Warehouse Cooling Solutions: Reducing Heat in a Large Commercial Facility in West Oʻahu
Transforming a 30,000-Sq-Ft Warehouse into a Comfortable Customer Environment
Executive Summary
A 30,000-square-foot commercial facility on Oʻahu struggled to maintain comfortable indoor temperatures despite operating multiple HVAC units. Dellew developed a comprehensive cooling strategy to address insulation, airflow distribution, and heat removal. Ultimately, reducing indoor temperatures from approximately 80°F to a comfortable 72-76°F while maximizing the effectiveness of existing equipment.
Client Background
The facility was originally designed as a warehouse rather than a customer-facing space. Located on West Oʻahu, where temperatures range from the mid-80s to mid-90s year-round, the building required significant modifications to support customer occupancy and comfort.
The Challenge
The building contained:
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30,000 square feet of floor space
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25-foot-high ceilings
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Only 50% roof insulation coverage
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Four large industrial ceiling fans
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Three existing 30-ton HVAC units providing 90 tons of cooling capacity
Despite substantial cooling equipment, indoor temperatures were well above comfortable seating conditions. The metal roof absorbed solar heat throughout the day, creating a constant thermal load that overwhelmed the HVAC system.
The Solution
Dellew conducted a comprehensive evaluation of the facility and implemented a phased cooling strategy:
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Increased Cooling Capacity: Added an additional 25-ton HVAC unit, increasing total cooling capacity to 115 tons.
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Completed Building Insulation: Installed R-30 insulation across the remaining 15,000 square feet of roof area to reduce heat transfer from the roof structure.
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Optimized Air Distribution: Designed and installed a custom sheet metal duct system throughout the facility to improve airflow and distribute conditioned air more effectively across the building.
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Implemented Heat Exhaust Strategy: Installed a high-capacity exhaust fan system to remove accumulated hot air from the building at the start of each day, reducing HVAC startup loads and improving system efficiency.
Key Takeaway
Successful HVAC design requires more than simply adding cooling equipment. By evaluating insulation, building materials, climate conditions, airflow patterns, and heat removal strategies, Dellew delivered a comprehensive solution that addressed the root cause of the problem rather than simply increasing cooling capacity.