SMACNA contractor Western Allied Mechanical of Menlo Park, Calif., used 3,500 square feet of pre-insulated non-fibrous, rigid thermoset, modified resin phenolic ductwork for a recent job for the Ghirardelli Chocolate Company.

The work, with a contract value of more than $820,000, involved updates to Ghirardelli’s chocolate chip manufacturing and packaging warehouse in San Leandro, Calif.

Western Allied Mechanical used 3,500 sq. ft. of phenolic ductwork.

“Using this product for supply and return air across the roof meant that supports were only required every 13 feet rather than every four feet if we had installed traditional galvanized sheet metal ductwork with duct board insulation and aluminum jacketing,” said Western Allied Mechanical Vice President Peter Kelly.

The phenolic ductwork is made of a mold- and mildew-resistant, closed cell foam ideal for applications in food processing plants.

Supply and return air across the roof meant supports were only required every 13 feet.

Using this product for supply and return air across the roof meant that supports were only required every 13 feet rather than every four feet if we had installed traditional galvanized sheet metal ductwork with duct board insulation and aluminum jacketing,

This white, 1,000 micron UV stable, IR reflective, factory-applied titanium-infused, vinyl laminate barrier seals the exterior and keeps it cool. “As a result,” Mr. Kelly said, “we achieve lower air leakage and increased thermal R values for optimal energy savings.” The exterior holds up well to all environmental conditions.

In addition to prefabricating long sections of ductwork and installing sensors in the shop, Western Allied Mechanical removed the existing 20-ton DX cooling AC unit and replaced it with a 60-ton chilled water air handling unit. The entire project was completed over a two-month period.