Summer heat can negatively impact the comfort and productivity of workers in large industrial buildings where air conditioning is not an option.  Heat stress can have a significant impact on worker productivity and accuracy. Research shows that for every degree Celsius increase in temperature above 25°C (77°F), worker productivity can drop by 2% .

In addition, heat stress can lead to:

 

  • Increased Error Rates: High temperatures can impair cognitive function, leading to more mistakes.
  • Physical Fatigue: Heat accelerates physical fatigue, reducing the overall output of workers.
  • Health Risks: Severe heat stress can cause heat-related illnesses, leading to absenteeism and decreased workforce efficiency.

Implementing effective cooling strategies is essential to maintaining a safe and efficient working environment. In this article, we discuss some best practices that will help make your building cooler and your employees happy, healthy, and productive. 

 

 

 

 

 

 

 

 

 

Night Flushing With Your Ventilation System

Night flushing is an effective way of getting the most out of existing ventilation systems by taking advantage of cooler night time temperatures.  This involves maximizing ventilation rates when the outside temperatures are lowest and reducing the ventilation rates when outside temperatures are the highest.

Benefits:

  • Reduced Daytime Temperatures: By bringing in cooler night air, the building’s internal temperature can be lowered, making it more comfortable during warmer daytime hours.
  • Energy Efficiency: Utilizing natural cool air reduces the need for other, more expensive cooling methods(e.g. mechanical cooling), saving energy. 

Implementation:

  • Maximize Ventilation At Night: Use all available exhaust fans and open vents at night to draw in as much cool air as possible while outside temperatures are the lowest.  This can be done manually or automated with time of day switches/controls. 
  • Limit Ventilation During Day: Minimize ventilation as the outside temperature increases.  This helps maintain the cooler air that was brought inside the building during the cooler night time hours. 

 

  “Our SuperDuty fan has been in about 10 months, so we’ve had summer heat and some cold temps. It’s been great to get the air moving and make it comfortable in my 50 x 60′, uninsulated, hangar. We are usually only running it at 50% to make it comfortable here in north central Texas! Thanks!” – Greg Judy Hudson Oaks, TX

 

Installing Industrial Fans / HVLS Fans

Industrial Fans ( HVLS Fans)  are designed to move large volumes of air at low speeds, creating a cooling effect through increased air circulation over a very large area. 

Benefits:

  • Cooling Effect: HVLS fans can make workers feel up to 10°F cooler by enhancing the natural cooling effect from perspiration on our skin. 
  • Energy Efficiency: These fans are highly efficient and consume less power compared to smaller, traditional fans. 

Implementation:

  • Strategic Placement: Install HVLS fans in key areas to maximize air circulation across the workspace where workers are located.
  • Regular Maintenance: Ensure fans are well-maintained to operate at peak efficiency.

 

Flexible Shifts

Aligning the most physically demanding work with cooler times can significantly reduce heat stress and boost efficiency.

Benefits:

  • Improved Productivity: Workers are more productive and accurate when performing strenuous tasks in cooler conditions.
  • Reduced Heat Stress: Minimizing exposure to high temperatures helps prevent heat-related illnesses.

Implementation:

  • Shift Scheduling: Plan shifts so that the most labor-intensive tasks are done during the cooler early morning hours.
  • Flexible Work Hours: Allow for flexible start times to take advantage of cooler temperatures.

 

Improve Roof Insulation 

Industry studies show that the roof of an industrial building can account for approximately 40 to 60% of the total heat gain inside the building.  This is due to the large surface area of the roof and direct exposure to sunlight during the day.  Improvements made to roof insulation can significantly reduce the amount of heat gain a building experiences during the day.

Benefits:

  • Lower Indoor Temperatures: Improved insulation and reflective surfaces/coatings reduce the amount of heat transfer through the roof, which lessens the amount of heat inside the building.
  • Energy Savings: Better insulation can lead to lower energy costs by reducing the need for additional cooling.

Implementation:

  • Insulation Upgrades: Install high-quality insulation materials in the roof.
  • Reflective Coatings: Apply reflective coatings/surfacing to the roof. 

Isolate and Ventilate Internal Heat Sources

Internal heat sources account for about 10 to 20% of the total heat gain in the average industrial building.  This percentage can be much higher in buildings where processes and/or machinery generate a large amount of heat.  In these situations, isolating and ventilating the heat sources can significantly reduce the heat gain in the remainder of the building. 

Benefits:

  • Reduced heat gain: Isolating heat sources prevents them from affecting the entire workspace.
  • Improved Air Quality: Ventilating heat sources removes hot air and potentially harmful fumes.

Implementation:

  • Heat Source Identification and Isolation: Identify machinery and processes that generate a significant heat load and Isolate them from the rest of the building with industrial curtains or permanent walls. 
  • Dedicated Ventilation: Install localized ventilation systems to expel heat directly from these sources.

 

Conclusion

Implementing night flushing protocols, using Industrial fans, adjusting shifts, improving roof insulation, and managing internal heat sources are not just effective strategies—they are “cool strategies” for keeping large, hard-to-cool, industrial buildings comfortable during the summer. These methods not only enhance worker comfort and safety but also mitigate productivity and accuracy losses due to heat stress. By implementing these solutions, you can ensure your building stays as cool as possible as the summer temperatures continue to rise. 

For more information on high-quality air movement solutions, visit www.superdutyfans.com