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    Star Innovation Center passive factory project

    Extension + refurbishment
    • Building Type : Factories
    • Construction Year : 1970
    • Delivery year : 2016
    • Address 1 - street : Colombo 0000 COLOMBO - KATUNAYAKE, Sri Lanka
    • Climate zone : [Am] Tropical Monsoonal
    • Net Floor Area : 3 675 m2
    • Construction/refurbishment cost : 2 400 000 €
    • Cost/m2 : 653.06 €/m2

    Certifications :

    • Primary energy need :
      344 kWhpe/m2.year
      (Calculation method : Other )
    Energy consumption
    Economical buildingBuilding
    < 50A
    A
    51 à 90B
    B
    91 à 150C
    C
    151 à 230D
    D
    231 à 330E
    E
    331 à 450F
    F
    > 450G
    G
    Energy-intensive building
    The Star Innovation Center is a product development facility located outside of Colombo in Katunayake, Sri Lanka. Intended to be a global model for the entire garment industry, the project sets a new high bar for sustainability, energy efficiency and worker comfort.

    By choosing to renovate an obsolete building to Passive House standards, the project dramatically reduces the waste, carbon emissions and fossil fuels typically required for demolition and a new build, and promotes the client’s commitment to maintain high standards in social, environmental, ethical and safety compliance within the global fashion industry.
    It is the first Passive House project in South Asia, and one of only two certified Passive House factory buildings in the world. Annual energy consumption will be cut by over 60% compared to a conventional “efficient” modern industrial building. and a payback period of 6-7 years is expected. This project also includes cutting-edge sustainable technologies, like a “heat pipe” system that reduces dehumidification energy use by 90%.

    The project is a pioneer in applying Passive House technology to a tropical monsoon climate, which features steady warm temperatures year round but extremely high relative humidity. Careful design and engineering of the building systems and enclosure ensures that workers enjoy year-round comfort in a workspace that provides abundant natural light, low humidity, filtered fresh air, and maintains temperatures near a constant 24°C (77°F).

    Because the Star Innovation Center is a milestone in industrial energy efficient retrofitting in a tropical monsoon climate, the Passive House Institute awarded the EnerPHit Pilot Project Certification. Thorough testing of the airtightness and remote monitoring of the ongoing energy usage provide quantitative confirmation of the building performance, confirming projected operational cost savings for the client and vastly upgraded workplace environmental standards for the employees.
    From the outset the idea was to assemble an integrated project team including local architects, engineers, fabricators and builders to encourage technology transfer and demonstrate the feasibility of high performance building in the region. By promoting the project and inspiring the local building industry there is a clear path to both reducing carbon emissions and putting an end to worker “sweatshop” conditions.

    See more details about this project

     https://passivehouse-database.org/index.php?lang=en#d_6030

    Photo credit

    Copyright Ganidu Balasuriya - https://www.archdaily.com/photographer/ganidu-balasuriya

    Contractor

      Star Garment Group / Komar Brands

    Construction Manager

      Jordan Parnass Digital Architecture

    Stakeholders

    • Steven Winter Associates

    • Passive House Institute

      Dragos Arnautu email: dragos.arnautu@passiv.de address: Rheinstrasse 44-46, 64283 Darmstadt, Germany

    • Vinod Jayasingh Architects

    Owner approach of sustainability

    By choosing to renovate an obsolete building to Passive House standards, the project dramatically reduces the waste, carbon emissions and fossil fuels typically required for demolition and a new build, and promotes the client’s commitment to maintain high standards in social, environmental, ethical and safety compliance within the global fashion industry.

    Architectural description

    This building has an exposed steel structure with few partitions. The upper floor is the main production area and features a broad column-free space. The lower area perimeter is pulled back up to a full bay in some areas.Cultural and Aesthetic Goals• Provide mix of treated and untreated interior and exterior program spaces.• Maintain exposed steel structure design intent.• Create a regional model and local experience for future high performance development.

    Energy consumption

    • 344 kWhpe/m2.year
    • 680 kWhpe/m2.year

    • 120 kWhfe/m2.year

      • The following values represent the renovated building's performance:
      Cooling and dehumidification demand: 183 kWh /(m2a )
      Cooling load: 21 W/m2
      Calculated according to PHPP

      The primary energy demand of 344kWh/m²a includes cooling, dehumidification, auxiliary and household electricity as well as domestic hot water, and is divided as below:

      - 27% cooling (sensible)
      - 20% Lighting
      - 20% Sewing Process Loads
      - 16% PCs / Office equipment
      - 7% Cooling (latent)
      - 6% Aux. elec & Summer ventilation
      - 4% Domestic Hot Water

      A breakdown of the energy consumptions before the renovation is not available. Only the final (260 kWh/m2a) and primary energy (680 kWh/m2a) demands could be verified and presented.

    • 260 kWhpe/m2.year

    Envelope performance

      Exterior wall: U-value = 0.329 W/(m2K)
      Basement floor / floor slab: U-value = 5.795 W/(m2K)
      Roof: U-value 0.182 W/(m2K)
      Frame: Gutmann F50, 1,81
      U w-value = 1.81 W/(m2K)
      Glazing: U g-value = 1.2 W/(m2K) - g -value = 22 %
      Entrance door: U d-value = 1.14 W/(m2K)

    • 1

    Real final energy consumption

    • 110
    • 2 018

    Systems

      • No heating system
      • Individual electric boiler
      • Fan coil
      • Double flow heat exchanger
      • Solar photovoltaic
    • 10 %

      • 5 units with heat and humidity recovery
      Average for all 5 ventilation units:
      72% heat recovery
      70% humidity recovery
      0.7Wh/m³ electric efficiency
      Manufacturer: DESICCANT ROTORS INTERNATIONAL PVT LTD., ARCTIC INDIA HOUSE, 20, RAJPUR ROAD, DELHI - 110054 (INDIA)

      Additional cooling and dehumidification (after the ERV) is beeing done via fan coil units which cool the air to a very low temperature in order to dehumidify it. The air is then reheated using Heat pipes with Heat Recovery. The heat pipes work in collaboration with the solar pannels on the roof which save costs in comparison with the classic electrical reheat systems.


      Generation of renewable energy: 48340 kWh/a which is 19 kWh /(m2a) based on the projected area of 2549 m2
      Renewable energy demand (PER demand according to PHPP): 164 kWh /(m2a) based on the used area on cooling/dehumidification installation, domestic hot water, household electricity and auxiliary electricity

    GHG emissions

    • 70 KgCO2/m2/year

      • CO2 factors GEMIS 4.6

    Health & Comfort

    • Careful design and engineering of the building systems and enclosure ensures that workers enjoy year-round comfort in a workspace that provides abundant natural light, low humidity, filtered fresh air, and maintains temperatures near a constant 24°C (77°F).

      Because the Star Innovation Center is a milestone in industrial energy efficient retrofitting in a tropical monsoon climate, the Passive House Institute awarded the EnerPHit Pilot Project Certification. Thorough testing of the airtightness and remote monitoring of the ongoing energy usage provide quantitative confirmation of the building performance, confirming projected operational cost savings for the client and vastly upgraded workplace environmental standards for the employees.

    Product

      Gutmann F50, 1,81

      Gutmann

    • Finishing work / Exterior joinery - Doors and Windows

      • Passive house curtain wall system with 50 mm or 60 mm face width.

      Passive house viability in accordance with IFT directive WA-15/2, in combination with the required service ability
      Identical profiles for mullion and transom, straight cutting, no transom profile notching: minimal off-cuts, rational manufacture and installation
      - Joint connector technology for gap-free connection between transom and mullion
      - Identical width of inner glass gaskets at mullions and transoms
      - Low edge radius for visually flawless transom connection
      - Maximum glass loads up to 600 kg, depending on wind loads

      This product was well accepted.

    Construction and exploitation costs

    • 2 400 000 €

    Urban environment

    The project is located in a low-rise industrial park adjacent to the airport. 

    Trees provide some shade but the majority of the building is exposed to the sun.

    Building Environmental Quality

    • indoor air quality and health
    • consultation - cooperation
    • acoustics
    • comfort (visual, olfactive, thermal)
    • energy efficiency
    • renewable energies
    • building process
    ??It is the first Passive House project in South Asia, and one of only two certified Passive House factory buildings in the world. Annual energy consumption will be cut by over 75% compared to a conventional “efficient” modern industrial building. This project also includes cutting-edge sustainable technologies, like a “heat pipe” system that reduces dehumidification energy use by 90%.
    The project is a pioneer in applying Passive House technology to a tropical monsoon climate, which features steady warm temperatures year round but extremely high relative humidity. Careful design and engineering of the building systems and enclosure ensures that workers enjoy year-round comfort in a workspace that provides abundant natural light, low humidity, filtered fresh air, and maintains temperatures near a constant 24°C (77°F).

    Contest

    Green Solutions Awards 2019 - Buildings

    Author of the page

  • C Camille Sifferlen
    Camille Sifferlen

    Project Manager

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    Contest

    Green Solutions Awards 2019 - Buildings