2025.07.18 |
To improve energy performance and overall maintenance, an expansive network of warehouses sought QEA Tech’s services to conduct a comprehensive envelope audit for its facilities. With numerous facilities globally, the client faces the ongoing challenge of maintaining a highly distributed network of buildings. Many of these facilities are leased, with terms that require landlords to address infrastructure and envelope issues. However, considering each facility spans hundreds of thousands of square feet, physical inspections to determine envelope issues and energy loss is a challenge.
The client was seeking a scalable solution to pinpoint issues and areas of energy loss across building envelopes, allowing for targeted, cost-effective retrofits. Due to the importance of operations inside the warehouses, issues such as moisture infiltration and excessive energy loss could be catastrophic to the business and are critical to mitigate. Given these circumstances, the client wanted a cutting-edge, innovative solution that could deliver detailed insights without disrupting operations.
Why QEA Tech? Speed, Scale, and Precision
The client selected QEA Tech for our unique ability to provide precise, quantified analysis for the entirety of the building envelope while being fast and scalable. Drone operations necessary to collect data for analysis took only a few hours for each facility. QEA Tech provides exact data on energy loss, predicts energy savings for each envelope component, and diagnoses a range of envelope issues down to inches, enabling us to deliver customized, ROI-driven retrofit action plans. Gaining this level of unparalleled detail in a scalable manner enabled the client to make informed decisions that save energy, reduce emissions, and improve operational resilience.
Facility Example: A Deeper Look at Envelope Performance
Coordinated Execution Across an Expansive Facility
A detailed pre-flight plan was developed to guarantee comprehensive coverage of the >1 million square-foot building. Our team captured >6200 high-resolution thermal and visual images of the building and >4500 additional data points necessary for accurate analysis. This data was then analyzed by our proprietary AI software and Building Science team.
Insights into Energy Savings
QEA Tech’s findings revealed significant inefficiencies across the building envelope, with various opportunities to improve energy performance. Key findings include:
- 59% of annual energy loss in megawatt-hours (MWh) can be saved if the envelope is upgraded to meet building code.
- >$400,000 USD in annual energy costs can be avoided if the envelope is retrofitted to meet building code.
- 40% reduction in annual tons of carbon dioxide equivalent (tCO2e) is possible if the envelope is improved to meet building code.
The roof emerged as the weakest link in the building envelope, performing at only 50% of building code guidelines. Energy loss throughout the roof was largely caused by:
- Thermal bridging
- Air leakage
- Failing insulation
- Connections between the roof and exterior walls/ parapets
Proportion of Energy Loss Caused by Various Roof Issues
Air Leakage: A Leading Cause of Energy Loss Throughout the Envelope
In general, air leakage was a primary reason for energy loss across the warehouse, effecting all building envelope components (walls, windows, doors, and the roof). Air leakage through the building envelope refers to the unintended flow of air in and out of a building due to gaps, cracks, or openings in its walls, windows, doors, and roof. This leads to significant energy loss, increased heating and cooling costs, and reduced indoor air quality. Instances of air leakage that were of most concern to the client were cases of air leakage around garage and docking doors, and air leakage from skylights.
A Targeted Retrofit Plan: Smart Solutions for High-Impact Areas
QEA Tech created a tailored retrofit plan focused on key areas of concern.
Air Leakage from Skylights
QEA Tech identified 316 skylights across the warehouse and determined that air exfiltration around skylights resulted in 490,236 kWh/year of energy loss and $85,000 USD/ year in energy costs. In order to cost-effectively reduce this energy loss QEA Tech recommended the following low payback solutions:
Silicone Sealant – Designed to create tight barriers around skylights. It is flexible, durable, and provides strong adhesion to various materials.
Payback Period: 3 months
Multi-Surface Sealant and Adhesive – Designed to bond and seal to various surfaces without the need for priming.
Payback Period: 3 months
Weather Tape – Foam strips with adhesive backing that can be applied directly to the skylight frame. This provides a seal against air infiltration and is suitable for mild to moderate weather conditions.
Payback Period: 5 months
Flashing Tape – A waterproof, self-adhesive tape designed to create an airtight seal between the skylight and roof.
Payback Period: 8 months
Air Leakage from Garage and Docking Doors
The warehouse has 59 doors, 44 of which are equipped with inflatable shelters. QEA Tech discovered that many of the inflatable shelters did not fully seal, resulting in significant energy loss due to uncontrolled air infiltration.
A single 10-inch square hole in a dock shelter resulted in 156,017 kilowatt-hour (kWh) per year of energy loss, leading to an annual cost of $25,000 USD.
To tackle this issue, QEA Tech recommended that the client applies either one of the following solutions to garage and docking doors with unsealed inflatable shelters:
- Air curtains – These are devices that blow a controlled stream of air across an opening to the other side to create an air seal. This helps to contain heated or conditioned air inside a building.
- Weather stripping seals – These are materials that are wrapped around doors to keep out air and debris. They are a cost-effective, long-lasting solution for sealing air gaps, helping to maintain energy efficiency and comfortable indoor environments.
- Threshold seals – These are strips of rubber that seal the gap between a door and the door frame or floor. Threshold seals create airtight barriers, keeping energy costs down and helping to prolong a door’s life.
A Clear Path to Energy Efficiency and Operational Resilience
QEA Tech’s detailed envelope analysis provided the client with the precise data and insights needed to take informed action, allowing for the implementation of cost-effective, targeted retrofits. Our use of drones and AI to collect and analyze data enabled us to easily scale across the large facility, provide key insights efficiently, and avoid disruptions to important business operations. By quantifying energy loss, pinpointing specific issues, and offering a customized, practical retrofit roadmap, QEA Tech’s innovation driven approach is enabling the client to tackle crucial issues related to energy loss and physical risks, ensuring the facility remains in optimal condition for future operations.
Interested in better understanding the performance of your building envelope? Contact QEA Tech for a free quote on our data-driven building envelope audit.
