmental assessment and rating programmes