6.3. SR 08-13-2012REQUEST FOR ACTION
TO
ITEM NUMBER
Mayor and City Council
6.3
AGENDA SECTION
MEETING DATE
PREPARED BY
Work Session
August 13, 2012
Rich Czech, Ice Arena Manager
ITEM DESCRIPTION
REVIEWED By
Ice Arena Renovation Options
Michael Hecker, Park and Recreation
Director
REVIEWED BY
Cal Portner, City Administrator
ACTION REOUESTED
Review and discuss the Ice Arena renovation options provided by 292 Architect Group.
BACKGROUND /DISCUSSION
Attached for your review are the value engineering studies performed this spring at the Elk River Ice
Arena. The reports outline four major areas of the arena, structure integrity of the Barn Rink, structure
integrity of the Olympic Rink, HVAC system of the entire arena, and the refrigeration systems of both
rinks.
At the last Arena Commission meeting, the Commission discussed bringing four options to the City
Council. The options, which are attached, outline the pros and cons of each option. Tom Betti from the
292 Architect Group will be in attendance to review these options.
The timing of the study coincides with a planned replacement of the Barn Rink after 41 years of service.
Neighboring communities have added new ice arenas, completed major renovations and have invested in
facility additions over the past few years. Although they do not compete with Elk River for ice usage for
our primary user groups, we do compete for high profile tournaments and events and are challenged to
increase operating revenues and save energy costs.
Further, the two rinks use separate ice - making plants with R -22 refrigerant. R -22 has been deemed an
environmental hazard and its use and production will be phased out over the next few years. With the
phase -out, repair parts for the plant will become increasingly expensive as will replacement and disposal
of the refrigerant. R -22 currently costs $15 - $20 per pound. Each ice plant carries about 5,000 — 6,000
pounds. If a major leak would occur, the cost of replacing the refrigerant could cost over $100,000.
Option One reflects the current capital plan for the arena. The Capital Improvement Plan (CIP)
includes major arena systems with their projected lifespans and replacement cycle. The CIP does not
include a full facility replacement or coordinated capital improvement. If the issues of the leaks in the
roof and air quality (dehumidification) in the Barn Rink are not addressed, the useful life expectancy of
the Barn Rink is projected for 9 -12 years.
POWERED By
N: `,Public Bodies Cite Coinicil ,Council RCA Agenda Packet o8- I3 -2oI2 ,Ice Sena RFA.doch INAMIRE1
Option Two is a coordinated approach to maintain essential systems that would buy time before major
improvements have to be made. The option is a short -term fix that does not address immediate or future
needs of the arena.
Option Three addresses some necessary repairs that are needed for the long -term operations of the
arena while providing a foundation to grow upon for the future needs. The proposed new roof would be
a long -term improvement, while the new dehumidification system would greatly increase the air and ice
quality. The much - needed expansion of the locker rooms in the Barn Rink and the lobby area would
bring the arena up -to -date with competing facilities. It replaces the refrigeration system in the Olympic
Rink with a state -of -the -art system designed to accommodate the Barn Rink in the future and would
significantly improve the arena's efficiency.
Option Four replaces the Barn Rink, adds new locker rooms throughout the arena, and expands the
lobby area to accommodate both rinks. Team locker rooms would be replaced with larger updated rooms
that would address air quality issues that are prevalent in the existing locker rooms. A new upper level
lobby would include a concessions area, storage, restrooms, and meeting facilities. Both ice plants and
HVAC systems would be replaced with centralized, energy efficient state -of -the -art equipment that would
address the need for dehumidification.
The newer facilities that have been built over the last few years in the region are more than just ice arenas,
included are training areas catering to skating sports as well as other sports and other activities in the
community. Field houses and domes have also been part of projects to make the facility a multiple use
facility. With summer sports now offered year -round and increased participation, field houses and domes
are increasing to meet training demands.
Most new or updated arenas include meeting and community rooms for programing and to rent for
private use. An example is the facility in Eagan where they recently added computer stations to their
meeting room so they can host day and evening computer classes for public and private organizations as a
new operational revenue source.
With new and expanded facilities recently built throughout the region, it's difficult to compete with these
facilities for tournaments and other events that could bring in added revenue.
ATTACHMENTS
■ 292 Design Group Recommendation
■ RJM Matrix
■ Lindau Structural Report
■ HVAC Study
■ Skyline Exterior Building Inspection Report
■ Stevens Ice System Evaluation
Action Motion by Second by Vote
Follow Up
N:APublic Bodies \City Council \Council RCA \Agenda Packet \08 -13- 2012 \Ice Arena RFA.docx
Option 1 (Leave existing facility as is):
• Estimate another 9 -12 years until structure will require significant repairs to remain in use
• Rink 2 refrigeration system is past its expected life expectancy.
• Rink 2 requires repairs to dehumidification system.
• Rink 1 refrigeration system is past its expected life expectancy (floor is in good condition).
• Rink 1 has no dehumidification system, and life safety systems in refrigeration room are
non - existent.
• Locker rooms are not properly ventilated.
• Numerous roof leaks on Rink 1, causing extensive deteriation of building structure.
Pros:
No cost
Cons:
Potential safety hazards regarding ventilation and life safety systems.
Maintenance costs will be unpredictable from year to year.
Roof leaks are causing further deterioration of structure.
No dehumidification causes further deterioration of structure and poor indoor
air quality environment.
Customers and citizens lose interest and stop utilizing the facility.
City loses value on a significant community investment.
ADA issues not addressed.
a
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Option 2 (Minimal Capital Repairs):
• Repair roof system in rink 1 including new roof membrane on Rink 1.
• Repair flat roof area between existing rinks, numerous leaks.
• Remove existing spray insulation from main steel frames and paint.
• Add Low -E ceiling.
• Repair existing steel framing based on inspection after spray insulation is removed.
• Add refrigeration room ventilation to Rink 1.
• Add ice resurfacer room ventilation to Rink 1.
• Replace radiant heating over bleachers.
• Add ventilation and make -up air to existing Rink 1 Team
• Add Dehumidification to Rink 1.
• Repair Rink 2 Dehumidification.
• Provide minimum improvements to Rink 2 Refrigeration;
and vessel integrity investigation.
Rooms.
limited to new compressors, motors,
Pros:
Minimal cost outlay to maintain Community asset.
Fixes dehumidification problem in Rink 1, helping to maintain the integrity of the steel structure.
Fixes roof leaks on Rink 1, helping to maintain the integrity of the steel structure.
Cons:
Expense
Energy efficiency of building is not improved. Insulation and waste heat recovery are not utilized.
Refrigeration issues on Rink 2 are not addressed.
Rink 2 refrigerated floor is still sand based.
Main components of 30 year old refrigeration systems are still being used.
Environmentally harmful refrigerants are still in use.
a
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W
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No operational improvements to facility, still maintaining two refrigeration and ice resurfacer rooms.
Team rooms for High School are not addressed. -
Non - regulation size of Rink 1 ice sheet is also not addressed.
ADA issues not addressed.
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Pros: W
New refrigeration plant sized and ready to add Rink 1 refrigeration.
Operationally more efficient; combined ice resurfacer and refrigeration room.
Concrete floor added to Rink 2, multi - purpose opportunities are possible and less maintenance and o
more efficient operation of ice plant. to
More energy efficient facility; insulated walls and roof for rink 1, efficient HVAC and dehumidification
systems. cu
Facility will have a new identity because of lobby expansion. �j
Larger lobby accommodates larger events.
Varsity Team rooms are addressed.
Cons: -
Expense
41 year old Rink 1 structure is being utilized.
Alternate: Reduce Rink 2 from Olympic size to NHL size
football
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(Renovation Plus): _ --
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• Same upgrades as #2
• New refrigeration (concrete floor) and refrigeration room for Rink 2, size and prep to add Rink
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1 in the future
-
• Add varsity locker rooms to Rink 2
• Renovate existing refrigeration and resurfacer room into new resurfacer room with internal large
snow melt pit.
• Add sprinklers over Rink 2 Ice arena floor surface.
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• Upgrade IT and PA systems
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• Add maintenance room to west side of Rink 1
• New front lobby addition including team rooms, concessions, pro -shop, restrooms, manager's
a
office.
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• Create "shell" space for dryland training facility above new varsity locker rooms.
• New exterior insulated wall and roof panels on Rink 1.
W
• Add football storage and ice arena maintenance storage to Rink 1.
• Add elevator (alternate)
J
Pros: W
New refrigeration plant sized and ready to add Rink 1 refrigeration.
Operationally more efficient; combined ice resurfacer and refrigeration room.
Concrete floor added to Rink 2, multi - purpose opportunities are possible and less maintenance and o
more efficient operation of ice plant. to
More energy efficient facility; insulated walls and roof for rink 1, efficient HVAC and dehumidification
systems. cu
Facility will have a new identity because of lobby expansion. �j
Larger lobby accommodates larger events.
Varsity Team rooms are addressed.
Cons: -
Expense
41 year old Rink 1 structure is being utilized.
Alternate: Reduce Rink 2 from Olympic size to NHL size
Option 4 (New Rink 1):
• New Rink 1, replace the barn
• New front lobby addition including team rooms, concessions, pro -shop, restrooms, managers office.
• New team rooms between the two rinks, including 2 varsity team rooms.
• Combined new refrigeration room for both rinks.
• New concrete rink floor for the Rink 2.
• Add sprinklers over Rink 2 Ice arena floor surface.
• Repair Rink 2 dehumidification. z
• New upper level lobby with concessions, restrooms, and storage. u,
• New upper level community meeting rooms and dryland training center. a
• Upgrade IT and PA systems W
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Pros:
New common refrigeration system.
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Operationally more efficient; combined ice resurfacer and refrigeration room.
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Regulation ice sheets for both rinks.
Y
Better seating for Rink 1.
Concrete floor added to Rink 2, multi - purpose opportunities are possible and less maintenance
W
and more efficient operation of ice plant.
N
More energy efficient facility; durable and energy efficient envelope for new rink 1, efficient HVAC
and dehumidification systems.
O
Facility will have a new identity because of addition and lobby expansion.
cv
Larger lobby accommodates larger events.
N
ADA accessibility to upper level.
Upper lobby, meeting rooms, and dryland training is a benefit to more of Elk Rivers citizens.
Varsity Team rooms are addressed.
Cons:
Expense
Alternate: Reduce East Rink from Olympic size to NHL size
Option 4 (New Rlnk 1):
• New Rink 1, replace the barn
• New front lobby addition including team rooms, concessions, pro -shop, restrooms, managers office.
• New team rooms between the two rinks, including 2 varsity team rooms.
• Combined new refrigeration room for both rinks.
• New concrete rink floor for Rink 2.
• Add sprinklers over Rink 2 Ice arena floor surface.
• Repair Rink 2 dehumidification.
• New upper level lobby with concessions, restrooms, and storage.
• New upper level community meeting rooms and dryland training center.
• Upgrade IT and PA systems
Pros:
New common refrigeration system.
Operationally more efficient; combined ice resurfacer and refrigeration room
Regulation ice sheets for both rinks.
Better seating for Rink 1.
Concrete floor added to Rink 2, multi - purpose opportunities are possible and
and more efficient operation of ice plant.
More energy efficient facility; durable and energy efficient envelope for new
and dehumidification systems.
Facility will have a new identity because of addition and lobby expansion.
Larger lobby accommodates larger events.
ADA accessibility to upper level.
Upper lobby, meeting rooms, and dryland training is a benefit to more of Elk
Varsity Team rooms are addressed.
Cons:
Expense
Alternate: Reduce East Rink from Olympic size to NHL size
less maintenance
rink 1, efficient HVAC
Rivers citizens.
a
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W
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W
Y
J
W
Q
0
i
N
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TV
CONSTRUCTION
ESTIMATE DATE: August 8, 2012
PROJECT: Elk River Ice Arena - DRAFT Arena Renovation Options
ARCHITECT: 292 Design Group
DRAWING DATE: May 21, 2012
DESCRIPTION
Option 1
"As Is"
Estimate
Option 2
"Minimal"
Estimate
Option 3
"Reno +"
Estimate
Option 4
"New"
Estimate
Construction Costs
Demolition
$0
$0
$85,000
$162,500
Concrete & Masonry
$0
$0
$347,054
$515,849
Precast Concrete
$0
$0
$376,200
$993,462
Metals
$0
$0
$224,564
$555,934
Rink 1 Structural Repairs (Allowance)
$0
$50,000
$50,000
$0
Carpentry & Millwork
$0
$0
$37,050
$156,698
Thermal & Moisture Protection
$0
$228,900
$620,723
$345,486
Doors & Windows
$0
$0
$208,119
$283,909
Finishes
$0
$75,000
$352,613
$421,237
Specialties
$0
$0
$39,785
$53,463
Low -E Ceiling
$0
$35,000
$35,000
$0
Seating
$0
$0
$80,000
$80,000
Ice Rink Systems
$0
$82,000
$1,771,100
$2,530,000
Dasher Boards
$0
$0
$0
$45,000
Elevator
$0
$0
$0
$50,000
MEP
$0
$567,250
$1,402,455
$1,629,655
Sitework Allowance
$0
$0
$250,000
$250,000
General Conditions
$0
$51,908
$264,585
$363,294
General Liability Insurance
$0
$11,991
$67,587
$92,801
Builders Risk Insurance
$0
$3,857
$21,741
$29,853
Building Permit
$0
$9,953
$62,336
$77,032
Bond
$0
$0
$0
$0
Subtotal Construction Cost
$0
$1,115,858
$6,295,912
$8,636,173
Contingency
$0
$55,793
$314,796
$431,809
Contractor's Fee
$0
$32,220
$181,794
$249,369
Total Construction Estimate
$0
$1,203,872
$6,792,502
$9,317,351
PAGE 1 OF 4
VP
CONSTRUCTION
ESTIMATE DATE: August 8, 2012
PROJECT: Elk River Ice Arena - DRAFT Arena Renovation Options
ARCHITECT: 292 Design Group
DRAWING DATE: May 21, 2012
Owner Costs
SAC /WAC Fees
$0
$0
$0
$0
Owner Furniture
$0
$0
$0
$0
Owner Equipment
$0
$0
$0
$0
Phone and Data
$0
$0
$0
$0
IT /PA Upgrades
$0
$0
$100,000
$100,000
Security Systems
$0
$0
$0
$0
Scoreboards
$0
$0
$0
$0
Owner Costs Subtotal
Design Fees
$0
$0
$100,000
$100,000
Construction A/E Fees
Included Above
$108,348
$441,513
$605,628
Design Fees Subtotal
Contingency
$0
$108,348
$441,513
$605,628
Owner Construction Contingency
$0
$60,194
$339,625
$465,868
Contingency Subtotal
$0
$60,194
$339,625
$465,868
Total Project Cost
$0
$1,372,414
1 $7,673,639
1 $10,488,846
Ten Year C. 1.P Projection
Construction Only 1 4,812,1581 3,746,1581 40,5601 0
Total 10 Year Realized Project Cost 4,812,158 5,118,572 7,714,199 $10,488,846
PAGE 2 OF 4
VP
CONSTRUCTION
ESTIMATE DATE: August 8, 2012
PROJECT: Elk River Ice Arena - DRAFT 10 Year C.I.P Projection
ARCHITECT: 292 Design Group Construction Only
DRAWING DATE: May 21, 2012
C.I.P. Outlay
Ten Year Projection
DESCRIPTION
Option 1
"As Is"
Estimate
Option 2
"Minimal"
Estimate
Option 3
"Renovation"
Estimate
Option 4
"New"
Estimate
Construction Costs
Replace Co- Ray -Vac Heating - Barn
$20,000
$0
$0
$0
Maintenance Storage Area
$75,000
$0
$0
$0
Replace Front Entry Doors
$12,000
$0
$0
$0
Heating System for Locker Rooms
$45,000
$0
$0
$0
Replace D.U. Unit in Barn
$275,000
$0
$0
$0
Membrane Roofing for Barn
$110,000
$0
$0
$0
Replace D.U. Wheel - Olympic
$80,000
$0
$0
$0
Paint Ceiling of Barn
$35,000
$0
$0
$0
Replace HVAC in Lobby
$15,000
$0
$0
$0
Expand Locker Room #5
$8,500
$0
$0
$0
Electronic Air Monitor
$14,500
$0
$0
$0
HVAC Locker Rooms 5 -8
$9,500
$9,500
$0
$0
Roof Repairs - Olympic Sheet
$22,320
$22,320
$0
$0
Crack Repairs at Precast
$16,200
$16,200
$16,200
$0
Roof Repairs - Miscellaneous
$3,840
$3,840
$0
$0
Replace Water Heaters
$7,200
$7,200
$0
$0
Replace Refrigeration System
$2,530,000
$2,530,000
$0
$0
Replace Dasher Boards
$140,000
$140,000
$0
$0
Exhaust System for MUA
$30,000
$0
$0
$0
Freon Detection System
$25,000
$0
$0
$0
Replace Rubber Flooring
$17,600
$17,600
$0
$0
Structural Repairs at Barn
$50,000
$0
$0
$0
Replace Co- Ray -Vac Htg - Olympic
$30,000
$30,000
$0
$0
Door Replacement
$50,000
$25,000
$15,000
$0
Toilet Room Repairs & Upgrades
$80,000
$80,000
$0
$0
Subtotal Construction Costs
$3,701,660
$2,881,660
$31,200
$0
Inflation (3% /year)
$1,110,498
$864,498
$9,360
$0
Total Construction Costs
$4,812,158
$3,746,158
$40,560
$0
PAGE 3 OF 4
VP
CONSTRUCTION
ESTIMATE DATE: August 8, 2012
PROJECT: Elk River Ice Arena - DRAFT 10 Year C.I.P Projection
ARCHITECT: 292 Design Group Equipment Only
DRAWING DATE: May 21, 2012
Owner Costs
Zamboni
$240,000
$240,000
$240,000
$240,000
Batteries for Zamboni
$10,000
$10,000
$10,000
$10,000
Floor Scrubber
$9,500
$9,500
$9,500
$9,500
New Scoreboards
$19,500
$19,500
$19,500
$19,500
Miscellaneous
$25,000
$25,000
$25,000
$25,000
Owner Costs Subtotal
$304,000
$304,000
$304,000
$304,000
Inflation (3% /Year)
$91,200
$91,200
$91,200
$91,200
Total Owner Costs
$395,200
$395,200
$395,200
$395,200
Design Fees
Arch. /Engineering Design Fees
$336,851
$262,231
$2,839
$0
Design Fees Subtotal
$336,851
$262,231
$2,839
$0
Total Project Cost
$5,544,209
$4,403,589
$438,599
$395,200
PAGE 4OF4
Re: Elk River Skating Facility — 2012 Preliminary Structural Report
Dear Rich,
Per your direction Lindau Companies, Inc. visited the "Barn" ice skating facility on
April 12, 2012 to visually review the condition of the roof structure over the west ice rink
and accompany American Engineering and Testing (AET) while they determined the
thickness of useable steel in various structural members. Lindau Companies, Inc
previously visited the facility in February 2009 and performed a visual review of many of
the same steel members that are now being tested by AET. At that time material
thickness testing was not performed.
Although a final report will be issued at a later date this letter presents our preliminary
findings and recommendations. It is possible that construction documents will be
required for moving forward with our recommendations.
Our review, observations, and opinions relate solely to the building structure and not to
non - structural items such as architecture, egress, mechanical and plumbing systems, or
environmental considerations. In the case that we note non - structural issues within this
letter it is for the sole purpose of noting the need for the review of these items by a
professional trained in that discipline.
Investigation:
The building complex consists of several interconnected structures. Our investigation
was limited to the roof of the pre- engineered metal building making up the west half of
the facility. Building structure in this area appeared to consist of a metal roof decking
supported by steel roof purlins and steel girder frames called bents. Almost the entire roof
structure was finished with foam insulation and a light fibrous material that could be
sound insulation, fireproofing or both.
In February 2009 several steel structural members were found to be covered with surface
rust. This corrosion was not significant at that time and we believed that the rate of
corrosion would be reduced if the environment within the facility was controlled. We
also suggested that any exposed steel be painted, to reduce the threat of increased
localized corrosion, and regular inspections performed to develop a historical perspective
and greater understanding of the issue.
LINDAU
COMPANIES, INC.
/ G G
April 17, 2012
PROFESSIONAL ENGINEERS
1074 OLD Hwy 35
HUDSON, W1 54016
Rich Czech
(715) 386 -4444 OFFICE
(715)386- 1441FAX
Arena Manager
1000 School Street
Elk River, MN 55330
Re: Elk River Skating Facility — 2012 Preliminary Structural Report
Dear Rich,
Per your direction Lindau Companies, Inc. visited the "Barn" ice skating facility on
April 12, 2012 to visually review the condition of the roof structure over the west ice rink
and accompany American Engineering and Testing (AET) while they determined the
thickness of useable steel in various structural members. Lindau Companies, Inc
previously visited the facility in February 2009 and performed a visual review of many of
the same steel members that are now being tested by AET. At that time material
thickness testing was not performed.
Although a final report will be issued at a later date this letter presents our preliminary
findings and recommendations. It is possible that construction documents will be
required for moving forward with our recommendations.
Our review, observations, and opinions relate solely to the building structure and not to
non - structural items such as architecture, egress, mechanical and plumbing systems, or
environmental considerations. In the case that we note non - structural issues within this
letter it is for the sole purpose of noting the need for the review of these items by a
professional trained in that discipline.
Investigation:
The building complex consists of several interconnected structures. Our investigation
was limited to the roof of the pre- engineered metal building making up the west half of
the facility. Building structure in this area appeared to consist of a metal roof decking
supported by steel roof purlins and steel girder frames called bents. Almost the entire roof
structure was finished with foam insulation and a light fibrous material that could be
sound insulation, fireproofing or both.
In February 2009 several steel structural members were found to be covered with surface
rust. This corrosion was not significant at that time and we believed that the rate of
corrosion would be reduced if the environment within the facility was controlled. We
also suggested that any exposed steel be painted, to reduce the threat of increased
localized corrosion, and regular inspections performed to develop a historical perspective
and greater understanding of the issue.
Our investigation on April 12, 2012 was the first time we observed structural members
within the facility since February 2009.
Over 20 areas were investigated during the April 2012 site visit. Many of the areas
previously exposed during the February 2009 investigation were reviewed again in
addition to newly exposed members. The amount of corrosion discovered varied from
little to no corrosion to scaling steel. For the purpose of this report the amount of
corrosion will be defined as the following forms:
No Rust Painted base metal with no rust. These areas were
used as control specimens.
Surface Rust that is removed easily with wire brush
without pitting or scaling and no loss of useable
thickness.
Pitting Surface rust with some pitting of base metal but no
Scaling and no loss of useable thickness.
Scaling Base metal has pack rust and presumably a loss of
useable thickness.
In order to access the steel structure the finishes and paint had to be removed at that area.
These materials should be replaced by you. Once the finishes were removed the steel
could be visually inspected for corrosion, the paint or rust removed with a sire brush or
emery wheel, and the useable thickness of the steel determined by American Engineering
and Testing.
Observations:
Throughout the roof structure areas of corrosion ranging from surface rust to scaling were
noted on the roof purlins, bracing members, and bents. The majority of the areas
investigated were corroded with surface rust that should not be a major concern at this
time. A few areas displayed some pitting and only a few areas were scaling. Although
only a few areas had scaling this is an increase in corrosion since the February 2009
investigation. This suggests that the conditions that promote corrosion within the
building still exist.
Typically areas of corroded steel were made evident by a discoloration or water marking
of finishes and bare steel. Because these water marks did not travel long distances and
appeared to dry without significant dripping we believe the presence of water is due to
condensation and not a leaking roof.
Recommendations:
Due to the amount and severity of the corrosion encountered we believe that the future
performance of the building structure could be compromised if not remedied. It is our
suggestions that, in addition to controlling the environment within the arena area,
individual steel members be further investigated, cleaned, repaired if necessary, and
painted. Afterward new insulation and sound /fireproofing should be applied.
Areas needing further investigation and repair will likely be associated with the areas of
discolored finishes the majority of which appear to be located near where the purlins are
supported on the steel girders (bents).
The process should be as follow:
1) Remove insulation and sound /fire proofing materials in areas where
discoloration is present.
2) Observe exposed steel for corrosion and continue removing finishes until
sound, non - corroded steel is encountered.
3) Contact engineer for review of exposed areas and determining course of
action. This will likely be either do nothing, clean and paint or repair and
pain.
4) Reapply insulation and fire proofing.
If you any questions regarding our work or this letter please give Lindau Companies, Inc
a call.
Sincerely,
I hereby certify that this plan, specification, or
report was prepared by me or under my direct LINDAU COMPANIES, INC.
supervision and that I am a duly Licensed
Professional Engineer under the laws of the State
of Minnesota.
6(�-•
William H. Lindau P.E. 424781 4 -17 -2012
Elk River Ice Arena
HVAC Study
R 12-1311.000
The ice arena complex consists of two (2) buildings that are connected with a sheet of ice in
each building. The Barn was built in 1971 and the Olympic size rink building was built in 1997.
Both rinks are open 7 days a week for about 14 to 18 hours a day between September and
March. During the summer the Barn Rink is shut down while the other sheet of ice is operating
during the week for about 12 hours a day. Both sheets of ice are maintained between 190 F and
200 F and get turned down to 17 '/20 F for events and are resurfaced by electric Zambonis and
edgers that have rechargeable wet cell batteries. Both buildings have a dry fire protection
system.
Barn Mechanical Systems
This building currently does not meet code based on the current ventilation air rates and make
up air required for the exhaust. The rink has a Dectron dehumidification unit hung from the
structure and the bleachers have gas fired radiant heat controlled by a dollar validator
machine that the spectators can turn on by inserting dollars. The locker room areas are served
by a gas fired condensing furnace that cannot supply the required outside air and make up air.
The Zamboni room is heated by gas fired unit heaters and is not ventilated. The ice plant has an
electric heater in it and does not have a code required Feron evacuation system.
Olympic Size Rink
The rink is ventilated and dehumidified by a Munters Dry Cool AM30GG unit that was installed in
1999. This unit has a desiccant wheel that removes humidity from the rink air and is reactivated
by a modulating gas burner. It also has an energy recovery enthalpy wheel. The spectator
stands have gas fired radiant heaters that are controlled by a dollar validator machine that the
spectators can turn on by inserting dollars. The lobby, concession, snack, office and toilet room
areas are served by a gas fired rooftop unit with DX mechanical cooling. This unit brings in
ventilation /make -up air for the toilet exhaust and occupants. The locker room area has in floor
radiant heat served by high efficiency boilers that were installed in 2009. Ventilation for these
spaces is supplied by a gas fire 100% make -up air unit that supplies air to the space and is
relieved out of gooseneck ducts on the roof. The ice plant room has a gas fired unit heater and
a Feron evacuation system consisting of outdoor air intake exhaust fan and Feron sensor
controller by an outdoor air intake and exhaust fan. The rink Managers office on the upper level
is heated, ventilated and cooled by a fan coil unit that supplies air from the rink to the office
and air is reheated as required by an electric duct coil.
Page 1
Mechanical /Electrical Consulting Engineers
1 750 Commerce Court ♦ White Bear Lake, MN 55110 ♦ Phone (651) 748-1100 ♦ Fax (651) 748 -9370
Barn Mechanical Deficiencies and Recommendations
Note: The following recommendations are assuming that the building envelope issues will be
addressed.
1. The rink and spectator area does not meet current indoor air quality code because no
outdoor air is being supplied to the space. The Dectron dehumidification unit is under
sized for the space and year round operation. As it gets warmer outside the humidity
levels raise and the space becomes foggy. The higher humidity levels have also caused
damage to the building envelope.
Recommendation: Provide a dehumidification unit similar to the Munters unit at the
Olympic rink but sized for the smaller rink. This will provide dehumidification and outdoor
air that is required by code.
ProbableCost .................................................................................... ............................... $275,000.00
2. The radiant heaters are ineffective and have outlived their service life.
Recommendation: Remove existing radiant heaters and provide with new heaters.
ProbableCost ...................................................................................... ............................... $20,000.00
3. The gas fired furnace does not have the capacity to provide the code required
ventilation /make -up air for the spaces it serves. Code requires locker rooms have
exhaust and make -up air.
Recommendation: Provide energy recovery unit with a hot water coil and all required
controls and ductwork that would supply outdoor air for the locker rooms and occupied
spaces.
ProbableCost ...................................................................................... ............................... $45,000.00
4. Code requires the Zamboni battery charging area to be exhausted.
Recommendation: Provide exhaust and make -up air system and control.
ProbableCost ...................................................................................... ............................... $15,000.00
5. Code required Feron evacuation system.
Recommendation: Exhaust and make -up air and Feron detection control panel.
ProbableCost ...................................................................................... ............................... $25,000.00
Page 2
Mechanical /Electrical Consulting Engineers
1 750 Commerce Court ♦ White Bear Lake, MN 55110 ♦ Phone (651) 748-1100 ♦ Fax (651) 748 -9370
The Olvmpic Sized Rink
1. The Munters desiccant wheel and enthalpy wheel have significant signs of deterioration.
Recommendation:
Option 1: Replace desiccant wheel and all required seals.
ProbableCost ...................................................................................... ............................... $25,000.00
Option 2: Replace both desiccant and enthalpy wheels.
ProbableCost ...................................................................................... ............................... $40,000.00
Option 3: Replace unit with similar unit.
ProbableCost .................................................................................... ............................... $200,000.00
2. The Munters unit has seven (7) standard efficiency motors that are close to the end of
their service.
Recommendation: If Option 1 or 2 from Items 1 is selected, replace motors with premium
efficient motors
ProbableCost ...................................................................................... ............................... $15,000.00
3. The interior of the unit is dirty.
Recommendation: If Option 1 or 2 from Item # 1 is selected clean unit.
ProbableCost ........................................................................................... ............................... $750.00
4. The radiant heaters are close to end of their service life.
Recommendation: Replace radiant heaters.
ProbableCost ...................................................................................... ............................... $30,000.00
5. The rooftop unit condenser coils are damaged causing the cooling function to be less
efficient.
Recommendation: Comb out fins and clean unit.
ProbableCost ........................................................................................... ............................... $750.00
6. One (1) of the locker relief vents is located too close per code to the make -up air units
outdoor air intake.
Recommendation: Extend duct away from the unit to maintain a minimum of 10' -0"
from intake wall. Rotate all gooseneck away from exterior wall
ProbableCost ........................................................................................... ............................... $750.00
7. There is not a building automation system that would maintain and control the Heating
and Cooling systems from a central work station.
Recommendation: Provide web based building automation system that could be
accessed remotely to monitor systems and change settings.
Probable Cost ......................................... ............................... .....................$50,000.00 - $150,000.00
Page 3
Mechanical /Electrical Consulting Engineers
1 750 Commerce Court ♦ White Bear Lake, MN 55110 ♦ Phone (651) 748-1100 ♦ Fax (651) 748 -9370
sill-l1 ��1 II��'ll! ��,����1.���`
BUILDING ENVELOPE
CONSULTANTS
ADVANCED ENGINEERING SERVICES FOR FACILITIES MANAGEMENT / CONSULTING SERVICES INCLUDE:
ALLTYPES OF ROOFING & WATERPROOFING, BUILDING ENVELOPE & FACADE EVALUATIONS & RESTORATION, ASPHALT PARKING LOT RESTORATION,
PARKING GARAGE EVALUATIONS & RESTORATION, FORENSIC ENGINEERING.
April 12, 2012
Rich Czech
Arena Manager
City of Elk River
1000 School Street N.W.
Elk River, MN. 55330
Reference: Exterior Building Envelope Inspection Report (with photos) on existing conditions and Leakage
investigation of the 1971 Elk River Ice Arena, this report includes recommendations and are currently
obtaining estimated costs for maintenance.
Dear Rich,
The following Exterior Building Envelope Inspection Report will show the present conditions and
approximate quantities and locations of the identifiable deficiencies and distress of the roof and wall
components of the Elk River Ice Arena. Defect photos have been provided. Included in this information will
be a Recommendation Summary for this portion of your facility.
OBSERVATION SUMMARY
;ter:
— -----------
Roof Area E
Roof Area E
All of the screw fasteners used to secure the
metal roof panels have been caulked over. Some
S
of the caulk has failed at multiple locations.
We observed temporary patches at a few
locations. The patches rely solely on sealant and
should be considered temporary.
Foam closure pieces were installed at the ridge
��.
cap and at the eves to try and seal the metal
�'.,.
panels.
NL
__-
Large gaps between the metal panels and the
foam closure pieces were visible at many
locations allowing the potential for wind driven
rain to enter into the building interior.
Attempts to stop the leakage included installing
_
sealant around the foam closure pieces and
extending the ridge cap flashing. Leakage was
still occurring at or near that location.
r
Open sealant was observed around an old
television antenna and cable.
Pr
The sealant was also deteriorated around two of
the pipe sleeves.
of �
_F
Physical damage of the metal panels was
observed on roof Area E.
4
Roof Executive Summary:
Roof Area D & E consists of metal panels with insulation boards adhered to the underside and spray coated
installed in 1971 (Area D) and 1997 (Area E). The metal roofs are in good physical condition with small
areas of minor surface rust. A few of these areas have been painted. We believe that the existing metal roofs
can last another 15 -20 years with recommended permanent repairs and do not have to be replaced.
We also observed mechanical saw cuts all the
way through the metal panel at one location on
roof Area E.
Deteriorated sealant was observed at the
roof /wall transition at roof Area E.
Roof Executive Summary:
Roof Area D & E consists of metal panels with insulation boards adhered to the underside and spray coated
installed in 1971 (Area D) and 1997 (Area E). The metal roofs are in good physical condition with small
areas of minor surface rust. A few of these areas have been painted. We believe that the existing metal roofs
can last another 15 -20 years with recommended permanent repairs and do not have to be replaced.
Wall Observations:
We observed deteriorated or missing
sealant at many wall penetrations
throughout the building. The old sealant
should be removed and replaced with foam
i
backer rod and sealant.
-
�k
W
o y
t
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1
7
We also observed open sealant around
doors, louvers, and windows. The old
sealant should be removed and replaced
with foam backer rod and sealant.
}
,r
A
There were many holes in the metal panels
throughout the building. The holes should
be repaired using appropriate materials and
repair methods.
Some of the fasteners have rusted,
including the underlying metal panel. This
condition was most prevelant on the West
elevation. The fasteners should be removed
and the metal panel primed and painted
and a new screw through neoprene washer
installed.
Other fasteners were backing out or were
missing. New screws through neoprene
fasteners should be installed at these
locations.
s
Some of the metal panels received physical
damage, distorting the metal. The metal
panels should be monitored if no leakage is
ocurring or replaced to match existing if
interior leakage is occurring.
II
I�
Some of the mortar around the concrete
masonry units has un- bonded deteriorated
or was missing. These areas should be
tuck- pointed. Ir
Some of the concrete masonry units were
cracked or had holes in them. These units
should be repaired using appropriate
materials and repair methods.
-,v
t,
10
11
12
r
AILs
2
South Elevation 1
Defect :
Description:
Quantity:
Comments:
B
Physical damage to metal panels. Metal
1 lineal foot.
Condition appears to be
drip edge is damaged.
watertight, monitor.
C
Deteriorated, missing, or un- bonded
11 lineal feet.
Remove existing sealant.
sealant at wall control joints, and light
Install new foam backer rod
conduit.
and sealant.
E
Holes in metal panels.
4 each.
Repair using appropriate
materials and methods.
12
C
C
_- g �_=x
C
E Typ. --
f
C
South Elevation 2
Defect :
Description:
Quantity:
Comments:
B
Physical damage to metal panels.
3 square feet.
Appear to be watertight,
monitor condition.
C
Deteriorated, missing, or un- bonded
48 lineal feet.
Remove existing sealant.
sealant at louvers, door, window and
Install new foam backer rod
wall penetrations (gas line and
and sealant.
electrical wire).
E
Holes in metal panels.
45 each.
Repair using appropriate
materials and methods.
F
Physical damage to brick.
2 each.
Replace with matching brick.
13
14
G
C
I� l
j
�Imo'
l
I
J-j 4
�
West Elevation 1
Defect :
Description:
Quantity:
Comments:
C
Deteriorated, missing, or un- bonded
30 lineal feet.
Remove existing sealant.
sealant at window, pipe penetrations,
Install new foam backer rod
cable, and control joints.
and sealant.
G
Deteriorated, cracked, or un- bonded
5 square feet.
Tuck point open mortar to
mortar.
match existing.
14
15
G
•
G --
-
1I
oil
iI
H
,1
�I 'I
H
West Elevation 2
Defect :
Description:
Quantity:
Comments:
C
Deteriorated, missing, or un- bonded
2 lineal feet.
Remove existing sealant.
sealant at pvc pipe and gas pipe.
Install new foam backer rod
and sealant.
G
Deteriorated, cracked, or un- bonded
15 square feet.
Tuck point open mortar to
mortar.
match existing.
H
Cracked concrete masonry units
4 each.
Replace with matching
(CMU's). Holes in CMU's.
CMU's.
Exposed wood at wall.
2 square feet.
Adhere waterproof material
to wood, cover with a color
coated metal enclosure
piece.
15
16
G
rte"
B
- C
A
West Elevation 3
Defect :
Description:
Quantity:
Comments:
A
Sheet metal fasteners missing or backing
9 each
Install new fasteners
out.
through neoprene washers.
B
Physical damage to metal panels.
20 square feet.
Monitor condition. Repair or
replace damaged panels if
interior leakage occurs.
C
Deteriorated, missing, or un- bonded
3 lineal feet.
Remove existing sealant.
sealant at pipe penetrations.
Install new foam backer rod
and sealant.
G
Deteriorated, cracked, or un- bonded
30 square feet.
Tuck point open mortar to
mortar.
match existing.
H
Cracked concrete masonry units
3 each.
Replace with matching
(CMU's). Holes in CMU's.
CMU's.
Exposed wood. Metal panels did not
15 lineal feet.
Install new metal panel to
extend to masonry wall.
cover exposed wood. Install
new foam backer rod and
sealant.
16
— -------
E
A
4
-
A
G A
West Elevation 4
Defect :
Description:
Quantity:
Comments:
A
Sheet metal fasteners missing or backing
11 each.
Install new fasteners
out.
through neoprene washers.
E
Holes in metal panels.
2 each.
Repair holes using
appropriate materials and
repair methods.
G
Deteriorated, cracked, or un- bonded
20 square feet.
Tuck point open mortar to
mortar.
match existing.
17
1.
s
�
I
:
Lil
North Elevation 1
Defect :
Description:
Quantity:
Comments:
G
Deteriorated, cracked, or un- bonded
5 square feet.
Tuck point open mortar to
mortar.
match existing.
Leak Investigation:
After performing a visual inspection of the roof, we performed a leak investigation at an active leak location
to determine the cause of water infiltration into building space and ice arena below. The majority of leakage
was occurring along the ridge at multiple locations. The following is a summary of our observations and
findings:
18
19
We performed our water test approximately
above the west goal on the ice arena.
f
We sprayed water using a spray bar at an angle
near the ridge cap onto the metal panels to
simulate wind driven rain.
e.
Leakage occurred immediately with water
dripping onto the ice adjacent to the west goal.
This was an area that has been very active with
recent leakage.
19
Leak Investigation Summary:
Based on our observations and water testing, the primary cause of leakage occurring along the ridge of the
1971 ice arena is due to the open gaps between the foam closure piece and metal panels at the ridge cap. The
previous attempts to stop the leakage by sealing around the foam closure piece and extending out the ridge
cap have failed. Other leakage may be associated with sealant failure at the metal seams and /or fasteners.
The metal roofs are in good physical condition with small areas of minor surface rust. A few of these areas
have been painted. We believe that the existing metal roofs can last another 15 -20 years with recommended
permanent repairs and do not have to be replaced. We recommend performing long term repairs in two
phases. (Phase I), which includes removing the sealant from the roof fasteners, sealing the existing seams at
the metal laps between panels, installing spray foam at the ridge cap and eves to seal between the ridge cap
and metal panels and the metal panels at the eves. Install an Elastomeric Roofing Membrane over these
repair areas. The estimated cost to implement these repairs is $ 36,610.00.
(Phase II), install an Elastomeric Roofing Membrane over the remaining metal roof area. This should
extend the expected life of the building an additional 15 -20 years with periodic maintenance. The estimated
cost to cover the remaining roof areas with an Elastomeric Roofing Membrane is $ 45,600.00.
SBEC has recommended and performed these repairs on similar roofs and have been very successful in
extending the service life of the existing metal roofs and saving the owners substantial amounts of money.
The Transportation Building in Eden Prairie had the same repairs completed in 2005 and is continuing to
perform without any issues and is expected to perform as intended for many years to come.
Some of the water issues may stem from condensation due to occupancy, air flow and existing mechanical
systems. Our review does not include a study of the existing mechanical systems. These issues should be
looked at after the roof repairs have been completed to separate the water infiltration due to the roof itself,
and possible condensation issues.
SBEC is currently obtaining estimates for the repairs of the exterior walls and will forward them to the City
of Elk River once we receive them.
Based on our observations and water test, we believe a large portion of water infiltration is related to the
performance of the existing roof components and long term repairs should reduce the moisture issues
significantly with completed repairs.
Remarks:
This is a summary of our visual inspection and leak investigation of the roof and wall systems on the 1971
original ice arena building. We recommend repairing the defects identified in the above report and to
perform roof inspections once a year to extend the life of the roof systems.
20
Skyline Building Envelope Consultants continue to look forward to building a strong business relationship
with you and the City of Elk River by helping to solve your roofing and waterproofing problems, by
combining knowledge and experience with excellent services, along with specifying the best products and
systems available in the market place. Thank you for considering us, part of your management team.
Respectfully Submitted,
Rob Johnston Project Manager
Skyline Building Envelope Consultants
15050 CEDAR AVENUE S. / SUITE #: 116-333/ APPLE VALLEY, MN 55124
OFFICE #: 952 - 303 -4824 OFFICE FAX #: 952 - 405 -6060 MOBILE: 763 - 229 -2771
ROB.JOHNSTONaSKYLINEBEC.COM
WVWV.SKYLINEBEC.COM
71
Ice System Evaluation and
Recommendations
Elk River Ice Arena
For:
City of Elk River, Minnesota
13065 Orono Pkwy NW
Elk River, Minnesota 55330 -5600
April17, 2012
Submitted By:
Stevens
2211 O'Neil Road
Hudson, WI 54016
800.822.7670
G Steven s
File No. 900.12.159
ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Table of Contents
SECTION TOPIC PAGE
1 Project Information ......................................................... ............................... 1
2 Project Overview .................................................................. ............................... 4
3 Ice Systems ............................................................................ ............................... 8
4 Alternative Energy Sources ............................................... ............................... 26
5 Project Schedule ................................................................. ............................... 29
6 Financial Assistance Programs ............................................ ............................... 31
UStevens 1
PV, NWF $ 'I '�NNHW7
ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Section 1
Project Information
UStevens
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ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Facility Address:
Elk River Ice Arena
1000 School Street N.W.
Elk River, MN 55330
Facility Manager:
Rich Czech
P. 763.635.1141
rczech @ci.elk - river.mn.us
Consulting Engineering Firms:
Stevens
2211 O'Neil Road
Hudson, WI 54016
P. 651.436.2075
F. 715.386.587
Scott A. Ward, P. E.
sward @stevensengineers.com
Electric Utility:
Xcel Energy, 1518 Chestnut Avenue, 1St Floor, Minneapolis, MN
55403
Account No: Meter No:
Account Manager:
Gas Utility:
Contact Information
Certification
I hereby certify that this report was prepared by me or under my direct supervision and
that I am a duly registered Professional Engineer under the laws of the State of Minnesota.
Scott A. Ward, P. E.
STEVENS
c Steven s
40921 4.17.12
Registration Number Date
3
ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Section 2
Project Overview
UStevens
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ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
PROJECT OVERVIEW
Background
The Elk River Ice Arena consists of two (2) ice arenas where both
ice rinks are served by individual Holmsten direct R -22
refrigeration systems. The refrigeration system serving the
original rink (Rink 1 or "The Barn ") has a capacity of 80 tons and
the system for the new rink (Rink 2) has capacity of 135 tons.
The ice rink floor and dasher board systems were replaced in
Rink 1 in 2004.
Due to the age of the Rink 1, the City is interested in completing
an evaluation of ice system (rink floor and refrigeration system)
to determine the condition and to identify and recommend
improvements and /or replacement options to assist in future
planning for the facility. The evaluation includes improvement
recommendations and estimated project costs for the
improvements. To plan long term, it was also necessary to
include discussion on the future of Rink 2's ice system. The
HVAC, electrical, lighting and building systems were not part of
our scope of services and are being evaluated by other
consultants.
Purpose
As part of a continued effort to: improve operation and
efficiency of Elk River Arena; to plan for future improvements to
the facility; and to continue to provide high quality ice for its
user groups; Stevens was retained by the City to prepare an
evaluation of Rink 1 (The Barn).
The primary objectives of this evaluation are as follows:
• To evaluate the ice system for Rink 1 and provide
recommendations for improvements.
• To provide accurate cost estimates to assist the City in
making informed decisions on future projects.
• To recommend improvements that maximize energy
efficiency while incorporating sustainable design practices
that reduce the use of fossil fuels, the production of
greenhouse gas emissions and reduce total energy use.
It is recommended that the findings presented in this report be
used to improve the operations and maintenance of the facility
and to assist in planning and budgeting of the recommended
improvements.
c Stevens 5
ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Scope of Services and Approach
The Scope of the ice system evaluation includes an overall
evaluation of the physical conditions and improvement options
for the following systems:
• Ice systems in Rinks 1
• Related waste heat recovery systems
Investigation Methods and Documents
Various methods were used to evaluate the existing facility
including:
Visual Observations: A site visit was conducted on April 3, 2012
to observe the operation of the facility and its ice systems.
Interviews: During the on -site visit, an in -depth discussion was
conducted with the facility's management staff to document
existing issues with the facility and discussed historical
problems with the ice systems.
Research: Where applicable, additional research was
conducted to provide accurate and detailed information
regarding improvements or systems recommendations.
Documents: The following documents were received and
reviewed for the evaluation:
• None
G Stevens 6
ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Estimated Project Costs
The proposed cost estimates presented throughout this report
were developed by estimating the probable construction costs
based on similar types of construction projects and work
performed and bid in 2008 -2012 and updated for 2013 costs
unless otherwise noted. The estimated costs include all
materials and labor for a complete installation unless otherwise
noted. Costs will vary depending on the time of year the
projects are bid, the current economic climate and the size of
project.
In addition to the probable construction costs of the proposed
work, other associated project costs are included to provide a
total estimate cost for the project. The Estimate, Design and
Construction Contingency line item in each cost table is included
during the evaluation phase of projects since the exact scope of
the project has not yet been determined. This percentage is
typically reduced from 15% to 5% during the final design phase
of the project.
The Engineering, Legal and Administrative line item in each cost
table is provided to cover all work performed by the design
team and all legal and administrative work required by the City
for projects of this type.
Applicable Codes and Standards
The following codes were considered during the evaluation:
• Minnesota State Building Code, 2007, including Chapter
1341 Accessibility Code
• International Building Code, 2006
• 2007 Minnesota State Fire Code (International Fire Code,
2006)
• International Mechanical Code, 2006
• 2009 Minnesota State Mechanical Code
• NFPA 70 (NEC), 2008
• Department of Labor & Industry — High Pressure Piping and
Code for Power Piping Systems, Chapters 326 (MN Statues
1999) and Chapter 5230 (MN Rules 2001)
• ANSI /ASHRAE Standard 15 -2007
• The City's CODE OF ORDINANCES were not reviewed or
referenced for this evaluation.
c Stevens
ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Section 3
Ice Systems
UStevens
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ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
ICE SYSTEMS
General
The facility is served by two separate ice systems (including
refrigeration system and ice rink floor), one for each rink. The
ice systems for both Rink 1 and Rink 2 are direct refrigeration
type systems and were installed with the construction of the
buildings they serve, 1981 and 1997 respectively. This report
will discuss another common type refrigeration system used in
the ice industry; indirect type systems. The options for
replacing the direct ice systems, including replacing them with
indirect systems, are discussed in this section.
Definitions for each type of system are provided below:
Indirect System: In an indirect system the primary
refrigerant (R -22 for example) remains in the refrigeration
room. Heat is removed from the ice rink floor through a
secondary refrigerant (glycol /water solution for example)
that is circulated in the floor. The heat exchange between
the primary and secondary refrigerants takes place in the
refrigeration room.
Direct System: A direct refrigeration system circulates the
primary refrigerant (R -22 in this case) directly through the
ice rink floor and refrigeration system. There is no
secondary refrigerant and therefore, no secondary heat
exchange process.
Overall, both systems have been very well maintained by the
facility's operational and maintenance personnel.
UStevens 9
ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Observations of Existing Conditions
We toured the ice systems for both Rink 1 and Rink 2 with the
facility's management and operating and maintenance staff and
have the following observations and comments.
Rink 1 (The Barn):
• The operational season typically runs from the middle of
September through middle of April.
• Rink 1 is served by a direct refrigeration system
manufactured by Holmsten Ice Rinks. The major of the
components include two (2) 4 cylinder York compressors,
one (1) low pressure receiver, two (2) pumper drum vessels
and one (1) motor control center. The 31 -year old
refrigeration system has exceeded its expected life of 25 -30
years. However, since this system only operates 6 months
per year, the life span of the equipment is likely to be
greater than 30 years. The system is in fair condition for its
age, but, it's becoming more difficult to maintain with its
outdated electrical and control systems, discontinued
compressors units, etc. Some improvements have been
performed on the refrigeration package over the years and
include rebuilding compressors, new valves and insulation,
new fill solenoids, float switches, top ends on compressors,
dryer cores, replaced relief valves, and new ASME certified
oil separator.
• The existing evaporative condensing tower, was replaced in
2010 and is manufactured by Baltimore Aircoil (BAC). This
system uses air and water to dissipate heat for the
refrigeration processes.
• There are no waste heat recovery systems on this
refrigeration system. The existing snowmelt pit that is
dedicated to Rink 1 is only used as a back -up and uses a
boiler system to heat the water and melt the ice shavings.
The primary pit is a common pit with Rink 2. There is no
subfloor heating system beneath the rink floor. All waste
heat is dissipated to the atmosphere, through the
condensing tower.
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ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
• The ice rink floor was replaced in 2004 with a new direct
refrigeration ice rink floor of similar design to the original
floor. The floor, which measures 85 feet x 185 feet, is
slightly smaller than the standard NHL size of 85 feet x 200
feet. The 8 -year old rink floor consists of: 3 -4 inches of floor
insulation; % inch steel tubing installed at 4 inches on-
center with welded connections; and a 5 inch of reinforced
concrete. It was very typical for the rink floors, in a
Holmsten Rink System, to be the first components to fail.
There are no reported problems with the existing rink floor
or with ice quality at this time.
• The existing dasher board system was installed new in
2004. It is a steel framed system with a supported tempered
glass system. The system is in very condition and should
have life expectancy of approximately 20 -25 years.
• The existing refrigeration room for Rink 1 is very small.
The room is not equipped with mechanical ventilation and
refrigerant leak detection systems and there does not
appear to be an emergency stop switch or ventilation
switch near the exterior door as is required by code. These
systems are addressed in the mechanical system review.
Rink 2:
• The operational season is typically year round.
Approximately every other year the rink is taken down for
one month to perform maintenance on the ice rink floor
and system.
• Rink 2 is also served by a direct refrigeration system
manufactured by Holmsten Ice Rinks. The major of the
components include two (2) 8- cylinder York compressors,
one (1) low pressure receiver, three (3) pumper drum
vessels and one (1) motor control center. The refrigeration
was purchased used 15 -years ago and is believed to be 28-
30 -years old exceeding its expected life of 25 -30 years. The
system is in fair condition. As with the Rink 1 Holmsten Ice
Rink system, it's becoming more difficult to maintain with
its outdated electrical and control systems, discontinued
compressors units, etc. There have also been some on-
going, fairly significant, problems with the system such as:
oil return problems which relates to ice quality concerns;
compressor shaft seal problems; R -22 leaks in the
refrigeration system; vent line damage; etc.
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ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
American Engineering Testing performed ultra sound
testing on the low pressure receiver to investigate the
effect of visible corrosion on the vessel. The test reportedly
showed no loss of vessel wall thickness.
• The existing evaporative condensing tower was replaced 5
years ago and is in good condition. It is manufactured by
Balitimore Aircoil Company (BAC). A variable frequency
drive was installed on the system when the new condenser
was installed.. This system uses air and water to dissipate
heat for the refrigeration processes.
• Waste heat is recovered and used for serving the snow melt
pit and the subfloor heating system beneath the rink floor.
The existing snow melt pit in the in- ground type which does
not work very well in terms of both allowing snow into the
pit and quickly heating and melting the snow. The
remainder of the heat is dissipated to the atmosphere,
through the condensing tower.
• The ice rink floor is a direct refrigeration ice rink floor. The
floor, which measures 100 feet x 200 feet, is larger than the
standard NHL size of 85 feet x 200 feet. The 15 -year old rink
floor is likely constructed to the standard design: 3 -4 inches
of floor insulation; Yz inch steel tubing installed at 4 inches
on- center with welded connections; and a 5 inch of
reinforced concrete. The only reported problem with the
existing rink floor is that oil gets trapped in several of the
tubes causing streaks and sometimes poor ice quality in
those locations.
• The existing dasher board system was installed new in
1997. It is a steel framed system with a supported tempered
glass system. The system is in very condition and should
have life expectancy of approximately 20 -25 years.
• The existing refrigeration room for Rink 2 is fairly large at
576 square feet. The room is equipped with mechanical
ventilation and refrigerant leak detection systems. It was
not verified whether an emergency stop switch or
ventilation switch was located near the exterior door as is
required by code.
U Stevens 12
. nNNERS SURVEYORS
ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Recommendations
The main focus of this report is to evaluate the 31 -year old ice
system in Rink 1 and provide recommendations to assist the
City in its planning and budgeting for its replacement. Given
that: the rink floor was replaced fairly recently in 2004; the
system is a direct system; and that the options for refrigerants
and systems in the ice rink industry are changing with the
phase -out of R -22 refrigerant; there isn't a clear, single
replacement option. This section outlines not only the options
for replacement, but for improvements to the existing ice
system as well. It is also prudent to consider the eventual
replacement of the ice system in Rink 2 and how combining
systems could maximize energy savings. Cost estimates are
provided for each option in the table at this end of section.
The following options will be discussed in this section:
Option 1:
Do nothing. Continue to maintain existing systems.
Option 2:
Make improvements to the existing direct system.
Option 3:
Convert to an indirect, industrial grade, R -22 or
other HFC refrigerant based system using the
existing refrigeration equipment.
Option 4:
New indirect, industrial grade, HFC refrigerant
based system.
Option 5:
New indirect, industrial grade, ammonia based
system.
Option 6:
Same as option 6 but includes future connection to
Rink 2.
Option 7:
New carbon dioxide (CO2) based system.
Option 8:
Alternate energy source system. See Section 6.
U Stevens 13
ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Before the system options are discussed in more detail, a
general discussions of six (6) major factors or considerations
that Stevens feels are most important to consider when
evaluating ice system options is presented below. A general
understanding of these factors, we believe, will aid the City in
making the best possible selection for improving or replacing
the existing ice system.
In a historically slowly- changing industry; recent breakthroughs
in new technology and cutting -edge design applications, and
changing environmental regulations have generated a laundry
list of design considerations for the City to evaluate when
renovating or replacing its direct ice systems. In general, this list
includes:
• Type of Refrigerant: R -22 has been the most popular
refrigerant, used in ice rink applications, in recent history.
However, with the signing of the Montreal Protocol, the
United States Environmental Protection Agency
implemented the final rule of Section 604 of the Clean Air
Act, in July 1992 limiting the production and consumption of
a set of chemicals known to deplete the stratospheric ozone
layer as measured by their ozone depleting potential
(ODP). R -22 refrigerant, a hydrochlorofluorocarbon or
HCFC, is the next refrigerant on the list to be phased out.
Starting this year, R -22 can no longer be produced and
imported in to new packaged type refrigeration equipment
and will be banned from installing in existing equipment in
2020. The EPA is also proposing to significantly reduce
allowances to produce and /or import R -22 in the U.S.
ranging from 11 -17% per year from 2012 -2014.
These regulations are certainly affecting the price of R -22 as
it has risen from $7 per pound to $13 per pound since mid
March. Replacement or "drop -in" refrigerants for R -22 are
starting to be manufactured and currently cost around $15
per pound.
U Stevens 14
ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
There is now pressure to consider phasing out refrigerants
that contribute to global warming as measured by their
global warming potential (GWP), in addition to those
affecting the ozone. This affects mainly hydrofluorocarbons
(HFCs) like those used in blended refrigerants such as R-
507A and R -404A. Europe has been on the leading edge of
this change. The European Parliament passed legislation
called the F Gas Directive that became effective in 2007,
that requires very strict inspection of systems for leakage,
rigorous record keeping and mandatory training and
certification on systems using HFCs.
With the changing of environmental regulations, careful
consideration of all refrigerant options should be made.
The new refrigerants and replacements for R -22 are
"blended" HFC refrigerants meaning they are a mixture of
several different, individual refrigerants. Since refrigerants
have different properties, each one reacts differently to
changes in its properties such as pressure and velocity.
When a leak occurs, varying amounts of each refrigerant
may leak out, throwing the original mixture out of balance.
Ammonia refrigerant is making a comeback from when it
was pushed aside in the early 1970's for R -22. Ammonia's
low cost, high efficiency and zero ozone depleting and
global warming potential make it a very attractive option.
Large global companies, such as Coke Cola, are leading the
charge to ban HFCs and use natural refrigerants such as
CO2, hydrocarbons and ammonia. Many ice skating
facilities in Europe have switched over to CO2 -based
systems. The first CO2 -based ice system in North America
recently opened in Les Coteaux, Quebec, Canada.
• Quality of Materials and Equipment: Balancing the initial
cost of materials and equipment with energy savings can be
difficult during the budgeting process of the project. For
example, the phrases "commercial grade" and "industrial
grade" systems, used throughout the report, refer to quality
and operational efficiency differences in the refrigeration
system. Commercial grade systems are similar to
supermarket type refrigeration systems, built on a rack
package, and have a lower life expectancy (15 -20 years).
These systems typically use copper and PVC pipe in place of
steel, disposable type compressors in place of rebuildable
ones, direct expansion type heat exchangers in place of
flooded type systems, etc. Industrial grade systems are
typically stick built on site, have a longer life expectancy
(25 -35 years), and are generally more efficient to operate.
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ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
• System Design: The design of the system is critical to
maximizing its efficiency. For example, lowering the
condensing temperature of the refrigeration system
increases its efficiency but decreases the amount of waste
heat that is generated. Finding the balance between these
system elements is key to a successful and efficient design.
• Energy Source: As energy costs rise, alternative sources of
energy, such as geothermal, natural gas, or co- generation,
may look more attractive. Electricity still remains the most
practical energy source for these types of systems.
• Waste Heat Recovery: Refrigeration systems generate a
large amount of heat that is typically wasted into the
atmosphere. A refrigeration system for a single ice sheet
can typically generate enough waste heat to serve the
subfloor heating system, snowmelt pit, the dehumidification
system, and potentially preheat domestic water source or
in- coming air. Historically, ice rink facilities have only
captured and reused approximately 25% of the waste heat
generated. It has now become normal design practice to
capture 100% of the waste heat and reuse this "free
energy" throughout the facility.
• Sustainability: Sustainability goes hand -in -hand with all the
items in this list of considerations. Energy savings, through
smart design practices, translates directly into the reduction
of green house gas emissions such as carbon dioxide.
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Option 1: Do Nothing — Maintain Existing Rink 1 Ice System
With a relatively new ice rink floor (8 -years old) and no current
major problems with the 31 -year old refrigeration system, the
City may elect to keep operating the existing system in the near
future and plan long term for its replacement.
The existing direct refrigeration ice systems in both Rinks 1 and
2, manufactured and installed by Holmsten Ice Rinks; were
commonly installed in arenas during the 1970's and 80's. The
design of this direct ice system is unique and has proven to
perform very well and be very efficiently. However, the system
is outdated and numerous concerns with the standard system
design and current code regulations have prompted facilities to
convert or change to indirect ice systems. These concerns
include:
• Aging equipment: Major improvements to the existing
refrigeration system will soon be required to extend its
safe and useful life.
• Safety: The direct ice system circulates R -22 refrigerant
in the ice rink floor, which is located in the occupied
space of the facility, potentially exposing spectators,
skaters and workers to leaking refrigerant as the floor
system ages.
• Environmental: The existing system uses a large volume
of R -22 refrigerant (approximately 4,000 Ibs) with a high
global warming potential (GWP) rating. R -22
refrigerant is scheduled to be phased out of production
in the near future.
• Cost and future availability: As the phase -out date for
R -22 approaches, the cost will continue to increase.
Since 2005, the cost of R -22 refrigerant has risen 850 %.
Because of these concerns, we do not recommend replacing the
existing direct refrigeration system with a new direct
refrigeration system even though the rink floor is only 8 -years
old. Replacing the rink floor in 2004 with the same system was
a good option at the time given the high operating efficiency
and performance of the Holmsten direct system and the quality
of construction of the refrigeration system. Unfortunately, the
phase -out of R -22 refrigerant started to accelerate shortly after
construction of the new floor was completed.
U Steve n S 17
ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Some of the potential downsides, or risks, involved in
continuing to operate the existing direct systems for too much
longer are as follows:
• Continued Equipment Costs: The equipment and parts
on the refrigeration system will continue to require
replacement in the near term. It's similar to driving a
vehicle with high miles; the longer it runs, the more
costly it becomes to repair and the lower the return on
investment. Parts for the existing York compressors are
no longer manufactured and becoming extremely
difficult to find and costly to purchase. Some valve
manufacturers (like Sporlan) no longer manufacture
some of the valves used on the system.
• Risk of a Refrigerant Release: As the system ages, the
risk of a major release of refrigerant increases. The
existing direct systems contain approximately 4,000
pounds of R -22 refrigerant in Rink 1 and approximately
6,000 pounds for R -22 in Rink 2. Depending on the
availability of R -22 when this occurs, the City may be
forced to install a new blended refrigerant which will
require additional modifications to the system.
• Dependability: The risk of problems occurring with the
refrigeration system, and therefore, the risk of losing
the ice sheet, increases as the system ages.
Option 2 — Make Improvements to the Existing Rink 1 Ice
System:
Holmsten Ice Rinks provided good quality vessels (e.g. high
pressure receiver, pumper drums, etc.) with their systems. This
opens up the option of renovating the existing refrigeration
system to extend its useful, dependable, and safe life. This has
successfully been performed at several facilities such as
Gustavus Adolphus College, University of Minnesota - Duluth and
others.
If the existing refrigeration system is going to remain in place,
whether in its current operation as a direct system, or
converted into an indirect ice system, we recommend the
following improvements be performed on the existing
refrigeration system.
G Stevens 18
ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Recommended minimum improvements include:
• Investigate the integrity of the existing steel vessels and
piping systems: The refrigeration system was re- insulated
and therefore the condition of the steel vessels and piping
systems could not be inspected. Corrosion along the
bottom of the low pressure receiver is common in these
systems. The extent of any corrosion cannot be
determined without removing the insulation. The
recommended repair includes: removing several sections of
the existing insulation on the system; conducting a visual
inspection of the vessels and piping; and conducting a non-
destructive ultra sound tests of the steel. If high levels of
corrosion are found, the entire insulation system should be
removed; the surface of the vessels and piping should be
sanded, primed, painted; and then the entire system should
be re- insulated.
If the steel vessels and piping systems are found to be in
good shape, this system could last another 15 or more years
with the other recommended improvements completed and
with continued proper maintenance.
If extensive corrosion is found, the vessels should be
repaired and recertified and /or replace and piping should
be replaced before reinsulating. Poor insulation can aid in
pre- mature corrosion and loss of efficiency.
• Replace vent solenoids on each pumper with some
materials: Inspect and replace the existing valve (typically a
Sporlan MA50) with same model. This valve cannot be
replaced with a higher quality valve as manufactured by
Hanson due to the inadequate space.
Table 2. Option 2 — Minimum Improvements to Existiniz Rink 1 Svstem
Item
Cost'
Investigate Integrity of vessels and piping systems
$3,000
Replace vent solenoid valves (2 total)
$2,000
Subtotal of estimated construction costs
$5,000
Estimate, design and constr. contingency (20 %)'
$1,000
Total estimated construction costs
$6,000
Engineering, legal, and administrative (18 %)'
$1,000
Total estimated project costs
$7,000
1. See explanation in Section 2 of this report.
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ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Other recommended improvements to the existing refrigeration
system include:
• Replace compressors: Parts for the existing York
compressor can be difficult to find since they are no
longer in production. These compressors can be rebuilt
and reused for well over 30 years. However, the
existing 42 -year old compressors are reportedly
showing wear on the main casting which would require
replacement in the near future. The compressors
should be replaced by compressors that can be used in
a future refrigeration system.
Table 3. Option 2 — Other Improvements to Existing System
Item
I cost'''
Replace compressors and motors
1 $75,000
1. See explanation in Section 2 of this report.
2. Costs also include contingency, engineering, legal, and administrative.
Option 3: Convert existine Rink 1 system to an indirect industrial
grades stem
Only recently has this option proven feasible for converting
Holmsten refrigeration packages from direct to indirect systems
while using the existing refrigeration equipment.
The option includes converting the existing refrigeration system
to an indirect system by installing a new heat exchanger and
rink pumps. This option includes reusing the existing low
pressure receiver, pumper drums and piping, and main motor
control center. The existing system would be updated as
recommended in Option 1. The existing ice rink floor would
require replacement under this option. The existing ice
equipment room would likely require expansion for the
additional equipment
This option will reduce the charge of R -22 in the system from
approximately 4,000 pounds to 1,000 pounds. The City could
store the extra R -22 refrigerant for future use. A reduction from
4,000 pounds of R -22 to 1,000 pounds of R -22 will noticeably
reduce the facility's carbon footprint.
Photo P -1: The 2010 conversion of
University of Minnesota - Duluth's ice
on- campus ice rink system has proven
very successful. See Option 3.
G Stevens 20
ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Option 4: — New indirect industrial grade system:
This option includes replacing the entire refrigeration system
and concrete ice rink floor with an industrial grade flooded
chiller, new blended HFC refrigerant, reciprocating
compressors, pumps, and concrete rink floor.
Option 5: Same as Option 4 but replace Freon with ammonia.
This option is the same as Option 4 but replaces the use of a
new blended HFC type refrigerant with ammonia refrigerant.
This option also includes installing a new mechanical ventilation
system to meet the current ventilation code requirements for
ammonia refrigerant and installing an exterior door for egress.
Option 6. Carbon Dioxide (CO2) Refrigeration System
Continuing the discussion from the refrigerant discussion earlier
in the report, the use of CO2 refrigerant will likely be the next
substantial "innovation" in the ice rink industry. Currently
European countries are using CO2 as a secondary refrigerant in
ice rink applications. One rink in Canada just recently installed a
primary CO2 system. CO2 applications in the U.S are increasing
especially in the supermarket industry. However the selection
of equipment is limited and the regulatory codes are still under
development.
The cost information provide in the table at the end of this
section is very preliminary. Because this is a new technology
and application, there is fairly limited information on the
systems. The cost estimates should be updated as the desired
project date approaches.
It is recommended that a CO2 refrigerant based ice system be
seriously considered, as a replacement option for the current
system, especially if the replacement of the West Arena's ice
system will be more than two years from now.
Option 7. Combined Refrigeration Systems using Ammonia
This system option was included to provide an option for long
term planning, including the replacement of the 15 -year old
refrigeration system in Rink 2.
A common refrigeration system that serves both Rinks 1 and 2
offers advantages such as lower life cycle costs, higher
efficiency, and lower operation and maintenance costs
compared to two separate single ice systems.
Photo P -2: An example of a "stick- built"
industrial grade, hydrocarbon,
refrigeration system for a single ice
sheet, Andover, MN. See Option 5.
Photo P -3: An example of a "skid package ",
industrial grade, ammonia refrigeration
system for a single ice sheet, Scottsdale, AZ.
See Option 6.
U Steve n S 21
ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
The one disadvantage of a common system is that if a major
problem occurs with the refrigeration system, both ice sheets
are down. However, most equipment and systems have
backups, minimizing the chance that a total system failure will
occu r.
A common ice system could be installed in phases as described
below:
Phase 1 includes the replaced of the existing ice rink floor and
refrigeration system in the Rink 2 since the existing refrigeration
room is likely large enough for the common system. At that
time the refrigeration system would be designed and installed
with the capacity and accommodations to connect to Rink 2 at
some point in the future. The existing ice rink floor in Rink 2
would be replaced with a concrete rink floor of the same size. A
new mechanical ventilation system and refrigerant leak
detection system would be installed to meet code
requirements.
The R -22 refrigerant that is salvaged from Rink 2 can be used in
the refrigeration system for Rink 1 alleviating some concerns for
an R -22 shortage in the future.
Phase 2 includes installing the final compressor(s), pump(s),
piping and controls to serve Rink 1, replacing the existing ice
rink floor with a concrete rink floor, and change over the snow
melt system to use waste heat from the refrigeration system.
The cost estimates presented in the following table for Option 8
are shown in two phases as described above and include the
complete replacement of both ice systems including
refrigeration systems and ice rink floors.
The cost estimates do not include the following items:
• Building a new refrigeration room for a common
refrigeration system to serve both rinks.
• Improvements to the Rink 2 refrigeration system to
keep it operating.
• Expanding the length of the ice rink floor in Rink 1 from
185' to 200'. This would require a building expansion.
• Reducing the size of the ice rink floor in Rink 2 from
Olympic to NHL size and expanding the bleachers.
Photo P -4: The City of Alexandria installed a
new industrial grade common refrigeration
system (for 2 rinks) in 2009 as discussed in
Option 7. The system currently operates
one ice rink but is designed to connect a
second ice rink in the future.
G Stevens 22
ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Summary of Ice System Replacement Options:
Table 4. Ice System Options - Cost Estimate Summary
1. See explanation in Section 2 of this report.
C Stevens 23
Cost Estimate'
Item
Cost Per Ice System
Combined System
Option 3
Option 4
Option 5
Option 6
Option 7
Option 7
Conversion
New
New
New
Phase 1
Phase 2
Refrigerant type
Ex. R -22
New HFC
Ammonia
CO2
Ammonia
Ammonia
Grade of System
Industrial
Industrial
Industrial
Commercial
Industrial
Industrial
Removal & reinstall
$30,000
$30,000
$30,000
$30,000
$30,000
$30,000
existing dasher boards
Demolition of existing
$10,000
$25,000
$25,000
$25,000
$25,000
$15,000
refrigeration system
Demolition of existing
$60,000
$60,000
$60,000
$60,000
$20,000
$60,000
conc. ice rink floor
Replace mechanical
N/A
N/A
$25,000
$25,000
$30,000
N/A
ventilation system
New exterior door and
N/A
N/A
$20,000
$20,000
N/A
N/A
concrete stoop
Repairs to Ex. System
$5,000
N/A
N/A
N/A
N/A
N/A
(From Table 2)
Other repairs to existing
Not included
N/A
N/A
N/A
N/A
N/A
system (Table3)
See Table 3
Expand refrigeration
$70,000
$70,000
$70,000
$70,000
N/A
N/A
room approx. 200 SF
New refrigeration
$225,000
$475,000
$575,000
$725,000
$775,000
$180,000
system or equipment
New concrete Ice rink
N/A
$350,000
$350,000
$475,000
$420,000
$338,000
floor & subfloor
New snow melt pit heat
N/A
N/A
N/A
N/A
$75,000
N/A
recovery system
Size of future
Additional heat reclaim
Not included
Not included
Not included
Not included
Not included
Not included
systems
See Table 3
See Table 3
See Table 3
See Table 3
See Table 3
See Table 3
Subtotal of estimated
$400,000
$1,010,000
$1,155,000
$1,430,000
$1,375,000
$623,000
construction costs
Estimate, design and
$60,000
$151,500
$173,000
$214,500
$206,300
$93,500
constr. Contingency
(15 %) 1
Total estimated
$460,000
$1,161,500
$1,328,000
$1,644,500
$1,581,300
$716,500
construction costs
Engineering, legal, and
$55,200
$139,500
$159,400
$197,500
$189,800
$86,000
administrative (12 %)1
Total estimated project
$515,200
$1,301,000
$1,487,400
$1,842,000
$1,771,100
$802,500
cost
Expected Useful Life -
15 -25
25 -30
25 -30
TBD
25 -30
25 -30
Refrig System (yrs)
Expected Useful Life -
40 -50
40 -50
40 -50
TBD
40 -50
40 -50
Rink Floor (yrs)
1. See explanation in Section 2 of this report.
C Stevens 23
ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Section 4
Alternative Energy
Sources
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ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
ALTERNATIVE ENERGY SOURCES
General
Ice arena facilities use large amounts of energy. With high
energy use come opportunities to apply new technologies that
may reduce energy use and the opportunity to explore
technologies that focus on sustainable and /or renewable energy
sources. This section briefly discusses several alternative energy
sources that the City may want to consider when the facility is
renovated.
Greenhouse Gas Reduction
Greenhouse Gas (GHG) emissions are increasingly being
considered when choosing between facility /process
alternatives. Although there is not currently a cost associated
with greenhouse gas emissions, there is the potential that there
will be. Alternatives with lower GHG emissions therefore have
the potential to have lower on -going costs. At the New Hope
Arena, the primary sources of GHG emissions are natural gas
combustion and electricity use. In addition, there are GHG
emissions associated with the manufacture and use of the
refrigerant R -22.
Geothermal
Geothermal exchange systems offer numerous opportunities for
energy savings in an ice arena application. Geothermal systems
are considered a renewable energy source and have been the
focus of a recent wave of funding opportunities from the
Federal Government. A detailed analysis should be performed
when considering incorporating geothermal systems with the
ice system improvements.
Construction of several geothermal type ice systems have
recently been completed using traditional well type systems
(e.g. Burnsville Ice Center in 2010) and non - traditional
geothermal systems (e.g. Brooklyn Park in 2010). The Brooklyn
Park Arena project used the City's well water source as a
geothermal sink in place of the traditional well field, saving over
$200,000 in construction costs and increasing the energy
savings. As these projects "season" or are "fine tuned ",
extremely valuable information will be available on lowering
energy use and GHG emissions to apply to the next generation
of ice rink systems. The City will benefit from the information
collected on these projects.
Photo P -31: Well drilling rig for a
geothermal system.
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ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
The cost to add a geothermal sink to the ice system
improvements options listed in Table 4 of this report could add
anywhere from $200,000 to $600,000 to the project costs.
Further investigation and analysis will be required to determine
if this is a feasible option for the City of Elk River.
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ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Section 5
Project Schedule
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ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
PROJECT SCHEDULE
General
The improvements should be planned well in advance of the
desired construction time so equipment and materials can be
ordered and delivered to the site. Minimizing disruption to the
facility's busy event schedule and user groups will be a key
element to the success of this project.
We understand the City will use the information in this study to
determine the scope of the project(s). Once the project scope
and funding sources have been identified, a detailed schedule
can be developed.
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ELK RIVER ICE ARENA - ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Section 6
Financial
Assistance Programs
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FINACIAL ASSISTANCE PROGRAMS
There are several financial programs that Xcel Energy has
available that the City may wish it take advantage of. They
include:
1. Engineering Assistance Study Program. The purpose of this
program is to provide the City with the necessary business
case justification to implement energy- saving opportunities.
This evaluation report can be expanded to identify energy
conservation opportunities, energy modeling, etc. to meet
the programs requirements. Xcel Energy will reimburse
the City up to fund up to 75% of the cost of this study. One
example where the City would benefit from this additional
energy analysis is in selecting a refrigerant (ammonia, CO2,
etc.) or refrigeration system to replacing the existing R -22
refrigerant or system. It is required that the program be
pre- approved by Xcel Energy prior to starting any work on
the study.
2. Rebate Programs. Rebate programs are available through
Xcel Energy for many energy improvement measures that
can be performed such as lighting replacement, motor
replacement, installation of variable frequency drives,
improving insulation systems, etc. Custom rebate
programs are also available and may apply to the
refrigeration system replacement depending on the type of
system selected. Xcel Energy should be contacted to
identify possible rebates prior to starting any improvement
project relating to energy savings. Some rebates require
preapproval prior to purchasing and installation.
State Appropriation Board
Programs should be reviewed for potential funding
opportunities.
Sports Commission
Programs should be reviewed for potential funding
opportunities.
American Recovery and Reinvestment Act
The initial program deadlines have pasted. However, new
programs continue to develop so this program along with other
Federal grant programs should be monitored for funding
opportunities.
There may be other grants or cost - sharing programs available.
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ELK RIVER ICE ARENA — ICE SYSTEM EVALUATION AND RECOMMENDATIONS
Alternate Project Delivery Method
Another delivery and funding option the City may consider for
this project is through guaranteed- savings contracts. Stevens
has teamed with several Energy Service Organizations to
successfully complete ice rink projects for the City of Brooklyn
Park, Northfield and Eden Prairie. We are currently working
with the City of New Hope on a guaranteed- savings contract
project at the New Hope Arena.
If the City is interested in learning more about this delivery
method we would be happy to discuss it in more detail with
you.
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