Bob meets with Peter Merianos and the crew from Coastal Heating and Air Conditioning who are fabricating the AC ductwork on site. With the Kenmore air handler already installed in the attic, the crew begins assembling the ductwork using five-foot lengths of pre-crimped sheet-metal ducting as the basic material. The sections snap together and are secured with sheet-metal screws and foil tape. To add a new line off the main trunk, the crew cuts a hole into the the trunk with a special tool. A starting collar from which the new line will extend is then inserted into the hole. The ductwork is insulated using vinyl wrap, which is a one and a half-inch vinyl-coated fiberglass blanket.

Bob walks through the Manhattan Brownstone floor-through apartment with project manager Chris Vila, looking first at the ductwork that has been run in the ceiling for the forced air heat. He then joins John McEvoy of Thorough Construction for a look at the drop ceiling installation they will be using to hide the ductwork and mechanicals in the ceiling. This Chicago bar system allows the crew to hang a perfectly level drywall ceiling instead of following the uneven pattern of the existing joists. First an anchor is screwed into the joists. A pencil rod is then fitted into the hole in the anchor and bent to hang from the joist. A lasar level marks the exact position for the kelly clips that will hold the main stays or block irons in place. The Chicago bar is then clipped to the block irons with a spaghetti clip to create a grid for the new drywall. The drywall will be screwed directly into the suspended Chicago bar.

Bob joins Paul Costello and Lou Mazzini in the old dairy building to discuss the SpacePak high velocity hydro air HVAC system that's being installed in both the house and dairy. The system will provide both heating and cooling. In the winter a boiler delivers hot water to coils over which air is drawn. This heated air rises and is distributed at high velocity through plenum ducts running around the perimeter of the structure and on to room outlets through to 2" diameter sound attenuating tubing. The systems uses insulated fiberglass ducts which are coated on the inside to prevent mold and other growth. The system creates a pressure center in the room with a differential of two degrees between floor and ceiling. Cooling is accomplished by the same system only the air passes over different coils cooled by a refrigerants from 5-ton American Standard condensers situated behind the dairy. Domestic hot water will be provided by a very efficient indirect hot water system. The SpacePak system is particularly well-suited to restoration/renovation projects where space for ductwork is at a premium.

Bob looks at the HVAC units in the basement of the Medford home. There are 5 SpacePak units that, with their state-of-the-art foil-wrapped ductwork, deliver conditioned air at high speeds throughout the house. The brand new RBI gas fired boiler provides the BTUs�the hot water�to the five different zones to heat the house and the hot water heater is a new John Wood water heater.

Bob meets with Alex Alexander to check out the new gas furnace, then takes a trip to the shop to see how Alex uses a computerized plasma cutter to cut out the ductwork.

Bob recaps the work done so far in the basement remodeling project in Melrose, Massachusetts, converting an old cluttered basement into a playroom for the homeowners' two children. A perimeter drain was dug and a triple pump installed in the basement to prevent any moisture problems. A vapor barier was also put in place over the foundation walls to channel water into the drainage ditch. A waterproof coating was applied to the concrete floor as well. Old plumbing fixtures were updated and the oil tank, heating ducts, and kitchen drain were all moved to make way for the playroom. The water tank was replaced with an on-demand hot water system that is more efficient. A Trane furnace and air filtering system were installed to maintain air quality in the home, which should help combat colds, allergies, and other illnesses. The old windows were also replaced with Energy Star-rated windows.

Jeff Akers of The Air Authority explains how heat is recovered from the water that flows to each of the units in the high-rise apartment to fuel the heat pump in this Miami condo. The water is received, the heat is rejected from the water and into the pump, then the water is sent back to the water tower for cooling and redistribution. The unit is housed in a utility closet that will be concealed by a louver door to provide the only air return for the HVAC system. The ductwork in the building must be fiberglass or metal, rather than flex, and is covered with mastic at all seams to prevent leakage as mandated by Florida energy policy. Akers then shows Bob the Energy Star thermostat that operates without wires or mercury, plugging right into the system at the wall. The thermostat features a five-minute delay to prevent short-cycling and resulting damage to the system. It also has a fan-only setting for cooler days. All settings can also be locked to avoid tampering, a feature that is critical for a vacation getaway that is frequently unoccupied.

The crew from The Ironhouse joins Dan DeMagistris of Heat-N-Glo to install the fireplace. The fireplace selected for the dining room is taller than it is wide, which makes it look like a traditional Count Rumsford fireplace. Because of the proportions it has a raised burner for aesthetic purposes to bring the flame up to fill out the area. The fireplace can be mounted right into the opening as it only requires a one-half-inch clearance. The diningroom fireplace is positioned in a framed area contiguous to the garage with the ductwork traveling through the wall into the garage, taking a sharp turn, then passing out through the front wall of the house. The fireplace is vented with an eight-inch direct vent double-walled pipe. The exhaust is carried through the pipe to the outdoors and fresh air for combustion is drawn from the outside into the combustion box. This is a totally radiant fireplace. The heats passes into the room through the glass panel. There is no convection system.

This home will be about 50 percent more energy efficient than a typical Florida home. Bill Zoeller, a consulting architect with Mercedes, has changed specifications and products to make this home as efficient as possible. First, there are low-e insulated windows that will block about 70 percent of solar heat gain. The solid concrete walls are insulated with one inch of polyisocyanurate insulation board that is applied directly to the concrete walls. This insulation, which has the highest R-rating of any insulation on the market, will block the heat buildup during the day from reaching inside the home. In addition to Energy Star-rated appliances, the air conditioning ducts have been dropped to the attic floor and surrounded with insulation to reduce the efficiency challenge presented by running ducts through hot, Florida attic space. This technique was developed in California and is now part of their energy code. Dropping the ducts, wrapping them in insulating foam, and covering them in a polyurethane insulating foam improves efficiency and blocks condensation buildup in this humid climate. Lance Keeling, of BioBased Systems, explains that this foam insulation is soy-based but converted through chemical reaction to become completely inert to eliminate organic matter that could promote mold or mildew growth. This chemical is pressurized and sprayed with a hose to form a foam that sets up in moments. This foam provides a 4.8 R-value per inch but with a desired value of 6 from this part of the insulation, must be sprayed at a 1 1/2-inch thickness. This completely encloses the ducts to prevent any air loss and resulting moisture buildup. If a homeowner were to attempt covering ducts with commercial insulation, potential moisture buildup could be produced causing mold and moisture growth. The key with this technique is that it completely seals the ducts to prevent air loss and resulting moisture buildup. Zoeller and Keeling predict a savings of $100 per month in operating expenses due to the energy-efficient measures employed. Zoeller shows Bob the 14 SEER (seasonal energy efficiency ratio) heat pump air conditioning unit installed to cool the house. It is about 40 percent higher in efficiency than a traditional air conditioning unit. While initially more expensive, a smaller unit can be installed due to the high-efiiciency of the overall home.

Here's another great tip from BobVila.com. Whether you re building a whole house or just adding a new bathroom, one of your first decisions has to be how you re going to heat the new space. According to the U.S. Department of Energy, radiant heat is more efficient than baseboard or forced air systems. Rather than just blowing hot air around the room in bursts, radiant systems slowly and steadily charge the floor with heat, keeping it where you want it, longer. Hydronic, or water-circulating, radiant systems are best for new construction or large additions. They come in many forms, for installation just below the subfloor between the joists, directly under tile or hardwood flooring, or even inside a concrete floor slab. Where you only need to heat a small space, like a bathroom, electric radiant is an easy luxury option. Electric radiant mats can be installed directly under tile and are ideal over a concrete subfloor. Set the timed thermostat to turn the system on only when you ll be using the room, like the morning when you shower, and it ll use less than 15 cents of electricity per day. This way, you don t have to make room for ductwork or baseboard units when you add a bathroom. On a cold winter morning, your toes will thank you for choosing radiant heat! Find out more at BobVila.com: The ultimate home improvement web site! BobVila.com 2008