Located in the heart of Sydney’s central business district is a building heralded as the modern benchmark in sustainable workplace design. Sydney Central at 477 Pitt Street is the culmination of ideas that re-imagine the workspaces of the future to focus on facilities that nurture well-being, create a positive flourishing work environment, and help usher in a new period of progress for the city. Sydney Central has many complex systems which contribute to the overall energy rating of the building and accordingly the decisions made to install those systems are meticulously planned. This helps ensure every element of the building is performing cohesively to deliver an optimal and sustainable environment worthy of its NABERS energy and indoor environment ratings of 5.5 and 5 stars respectively.

Objective
The 2018 remodel of the 32-storey building had a vision to create an Atlassian tech hub and further reduce energy consumption.

With ventilation systems using around 40% of a buildings total energy consumption and air quality being a significant factor in comfort and productivity, choosing the right air delivery system was essential in maintaining the tower’s exceptional ratings. Furthermore, with the ceilings removed to create an industrial theme whilst providing more head room, the 4,500 metres of ductwork would be exposed and appear to float in the space above.

Approach
Hugh Wilson of Integral Group consultancy was tasked with the mechanical engineering of the tower. A major consideration was the integrity of the ventilation system. Emphasis on suitability, design and performance requirements of the office tower was essential, “We explored pre-insulated light weight duct for the floating runs as an alternative to heavy sheet metal and found a complete light weight duct system that ticked all the boxes”.

ALP pre-insulated duct systems would provide a greater cross section without appearing bulky and compromise the floating effect of the exposed ductwork. Fewer hangers and support structures would be needed, and the ductwork would float much higher creating additional space allowing in more light for the occupants. Ductus was also able to provide a round duct, ALPround, that would complement the desired aesthetic appeal of the entire space.

“We decided to go with Ductus based on the performance data provided. It was clear that Ductus experience and knowledge within the industry would be a benefit to the outcome of the application.” said Hugh.

The Finish
“ALP was light and easy to transport into the building, required a thinner profile maximising headroom, had minimal leakage rates, came with a full accredited system and was aesthetically pleasing. The architect was very excited”. “As a designer it was an easy specification as it came from one source that had already been tested and certified, guaranteeing the performance and reliability we needed”.

Acoustic challenges were met with Sekisui Acousticplus lining supplied through Ductus and another example of a well thought out product that is easy to apply and will perform to expectation.

Benefits
Further advantages of the ALP system rose in hindsight with the arrival of Covid and the threat of spreading pathogens. ALP’s internal components will not break down, absorb moisture, and requires minimal cleaning.

“Knowing we had a clean product enabled us to advise the occupants they were getting the best possible outcome with the system’s ability to remain clean and not contribute to Covid challenges”, said Hugh. “Integral Group is founded on the ideal of leading the world into more efficient designs”, “ALP gave us the opportunity to achieve some of these goals by reducing the building’s embodied energy and running costs through the systems overall efficiency”.

Ductus’ fully certified/accredited pre-insulated duct systems

are paving the way forward within the HVAC industry. The significant advantages pre-insulated ductwork has over traditional sheet metal are widely recognised. They are the best performing duct systems in the industry as well as being the only feasible option in certain applications.

No example highlights this better than the recent renovations made to Australia’s renowned Sydney Opera House. Contracted to manage the HVAC renewal, Engie Mechanical Services are leaders in providing professional project management services around the globe, and they reached out to Ductus to provide a solution for the proposed works.

Ductus’ ALP pre-insulated duct was selected for being light-weight, easy-to-install, capable of intricate fabrication and its ability to adapt to the existing run of metal ductwork.

THE SYDNEY OPERA HOUSE –MAINTAINING HERITAGE Increasingly, OH&S measures for work conducted within the sails has been a prime concern. The rectification work involved the removal of hundreds of tonnes of ductwork and plant and replaced with considerably more tonnage of new plant and ductwork, adding platforms, and increasing overall stair safety provisions. This effectively reduced the available space for ductwork within the sails including the access needed for installers to pass ductwork through and join.

The ALP System™ due to its light weight and space saving properties, was selected to be used in a critical and difficult access area of ductwork. Fitted to a sound attenuator the ALP duct started on level 10 (approx.43M off the floor), and travelled out towards the sail, then down following the contour of the sail to level 6 and back into join with the remaining original ductwork.

A representative from Engie Mechanical Service states, “The prime objective of using ALP for this project is its light-weight nature. The Sydney Opera House was aiming for a reduction in the mass of services supported on their acoustically treated surface over the concert hall”.

Quality Air Equipment (QAE) were appointed by Engie Mechanical Service to carry out the fabrication.Their experience and “state of the art” manufacturing systems were critical to ensure the specified outcomes were achieved. “Traditional metal duct would be unfeasible due to the access and installation restrictions” said Peter Freney, Commercial Business Manager at QAE. “The lightweight R2.0 duct was faced with 2mm of external aluminium laminate and internally lined with 25mm Sekisui Acousti Plus insulation to maintain the sound absorption required.”

SAFETY, PERFORMANCEAND SUSTAINABILITY Further conditions required the use of specialised installation methods. Outside contractors trained specifically to work whilst being suspended from ropes were employed. The light-weight nature of pre insulated duct enabled this requirement to be met safely and efficiently, which no other product could do while meeting the required R2.0 performance rating.

Ductus’ ALP pre-insulated duct systems are accredited to withstand 2000 pascals of air pressure with under 5% leakage rate compared to traditional metal ducts, typically 15%. This means less energy would be consumed to maintain the 22.5˚C needed to keep instruments in tune which adds to the overall sustainability of the building.

ALP pre-insulated duct boards produce less embodied energy than sheet metal and leave a much smaller carbon footprint in the environment.

QAE’s expertise and experience in fabricating pre insulated ductwork was also needed to overcome the challenges mentioned above. “After almost 30 years in the industry it’s great to see this innovation in the Australian HVAC industry. With the uptake of new concepts becoming more prevalent in this region, modern technology and sustainability are within the grasp of engineers and project managers here and around the world”, said Mr. Freney

Ductus Managing Director, Jim Malek explains, “We are very excited to be part of this iconic building. Projects like the Sydney Opera House are a great example of the system acceptance and confidence within the Australian market, with the requirement of meeting the global environmental challenges ahead. It is time for us to step up and look forward to advancements within the building sector to help us meet our climate goals.”

Running a successful enterprise over the last couple of years has been extraordinarily challenging for everybody having to contribute in the effort to eliminate the covid pandemic. Along with these contributions, further sacrifices have been forced on many who rely on the transportation of goods and services, which have increased demand and a depreciated ability to supply.

Those worst affected lost their ability to trade with the manufacturing of their inventory ceasing altogether and without any practical indication of how long before life goes back to normal. As the saying goes, “we are at our best when we face the worst” and the necessity to rise above such times can sometimes produce some inspiring results.

Ductus along with their partners Quality Air Equipment (QAE) have achieved this with the development of an Australian manufactured substitute to the ALPRound duct insulation system, previously manufactured in Italy.

Unfortunate circumstances related to the covid pandemic had caused the manufacturing of ALPRound duct in Italy to temporarily cease. This was a huge concern for Ductus director Jim Malek, the exclusive supplier of ALP Systems and ALPRound duct in Australia and currently responsible for providing 32 floors of ALPRound duct to the prestigious Sydney Central Tower located in the heart of Sydney CBD on Pitt Street through delivery partner Quality Air Equipment.

When asked about his thoughts at the time Jim responded, “We knew we had a big problem. We had worked extremely hard in delivering the concept of ALPRound duct knowing it would be a great feature of the building’s aesthetics, performance, and environmental rating”. “We were extremely proud to have our brand chosen for this project and determined to meet our obligations”.

Early indications of a 4-week delay in production soon became unclear when further covid related complications arose. Jim said, “When we could no longer guarantee the supply of ALPRound duct for the next stage in the Pitt Street project, we knew it was up to us to find a suitable replacement. One which would not only suit the required fit-out but also maintain its unique appearance whilst providing a comfortable working space”.

“Working closely with QAE we decided on three existing alternatives and one which we could fabricate ourselves using the same ALP board,” Jim said, “We call it RegalRound Duct and it was satisfying to find that we could do this ourselves solving the supply issue. Working closely with our delivery partners at QAE on this project with their expertise, extensive understanding of the system, and professional care being of great benefit, we were able to achieve a great result in a timely manner.

With the obvious benefits of using the same board and control of supply “RegalRound duct” was selected to complete the project and is now part of the Australian Ductus brand as another example of Australian innovation, ingenuity, and response to adversity. RegalRound duct is the latest pre-insulated HVAC system on the market and already promises to be a huge success with reports coming back from installers R&D saying,” Great product to work with, RegalRound duct is easy to manage to be lightweight and so easy to install. It all fits together very nicely, looks clean and aesthetically pleasing”.

Integral Group who has been working on the design of the HVAC systems being used on 477 Pitt Street were also pleased with the result. Mr. Hugh Wilson of Integral and acting Project manager says “I’m very happy with the work put in by Ductus, QAE, and R&D. Their ability and willingness to work together and manage the problem and ability to find a suitable solution during some very challenging times is a credit to the industry”. “It was also very comforting knowing how determined they were in avoiding any delay to the ductwork being installed”.

We are happy to announce that Ductus, a leader in the Australian HVAC industry has joined forces with Kingspan to be the new National KoolDuct Distribution Partner.

Kingspan KoolDuct is an advanced and innovative pre–insulated rectangular HVAC ductwork system, which is installed in a single–fix.

“The phenolic based KoolDuct insulation board, produced in our Somerton VIC facility, is a real game changer for the HVAC market and we are excited to make it more readily available to Australian consumers through our new partnership with Ductus”, said Scott Gibson, Kingspan Insulation Australia’s Managing Director.

Ductus is Australia’s leading supplier of high-end air conditioning ducting supplies, ventilation and duct system products. It specialises in supplying innovative products that meet the required strict building standards of the medical, industrial and commercial industries.

“Ductus has always focused on delivering proven and tried products into this sector of the market. We are excited to add a global leader into our product range and we feel that the Australian made Koolduct, with its green credentials, is the perfect fit for us”, said Jim Malek, Ductus’ Managing Director.

“Our experience and knowledge within the sector along with our vast experienced fabricating partners, ensures that we deliver quality all the time, every time. We will continue to focus on the implantation of Koolduct with the engineers introducing the concept of qualified pre-insulated duct systems within the region. Sheetmetal has its place, but I see that its time has come. Building owners and occupiers globally have become more environmentally focused on their HVAC systems, demanding products that are more sustainably manufactured, lighter, more airtight and ultimately deliver greater energy efficiency and comfort”, added Malek.

Kingspan KoolDuct System is the clear leader in the new generation of pre-insulated ductwork. It offers the triple benefits of cutting energy, cutting carbon and cutting cost.

KoolDuct is the only premium performance pre–insulated ductwork in the world to be UL Listed as a Class 1 Air Duct under the UL 181 Standard for Safety when fabricated to the UL specification.

It weighs up to 75% less than ductwork constructed from conventional galvanised sheet steel and bulk insulation – this makes it ideal for refurbishment projects, where existing building structures have insufficient load capacities for new services.

Made from a thermoset phenolic material, KoolDuct has exceptional fire performance, demonstrating low flame spread, smoke emissions and toxicity emissions under fire.

To find out more about the benefits of KoolDuct click here or get in touch with our Technical Service Team on 1300 247 235 or email [email protected] .

For sales inquiries, call Ductus on 03 9464 1433 or email [email protected] .