ALCOA: EAST HALLS RENOVATION

Eddie TaddeiDaniel GuarracinoRichard HaywardNicholas KappelerBrianna Haglan

EDSGN 100Section 00812/9/13

Table of Contents

1. The Opportunity

2. Background Information

3. Conditions & Objectives

4. Collective Creative Ideas

5. Evaluation

6. Analysis

7. Prototype

8. Conclusion

ALCOAThe company… Leading producer of aluminum

Largest miner of bauxite

Largest refiner of alumina

Involved in multiple markets

The product… Infinitely recyclable

Hall-Heroult Process

*Properties of Aluminum• Light weight• Corrosion resistance• Conductivity• Reflectivity• Recyclability

Why are we here today? Penn State & Sustainability

• Identify campus opportunities

• Examine inputs & outputs

• Take advantage of aluminum’s intrinsic properties

• Increase efficiency or sustainability

Opportunity: to increase sustainability by using aluminum and taking advantage of the upcoming east halls renovation

East Halls Built over 60 years ago in the 1950s

Comprised of 15 buildings, ranging in size,layout, and energy usage

Last year’s East Halls energy usage data shows that all fifteen halls used a total of 5.1 million kWh of energy, with an average energy per building of 339,836 kWh

Hastings Hall (average building assumption)

A look at a recent energy consumption will give us an estimation as to how much energy our solution will need to save over the course of its lifetime

Bigler Brumbaugh Curtin Fisher Geary Hastings McKean Packer Pennypacker Pinchot Snyder Sproul Stone Stuart Tener0

50,000

100,000

150,000

200,000

250,000

300,000

350,000

400,000

450,000

500,000

Energy Usage of East Halls By Building

Halls

Energ

y U

sage (

kW

h)

2012-7 (Jan-12)

2012-8 (Feb-12)

2012-9 (Mar-12)

2012-10 (Apr-12)

2012-11 (May-12)

2012-12 (Jun-12)

2013-1 (Jul-12)

2013-2 (Aug-12)

2013-3 (Sep-12)

2013-4 (Oct-12)

2013-5 (Nov-12)

2013-6 (Dec-12)

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

Hastings Hall Energy Usage 2012

Energ

y U

sage (

kW

h)

The opportunity at hand… Customer Needs

• Students

• Not enough natural lighting in dorms

• North and south facing

• OPP

• Increase sustainability

• Increase attractiveness of living area

• Decrease energy consumption

• Implement student ideas

• Alcoa

• Expand market and advertise products

• “Mine” ideas

Who does this project affect?• Stakeholders

• Alcoa

• Penn State OPP

• Students/RAs

• Construction contractors

• Legal Departments

• Researchers

• Environmental groups

• Waste Management

• Local Centre County residents

• Local businesses

Project Guidelines• Efficiency/ Sustainability

• Must use less energy than previous solutions

• >60.8 kilowatt-hours

• Marketability

• Feasible implementation within 5 years

• Cost-Effective

• Cost of design < cost of electricity saved from design

• Safety

• Must meet OPP safety codes

Process Interaction: Systems Diagram

Objective TreeEast Halls Renovation

Efficiency/Sustainability

Cost-effective

Cheap

Materials

Energy consumption

Safe

Durable

Marketability

Aesthetically Pleasing

Originality

Modern

Ease of implementation

Installment

Calculating Weight using AHP

Table 1. Weight MatrixSpecificatio

nEnergy Efficient

Marketable

Cost Efficient

Physical Durability

Safety

Longevity

Row Total Weight

Energy Efficient 1.0 1.3 1.0 0.5 0.5 2.0 6.33 0.14

Marketable 0.8 1.0 2.0 0.5 0.5 2.0 6.75 0.15

Cost Efficient 1.0 0.5 1.0 0.3 3.0 3.0 8.83 0.19

Physical Durability 2.0 3.0 3.0 1.0 0.5 1.3 10.83 0.23

Safety 2.0 2.0 0.3 2.0 1.0 3.0 10.33 0.22

Longevity 0.5 0.5 0.3 0.75 0.3 1.0 3.35 0.07

TOTAL 46.43

Weighted Objective TreeEast Halls Renovation

Efficiency/Sustainability.50

Cost-effective.30/.15

Cheap1/.15

Materials1/.15

Energy consumption.50/.25

Safe.20/.10

Durable1/.15

Marketability.50

Aesthetically Pleasing.25/.125

Originality.50/.0625

Modern.50/.0625

Ease of implementation.75/.375

Installment1/.50

Brainstorm Ideas

Option 1 Option 2 Option 3

Brainstorm Ideas

Option 4 Option 5 Option 6

Imagine...aluminum

Brainstorm Ideas

Option 7 Option 8

Similar to option 6 with filtration system

Evaluate Ideas

   Selection Criteria

Side Paneling

Aluminum Roofing

Elevator Cages

Handicap

Ramps

Trash Deposito

r

Gutters Light Reflectors

Rain Drainage System/

FilterEnergy Efficient

+ 0 + - - 0 + +

Marketable + + 0 - - 0 + +Cost-Efficient + 0 - + - 0 + 0

Durability + + - + - 0 + 0Safety + + + + 0 0 + +

Longevity + + 0 0 0 0 + +Pluses 6 4 2 3 0 0 6 4Sames 0 2 2 1 2 6 0 2Minuses 0 0 2 2 4 0 0 0Net 6 4 0 1 -2 0 6 4Rank 1st 2nd 4th 3rd 5th 4th 1st 2nd

Continue Yes Yes No No No No Yes Yes

Table 2. Concept Screening

Evaluate IdeasTable 3. Concept Scoring

Analysis• The light reflectors were chosen due to their feasible implementation.

• Their simplistic design makes them durable and sustainable

• They had the highest rate of return on the investment

• Light reflector maintenance is easy to learn

• Design can be retrofitted to fit different sized areas

• Available in depths up to a maximum projection of 30 inches (762mm) and a maximum span of 72 inches (1828mm)

• LEEDs certified in three categories

• Materials & Resources-Recycled Content

• Energy & Atmosphere – Optimize Energy

• Performance and Indoor Environmental Quality – Daylight and Views

Prototype Construction

Fig. 1 Without Shelves

Prototype Construction

Fig. 2 With Shelves

Prototype Construction

Fig

. 3 In

div

idu

al Lig

ht

Sh

elf

Prototype Construction

Fig. 4 Future of East

Prototype Construction

Fig. 5 InLighten Light Shelves

Prototype Construction

Fig. 6 InLighten Light Shelves

Design Solution• Energy efficient design

• Implementation meets OPP deadlines for East Halls Renovations

• Meets OPP safety Codes

• LEEDs certification accredits sustainability of product

• $14,000 to retrofit 1 building (140 rooms at $100 each)

• Over 50 years:

• $1.5 million spent at 9 cents kw-h (1 building average)

• 6.1 ft width for avg. window (saves $10 per foot)

• $427k saved over 50 years

• Break-even point after 5 years

Gant Chart

ReferencesPhoto Credits1. http://c2ccertified.org/images/product_images/Alcoa.jpg

2. http://www.scielo.br/img/fbpe/jbchs/v11n3/n3a7f1.gif

3. http://onwardstate.com/wp-content/uploads/2013/02/east-halls.jpg

4. http://www.psu.edu/sites/default/files/styles/landing_page_focus_245_170/public/AC_colleges.jpg

5. http://www.santorobuilding.com/santoro-images/construction/construction-management-2.jpg

6. http://www.yorkproperty.com/images/C21.jpg

7. http://66.147.244.229/~colonic4/blog/wp-content/uploads/2011/08/metal-roofing1.jpg

8. http://www.lift-report.com/Bilder/LR_5_04_22e//Bild1.jpg

9. http://www.reddteam.com/wp-content/themes/redd/category_images/universal-wheelchair-ramp-system.jpg

10. http://thecompactorguy.com/images/article_photos/53.jpg

11. http://www.kawneer.com/kawneer/green/en/images/img-inlighten-info3-main.jpg

12. http://www.opp.psu.edu/services/energy/energy-usage

13. http://www.alcoa.com/global/en/products/product.asp?prod_id=1852&Product=&Category=&Query=inLighten&page=0

14. http://www.kawneer.com/kawneer/north_america/en/product.asp?cat_id=1344&prod_id=1852

15. http://www.alcoa.com/aap/north_america/catalog/pdf/specifications/ReynobondEngProperties.pdf

16. http://www.hfs.psu.edu/housing/housing/residence-areas/bigler-curtin-geary-packer.cfm

Questions?