How Hardcast Spray-Seal™ Mobile Delivery System Helps Cut Labor Time

Parkview Regional Medical Center

Contractor: Bright Sheet Metal

Job Location: Fort Wayne, Indiana

Project Type: Ductwork Installation and Sealing

Products Used: Spray-Seal™ Mobile Delivery System

Parkview Health is a not-for-profit, community-based health system serving northeast Indiana and northwest Ohio. When they decided to expand its facilities by building out the Parkview Regional Medical Center, indoor air quality and HVAC system performance were a top priority. This is for many reasons, but perhaps most importantly because indoor air quality (IAQ) is an absolute necessity for the promotion of a clean, healthy, contamination-free environment for patients.

Ductwork is probably not the first thing that comes to mind when thinking of healthcare facilities, but it is one of the most vital aspects of design and construction. Indoor air quality (IAQ) is largely determined by the performance of a building’s HVAC system.

During the planning phase of the project, Parkview not only wanted to build the most efficient, cutting-edge facility possible, but also wanted to promote the local economy by utilizing local contractors. The contractor chosen for the construction and sealing of the HVAC system was Bright Sheet Metal, based in Indianapolis, Indiana. and known for high-quality products and service.

The facility’s HVAC system is extensive and includes 32 miles of ductwork that needs to be installed properly, sealed and tested, ensuring it meets the highest quality standards. The ductwork also must meet stringent jobsite requirements, which states ductwork must be sealed with a maximum leakage of 3 percent.

With nearly 50 years of experience, Bright Sheet Metal knew the importance of sealing and initially bid the job to use a traditional bucket and brush method, which is the industry’s longest standing, proven method for ensuring airtight ductwork. While this traditional bucket and brush sealing method is effective, it is also time consuming and labor intensive, sealing more than 100 miles of duct seams and joints at Parkview would have taken 4,000-5,000-man hours to complete.

They had learned about a Hardcast Spray-Seal™ mobile delivery system, through the team at Carlisle HVAC, who demonstrated how it can cut labor time in half while providing a more effective, consistent seal. This mobile delivery system would also enable the crew to be more efficient because there would be no repetitive motions, compared to the traditional sealing method. The crew would be holding a spray nozzle and injecting the sealant at more than 1,000 psi into the seams and joints, while pulling the sealant behind them on a mobile, wheeled cart.

Not only would Spray-Seal cut labor time by at least 50 percent, but it would also enable the crew to move the ductwork after sealing it, providing an easier overall application and more flexible time schedule. The product is also designed to accommodate minor vibrations and movement, and unlike traditional brushed sealants, will not crack when sealed ductwork is moved on the jobsite. Spray-Seal, which contains low VOCs, also eliminates the sticky messiness of the bucket and brush method, while significantly reducing waste produced on the jobsite. It is packaged in 5-gallon pails instead of traditional 1-gallon containers. Using this method, enabled the Bright Metal Team to work more efficiently while providing a high standard of duct sealing that promotes a safe, healthy and clean environment for occupants at Parkview Health.