Honorable Mention: Educational Facilities, Existing

During a remodel, Northwestern High School in Maple,

Wis., repurposed as many of its old sections as possible.

Old School Learns

Cool New Tricks
By Ryan Thorson, P.E., Member ASHRAE; and David Williams, P.E., Member ASHRAE

T
 he School District of Maple, located in the northernmost part of Wisconsin along

the south shore of Lake Superior, covers a rural area of approximately 500 square

miles (1295 km). The district’s aging facilities needed upgrading, including extensive

remodeling and additions. All construction had to occur without disrupting classes.

The largest of the projects was Northwestern High School in Maple, Wis., which was

built in 1937. The oldest portions of the building were removed and other sections

were repurposed to give them new life.

About the Authors Ryan Thorson is a mechanical engineer and David Williams is a high performance projects principal at LHB
in8Duluth,
4 Minn.
AS Williams
H R A E isJ a
o umember
r n a l of SSPC 189.1. Both are members
a s h r aofe ASHRAE’s Minnesota chapter.
. o r g May 2012
 2012 ASHRAE Technology Award Case Studies
This article was published in ASHRAE Journal, May 2012. Copyright 2012 American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. Posted
at www.ashrae.org. This article may not be copied and/or distributed electronically or in paper form without permission of ASHRAE. For more information about
ASHRAE Journal, visit www.ashrae.org.
The high school project consisted of
the renovation and addition to a grade
nine to 12 high school in northern Wis-
consin (Climate Zone 7) with the goal
of improving student services and avail-
able programs. The original Northwest-
ern High School was built in 1937 with
additions in 1949, 1965 and 1980.
The team used integrated design to cre-
ate systems that provide operational ben-
efits without an increase in construction
capital costs. The project involved large
two- and three-story additions, with the
remainder of the building being remod-
eled or demolished to accommodate ADA
accessibility throughout the facility.
The steam heating system was com-
pletely demolished and the boiler room
was relocated and replaced with two
high-efficiency hydronic hot water boil-
ers. One chiller was installed to serve
four air-handling units, two for the office
areas, one for the computer classrooms,
and one for the community and school
use fitness area.
The building sections allow enhanced
performance of the daylighting control
and ventilation systems. The selected
mechanical systems reduced the amount
of ductwork, which enhances the build-
ing section design. Exterior materials,
such as brick and precast walls, and pre-
cast and sloped roofs contribute to the
long service life expected for this project.
The project was phased and classes
were in session from September through
May during the project time line from
2007 to 2009. A new boiler room was
constructed during the first phase and
the building was converted to hydronic
hot water heating, along with natural
gas-fired semi-instantaneous domestic
water heating. The existing boiler room
was demolished during Phase Two of
construction.
Wisconsin Code requires the building
to be designed for winter conditions of
–25°F (–32°C). and summer design con-
ditions of DB 86°F and WB 70°F (30°C
and 21°C). 2009 ASHRAE Handbook—
Fundamentals lists the closest Wiscon-
sin location as Hayward, Wis., which is
about 50 miles (80 km) south of Maple,
Wis. ASHRAE winter design condi-
tions at 99.6% are indicated as –17.2°F
May 2012 ASHRAE Journal 49
A gym that was converted to classrooms was transformed into an auditorium.
(–27°C), and summer design conditions
at 1% of DB 84.3°F and WB 69.8°F
(29°C and 21°C). Heating degree days
(HDD base 65) are 8610 and the cooling
degree days (CDD base 65) are 336.
Reuse Before New
Although many of the high school’s
component buildings were old, a num-
ber of the sections were thought to have
value in a renewed facility. The old-
est portions were removed. The former
small gym that had been converted to
classrooms was repurposed again, this
time as a sloped floor auditorium. The
challenge was to keep it all going while
the construction progressed over two
years.
Energy Efficiency
The basics of energy efficiency start
with the site and building orientation.
Changes in either of these areas were
limited by the existing site, and the de-
sire to improve the outdoor recreational
facilities. The gently rolling site was lev-
eraged through location of new entranc-
es and optimizing cut and fill around the
complex. Even the location of the rain-
water retention and fire protection tanks
considered the impact on the amount of
fill required (or not required) at the final
location under the building.
As per standard office practice, the
envelope insulation system exceeded
code minimum; the spray-applied air
barrier, and new high performance win-
dows, created the proper conditions to
allow the use of low-temperature perim-
eter heating systems. The generous use
of precast concrete panels overlaid with
a brick cladding also provided a high
performance, high mass, low life-cycle
cost envelope system.
HVAC Systems
Two 3.3 MMBH (967 MW), 95%+
efficient condensing boilers were de-
signed and installed to handle the entire
facility. The hydronic heating system
distributes hot water out to the heating
system at 140°F (60°C) and returns it
to the boilers at 100°F (38°C). The air-
handling unit heating coils are designed
for a 40°F (22°C) temperature drop.
This helps to reduce pump sizing and
reduce operational costs by 40% and re-
Building at a Glance
Maple School District
Northwestern
High School
Location: Maple, Wis.
Principal Use: Public High School
Includes: Classrooms, labs, audito-
rium, gymnasium, and district offices
Gross Square Footage: 175,000
Substantial Completion/Occupancy:
2009
2012 Technology Award Case Studies

Fitness room with TDV, floor heat and daylighting. Typical AHU with heating coil and upstream ERV.

duce distribution piping sizing by 50%. The water temperature
was a good match with the design floor temperature of 80°F
(27°C) and allowed the stainless steel condensing boilers to
achieve high combustion efficiencies. Air-handling coils, unit
heaters and perimeter radiation in the existing remodeled ar-
eas did require larger heat transfer surface areas to compen-
sate for the low supply water temperatures. A combustion air
control system increases the boiler plant efficiency further by
preheating the combustion air.
Air-to-air hyroscopic resin plate energy recovery was added
to the air-handling systems for every air-handling unit with the
exception of the industrial shops and the kitchen makeup air.
Air-to-air hyroscopic resin plate energy recovery can recover
up to 70% of the exhaust heat from the removed air during the
heating season, and about 50% of the exhaust cooling from
the removed air during the cooling season. No condensation is
created by the energy recovery unit. Therefore, no frost con-
trol is required, which means that ventilation rates can remain

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50 A S H R A E J o u r n a l May 2012
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2012 Technology Award Case Studies

consistent. Sensible and latent transfer occurs, which assists in was in force at the time, using whichever was more stringent.
humidification and dehumidification, reducing cooling demand Thermal comfort is based on ASHRAE Standard 55-2004.
and limiting added humidification. Energy recovery unit bypass The air-handling systems serving the classrooms, music ar-
controls and ductwork allow outdoor air economizer use in the eas, and commons areas are designed for 100% outdoor air,
swing seasons. through the dedicated outdoor air system (DOAS) in conjunc-
Chilled water cooling via the air-handling units is limited to tion with the energy recovery units, economizer damper by-
the office areas, computer labs, media center pass and VAV box controllers, so most rooms
and the fitness/multipurpose areas. A high- Electricity Natural Gas have a traceable method of ensuring ventila-
efficiency screw chiller was installed with a (kBtu/ft2·yr) (kBtu/ft2·yr) tion rates.
16°F (9°C) temperature drop, to reduce pipe 2005 – 06 12.62 65.40 Thermal displacement ventilation (TDV)
and pump sizes compared with the typical de- 2006 – 07 11.19 70.61 was installed throughout the facility, with the
sign of 8°F to 10°F (4°C to 6°C) temperature 2007 – 08 11.01 35.80 exception of the existing gymnasium, kitchen,
drop. service/receiving and shop areas. The audi-
2008 – 09 11.12 38.56
The existing, preconstruction (2005–06) torium air-handling system is designed for
energy use intensity (EUI) was 78 kBtu/ft2·yr 2009 – 10 11.14 26.78
100% outdoor air and the space is supplied
(839 kBtu/m2·yr) for the existing 95,000 ft2 Energy use pre/post-remodeling. with mushroom diffusers below the seating
(8800 m2). The EUI post construction (2009– area. Air is returned high in the auditorium
10) was 38 kBtu/ft2·yr (409 kBtu/m2·yr) for 175,000 ft2 (16 and stage areas. The new gymnasium is supplied with displace-
258 m2). The building has earned an ENERGY STAR rating ment temperature, low velocity, air behind the bleacher seating
of 96. and the stratified air is returned high in the structure.
Prefilters and MERV-13 final filters are provided for all
Indoor Air Quality air-handling systems to help prevent particulate distribution
Indoor air ventilation was designed to Standard 62.1-2004 throughout the air-distribution system. Airflow measuring de-
with addenda and/or the Commercial Wisconsin Code that vices are installed on all air-handling systems serving class-
rooms and the majority of the remaining air-handling systems.
Individual VAV boxes are installed for each space, so control
and monitoring of each space can be accessed easily. Carbon
dioxide monitoring and control are incorporated into the return
air from the gym, auditorium and commons/cafeteria for reset
control upon high or low CO2 concentrations being detected.
TDV is designed to supply lower velocity supply air at the oc-
cupant level compared to mixing systems. TDV is typically more
comfortable for the occupants, although diffuser placement is criti-
cal to limit air draft issues. The ventilation effectiveness of thermal
displacement ventilation is considered 1.2 at a minimum, meaning
a minimum of 20% more ventilation air is getting to the occupants.
Advertisement formerly in this space. Removal of pollutants and contaminated air is more effective with
TDV due to the space stratification. This stratified air is exhausted
directly out of the building in 100% outdoor air systems.
The DOAS, in conjunction with the TDV, reduced the duct
sizes in most rooms, allowing higher ceilings for the given
wall height. This provides better daylighting and allows the
indirect lighting system to function more effectively.
Radiant floor heating is provided as the primary method of
heating for the majority of the new spaces, providing better
thermal comfort during the heating season. Excluding the new
gymnasium and auditorium, the radiant floor is designed with a
20°F (11°C) temperature drop and underfloor insulation to pro-
vide quicker response time. Finned tube radiation is designed
for existing spaces, the gyms, and the wrestling area for primary
space heating. Space activity levels varied by space and are fac-
tored into the building load calculation, but are based on 2005
ASHRAE Handbook—Fundamentals, Chapter 30. Clothing R-
values were not factored into the load calculations due to the wide
range of seasonal temperatures.

52 A S H R A E J o u r n a l May 2012
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 2012 Technology Award Case Studies

Daylighting
Indirect light fixtures with daylight sensors and occupancy
sensors are provided in offices, classrooms and public spaces.
Daylighting was integrated into the building for approximate-
ly 85% of the spaces. Building additions were provided with
windows throughout to provide good daylighting; in existing
areas the window openings were expanded to provide im-
proved daylighting.
Innovation
Innovative items incorporated into the facility are: rainwa-
ter collection for community fire fighting; heat-trace domestic
water temperature maintenance system with local zone con-
trols; high-efficiency semi-instantaneous natural gas-fired wa-
ter heater serving the entire facility; and variable frequency
drives with static pressure control for all motors serving major
air-handling and pumping systems.
The rainwater collection system is a combination of rain-
water separators for debris removal and three 35,000 gallon
(132 500 L) tanks located below the commons/cafeteria. The
tanks are gravity piped to a fire pump building for commu-
nity fire department connection.
A coordinated effort with the client, the civil engineers, the
Wisconsin Department of Natural Resources, and the design
team was needed to reuse and upgrade the existing domes-
tic water wells on site to serve the buildings and associated
athletic fields. Poor recharge rates meant that using low-flow
plumbing fixtures was vital. The domestic water system in-
corporates three individual wells throughout the site for the
domestic water system.
Operation and Maintenance
Nearly all of the equipment is located within the building,
making maintenance more convenient due to the cold tem-
peratures and annual snow fall of 60 in. to 100 in. (1.5 m to
2.5 m). Additionally, Lake Superior’s lake effect snowfall can
dump 12 in. to 24 in. (300 mm to 600 mm) in a single storm,
not a good environment for exterior equipment.
New direct digital control (DDC) is incorporated through-
out the facility, replacing the existing pneumatic controls sys-
tem, which was outdated and inefficient. This substantially
improved maintainability and the operational oversight of the
system. The controls contractor has remote access to the con-
trols system, providing assistance and updates to the system
and helping the owner with building operation.
The air-handling and energy recovery units are stacked to
provide a compact system increasing usable space. The air is
filtered to air quality requirements of MERV 13.

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A couple of items have needed to be addressed after com- Cost Effectiveness

pletion. First was poor performance of the heat trace domestic
water temperature maintenance system. This was the design
team’s second experience with such a system not meeting per-
formance expectations.
In this case the supplier did not perform the specified facto-
ry startup of the four heat trace controllers and the contractors
failed to set the equipment up properly. After a lot of finger
pointing (and cold showers), the proper factory startup was
performed and the controllers economically control the do-
mestic water maintenance system, with scheduled operation
of the system to match the occupancy and setback during the
unoccupied summertime.
Another HVAC performance problem was chiller shut
down on low water flow through the chiller flow switch. The
specified chiller had a lower listed minimum flow rate than
the chiller that was provided by the manufacturer, and the
system flow rates were not adjusted on the substituted equip-
ment. Also, it was discovered that the chiller flow switch was
not working properly. A higher quality flow switch and re-
balancing of the chilled water system to provide the chiller
minimum flow requirement, including proper setup of the
chilled water pump VFD, resolved the problems with the
chilled water system.
The project HVAC system cost was less than a conventional
AHU-based VAV system, with smaller supply and return duc-
twork, smaller hydronic pipes and lower volume pumping.
Some items were more costly such as the condensing high ef-
ficiency boilers and energy recovery units. Wisconsin’s Focus
on Energy program provided more than $108,000 in incentives
for energy-efficiency measures on the project. The largest in-
centive was provided for the energy recovery system at about
$91,000. HVAC construction cost was $16.7/ft2 ($180/m2)
compared with a regional average of $18.5/ft2 ($199/m2).
Electric construction cost was $13.9/ft2 ($150/m2) compared
with a regional average of $15.3/ft2 ($165/m2).
Environmental Impact
The chiller system does not use CFC-based refrigerant, re-
ducing global climate change potential. Carbon dioxide emis-
sions have been reduced, using energy-efficient practices, by
957 metric tons of CO2 per year compared to the national av-
erage for schools. Storm water is collected on site with the
three 35,000 gallon (132 500 L) tanks located under the com-
mons and is stored for community fire fighting system. Ad-
ditionally, the tank overflow storm water is managed via storm
water retention basins.

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