by John Crowley | Apr 30, 2025 | Uncategorized
Industrial: Aiming High Twice a day, Mike Clark drives past Tinker Air Force Base in Oklahoma City as he goes to and from his job at Matherly Mechanical Contractors LLC. The sprawling base has been a part of the city for so long that many commuters may not pay much attention. But Clark always notices. That’s because, for Clark, the 66-year-old vice president of operations at Matherly, Tinker AFB isn’t just a bunch of military planes and hangars. It’s been an important Matherly client for a long time. Matherly Mechanical employees install painted ductwork on the roof of a hangar at Tinker Air Force Base in Oklahoma City. The $3-million contract had Matherly replacing four 100,000-cfm blowers; fabricating and installing large, round, industrial exhaust ductwork; and installing a new filter bank. “They know us,” Clark says. “They know our work.”Many area companies could say the same about Matherly Mechanical. It was founded by Jack Matherly in 1962. With an initial headcount of just four workers, today the third-generation industrial and commercial HVAC, architectural, plumbing, pipefitting and fabrication company has 200 employees and is one of the larger sheet metal contractors in Oklahoma. The industrial exhaust ductwork at Tinker Air Force Base was made of 12-gauge metal.Since the 1960s, Matherly has fabricated and installed numerous HVAC systems and components at Tinker, which has long been the site of military aircraft maintenance, repair and refurbishment projects.Tinker Air Force Base dates to 1941, when it was established as the Midwest Air Depot. It was the site of a Douglas Aircraft Co. factory, producing military transport aircraft during World War II. Workers at an on-site industrial plant repaired B-24 and B-17 bombers. In 1942, it was renamed Tinker Field after Clarence L. Tinker, the first Native American U.S. Army major general. Following the founding of the Air Force in 1947, it became a U.S. Air Force Base. A Major EmployerToday, Tinker is a major force in Oklahoma’s economy, with an estimated annual impact of over $3.5 billion, according to government officials. Located just five miles from downtown Oklahoma City, it encompasses 5,000 acres and has more than 700 buildings. The largest single-site employer in the state, more than 26,000 people (military and civilian) work at the base. The Navy and Department of Defense also have major presences there. Matherly’s most recent work at the base was a $3-million ventilation project at a hangar at the base’s southeast corner. The sheet metal contractor was hired to replace four 100,000-cfm blowers; fabricate and install large, round, industrial exhaust ductwork; and install a new filter bank. The ventilation upgrades were needed because the hangar is used for aircraft stripping and repainting, which can generate toxic fumes. Ventilation is critical. The filter banks Matherly made for Tinker Air Force Base are designed to hold three-stage, 24- by 24-inch filters. “It has to have full-blown ventilation, plus the hangar’s cross flow ventilation,” Clark says. “It’s push-pull ventilation. So one side’s bringing the air, and they’re kind of bringing it up high, probably 30 to 40 feet. Then it cross flows down to the filters on the ground.”And those filters are large, Clark added: (350) three-stage, 24-by-24 inches. They feed into large, ducted exhaust plenums outside the hangar. The ductwork was all negative 10-inch static pressure, made of 12-gauge metal. Discharge duct was mostly 70-inch round, but some went up to 84 inches, Clark says. Big FansThe 100,000-cfm fans Matherly installed had 5.5-inch external static pressure and 150-horsepower motors. Each weighed up to 15,000 pounds, driven by variable frequency and variable speed drives. Matherly workers also rebuilt an existing plenum at the hangar. The ductwork — all 35,000 pounds — was manufactured at Matherly’s sheet metal shop, located about 1.5 miles from the base. Fabrication took approximately 3,100 hours, plus another 200 hours for drafting work in the shop. Eight workers were assigned to the project.A Matherly Mechanical worker inspects large industrial exhaust ductwork before it’s installed at a hangar at Tinker AFB in Oklahoma City. Duct ranged from 72 to 84 inches in diameter. Installation required extensive coordination, Clark says. “It was all done by airlift and crane because it’s too big,” he says. “There was nothing you could install by hand on this.”Pressure testing was also required. The duct had to tie into the existing plenum and bracing was necessary.“Because we went from 6-inch, negative 10, we had to put these braces on 20-inch centers,” Clark says. “They were four-by-four hat channels. Those all had to be attached to the existing plenum. Then we had to pressure test all that to make sure that when we fasten all those channels and the seams that we met the SMACNA duct air leakage testing standards.”Altogether, field installation took around 8,000 hours. Clark says he likes working on projects at the base, although Air Force work isn’t for everyone, he adds. They’re demanding clients and don’t tolerate delays. “It’s a tough place to work,” he says. “Air Force officials are there every single day. The standards are tougher, more stringent. This is not a job for the weak to take on because of the size of it. They can’t be down for too long because the Air Force has to be cranking those planes out constantly. We didn’t have a whole heck of a lot of time to do it. It all had to be prefabbed, and we had to design it to where it all fit in place perfectly.”But that kind of scrutiny doesn’t bother Clark. “We had no issues on this job,” he says. And unlike some projects where owners can be slow to pay — dragging it out for 60, 90 or more than 120 days — the Air Force pays promptly. “They usually pay in approximately 30 days.”
by John Crowley | Apr 30, 2025 | Uncategorized
HVAC: Understanding Refrigerant Transitions The HVAC industry is standing at the edge of a major shift — one that will change the way contractors handle refrigerants, service equipment and train technicians. The transition to low-global-warming-potential (GWP) refrigerants isn’t just a suggestion; it’s a reality driven by regulatory mandates.“The industry has known this was coming for years, but now it’s here,” says Paul Dombrosky, Refrigerant Manager for Service Operations at CHVAC North America. “Contractors who prepare now will be ahead of the curve. Those who don’t will be scrambling when these refrigerants become the standard.”Here’s what HVAC contractors need to know and how they can get ahead of the coming refrigerant shift.Why the Transition Is HappeningAt the heart of the change is the American Innovation and Manufacturing (AIM) Act, which mandates a phasedown of hydrofluorocarbons (HFCs) in favor of lower-GWP refrigerants. This legislation aligns with the global Montreal Protocol Kigali Amendment, which sets aggressive reduction targets for HFC production and consumption.“The AIM Act isn’t a future problem; it’s happening now,” Dombrosky says. “As of Jan. 1, common refrigerants like R-410A, R-404A and R-134a are no longer permitted in new equipment.”That means contractors need to adapt to A2L refrigerants, which are mildly flammable but significantly better for the environment.How This Affects HVAC ContractorsContractors must prepare for changes in:New equipment installations: In 2025, most new air-conditioning and refrigeration systems must use low-GWP refrigerants.Servicing existing systems: While current HFC-based systems can still be repaired, reclaimed refrigerants will be required for servicing by 2028.Component compatibility: New refrigerants mean new components, tools and safety measures.“If you’re still using legacy refrigerants, your costs are going to skyrocket,” Dombrosky warns. “Refrigerant supply will be tighter, and prices will continue to rise. Contractors need to have a long-term game plan.”How to Prepare for the Refrigerant TransitionAfter understanding the background on why the change is happening and the related business impacts, the next step is taking action. HVAC contractors can follow these guidelines from Dombrosky to ensure a smooth transition.1. Train Your Technicians on A2L Refrigerants. One of the biggest changes with the new refrigerants is their mild flammability, which requires updated safety protocols.“Technicians can’t treat A2Ls the same way they did R-410A,” Dombrosky says. “They need to understand proper handling, leak detection, ventilation and evacuation procedures.”HVAC businesses should invest in A2L certification courses to ensure their teams are trained before these refrigerants become widespread.2. Upgrade Tools and Equipment. Contractors will need A2L-compatible tools, including:Refrigerant recovery machines specifically designed for A2LsManifolds and gauges that can handle the new pressure and flammability concernsLeak detectors calibrated for A2L refrigerants“Your existing manifolds and scales will still work, but some digital manifolds may need firmware updates,” Dombrosky notes. “And leak detection becomes even more critical with A2Ls.”3. Plan for Rising Refrigerant Costs and Supply Constraints. With the phase down of HFC production, contractors should expect supply shortages. Some states, like California, New York and Washington, may even restrict refilling with virgin refrigerants altogether. “This isn’t just about new installations; it’s about how you’re going to service existing customers,” Dombrosky says. “If you don’t have a plan for refrigerant recovery and reuse, you’re going to be at a disadvantage.” He recommends that contractors:Stock up on reclaimed refrigerants to prepare for rising costs.Educate customers about retrofit options for existing systems.Adopt leak prevention practices to extend system life and reduce refrigerant waste.4. Understand the New Compliance Deadlines. Key transition dates for these refrigerant changes include:Jan. 1, 2025 — R-410A, R-404A, and R-134a banned in new equipment.Jan. 1, 2026 — VRF (Variable Refrigerant Flow) systems must switch to low-GWP refrigerants.Jan. 1, 2028 — Reclaimed refrigerants required for servicing existing systems.“Regulations will only get stricter,” Dombrosky says. “The sooner contractors align with these changes, the smoother the transition will be.”Don’t Wait Until It’s Too LateWhile the refrigerant transition presents challenges, it also creates opportunities for contractors to lead the industry forward. Those who invest in training, upgrade their tools and educate their customers will have a competitive edge over those who wait until the last minute.”This is one of the biggest shifts the HVAC industry has seen in decades,” Dombrosky says. “But if contractors get ahead of it, they won’t just survive, they’ll thrive.”
by John Crowley | Apr 30, 2025 | Uncategorized
Leading by Listening Idustry involvement can unlock valuable partnerships, project opportunities and operational excellence. Tom Martin having a conversation with contractors at the SMACNA tradeshow booth. Just ask Tom Martin Jr., second-generation president of Cleveland, Ohio-based T.H. Martin Inc., a full-service mechanical contractor with a large-scale commercial project portfolio that includes Northeast Ohio sites such as Sherwin-Williams, MetroHealth Glick Center and the Lordstown Ultium Cells plant. Martin was named president of SMACNA National last October after decades of dedication to the sheet metal and HVAC trade as an advocate, educator and connector who listens and invites everyone to the table. Tom Martin talking with SMACNA CEO Aaron Hilger.He served as chapter president of SMACNA Cleveland for 10 years, beginning in 2014, and he increased its associate membership program from five to 30. He’ll pursue this effort nationally to advance collaboration for adopting new technologies and equipment. “Our industry is relationship-driven, and our peer-to-peer engagement is really strong with a willingness to share best practices and approaches for expanding business and helping other contractors be more efficient and profitable,” says Martin, who ramped up his travel schedule to further strengthen local and national SMACNA relations. Martin has long served as a conduit for change. He was recognized in 2018 as SMACNA’s Contractor of the Year and as SMACNA’s Legislative Contractor of the Year in 2021. Martin is a savvy, fair player in ongoing lobbying efforts to reform registered apprenticeship laws and regulations, pension reform, infrastructure policies and prevailing wage enforcement legislation. His approachable demeanor and sincere interest in forwarding members’ and associates’ pathways to success make him an affable colleague, partner and friend. Tom Martin “I am making sure we are listening and offering value to everyone, and I want to understand members’ concerns, challenges and how we can help out or connect them with a peer opportunity,” Martin says. ‘We Can Offer All Of This’Martin grew up in the industry alongside his father, Thomas Martin, who started the business out of a 1985 GMC pickup truck with $5,000 for tools and equipment. Now, it’s a full-service mechanical contracting operation with a 67,000-square-foot manufacturing plant. Martin Sr. grew a reputation in Cleveland for quality service and craftsmanship. When Martin and his brother, Mike, Vice President, joined the business in the early 1990s, they continued the brand’s momentum as a premium contractor clients could trust. Tom Martin with Ben Cooley, Vice President at T.H. Martin, Cleveland, Ohio. Martin immediately got involved in the Joint Apprenticeship and Training (JATC) committee. “We were one of the biggest contractors and contributors locally, and I wanted to have a say in matters related to training, curriculum, safety and expanding opportunities for young men and women, including elective classes for our journey people,” he says. As T.H. Martin grew, so did Martin’s role in SMACNA in Cleveland. He removed barriers like transportation and expenses so team members could travel to SMACNA events. “There are so many valuable initiatives and programs going on at SMACNA National, and I pushed to ensure our contractors were privy of everything in order for them to leverage the best practices that would help them be successful,” Martin says.“We can offer all of this,” he says of SMACNA’s reach. Martin is an answer man because of his ability to listen and learn. He was and continues to be a go-to for legislative insight, labor relations information, safety and technology updates, and educational resources. He consulted on a New Horizons guide for expediting project close-outs; a report written by two Clemson University professors with the input of 21 SMACNA members. Martin is passionate about sharing proven processes and lessons-learned insight with industry members. “You learn about an area where a contractor is doing something well, such as recruitment or relations with labor partners or market recovery,” he relates. “You find out what’s working for safety or technology. Then, we take that back to our businesses and find a way to implement it.” As SMACNA president, Martin will continue to elevate the association’s education efforts. Notably, he advocates and facilitates progress in converting white papers and manuals into podcasts. Topics such as how to close out a job on time are more accessible to many when they can be downloaded and consumed as an audible. “We are getting five times the traction on educational podcasts,” he says. ‘A Ton Of Opportunities’Martin says SMACNA’s range of specialty contractors and full-service operators offer an invaluable global perspective on pressing issues, including labor relations, recruitment and retention, market recovery, regulatory challenges, and project opportunities. As a SMACNA leader, he has championed these issues, holding posts on committees including the National Contractor Manual Task Force, HVAC Steering Council, SMACNA/SMART National Market Recovery Committee, and SMACNA National Strategic Planning Task Force. “Getting involved in SMACNA to support our industry is the best thing I ever did for me, personally, and for my business,” says Martin, again pointing to collaboration. “I’m a huge advocate for partnering with other contractors locally and nationally, assisting them and generating volume to generate new customers and profit.” When SMACNA contractors connect, they win. Engaging locally and nationally can help contractors forecast, prepare, strategize, execute and manage evolving technology and economics. Aside from ongoing SMACNA initiatives, Martin’s term will also focus on attracting talent, engaging more associate members to promote vendor-industry collaboration, expanding task forces in emerging areas like AI and easing labor relations. Seth Lennon, Director of Content Development and Media Relations at SMACNA, interviews Tom Martin.Martin emphasizes that jobs in HVAC/sheet metal offer opportunities. He retraces his progression from helping his dad to working as an estimator and taking shop inventory. He progressed to project management, and now he and his brother are setting the stage for future generations of SMACNA members. “We are putting a lot of resources into recruitment and retention via social media, job fairs and educating high school guidance counselors about what a great opportunity this industry offers,” Martin says. “We also network with and educate our politicians, and when we can get in front of a candidate or a student’s parents, we talk about the financial and healthcare benefits, as well as the endless opportunity to move up and become a future leader or business owner in this industry.” Martin adds, “Our contractors have many opportunities in the M&A space, and SMACNA offers many resources and guidance for succession planning.” Regarding SMACNA associate membership, Martin says face time with SMACNA contractors will advance the adoption of technology and processes. “Moving forward in our industry, we are seeing more collaborative delivery methods,” he says. “It’s great to have a robust associate member program to assist our contractors,” he continues. “We need to understand the equipment vendors are selling and the services they provide to help us decide which direction we want to go in with regard to software or equipment.” As technology evolves, task forces within SMACNA are emerging to respond to modern business demands. “Prefabrication and modulization continues to be a trend because we must be efficient,” Martin says. “Job sites will not allow you to stockpile anymore, which forces us to be lean and prefab as much as possible.”Prefab contributes to lean principles and sustainable practices. “You can maximize as much material possible, cut to length and save time in the field — it’s all done in a lean manufacturing shop to minimize waste and maximize efficiency,” Martin says. AI is embedded in software programs and implemented as diagnostics tools, allowing instant data compilation and report delivery. Martin says contractors should leverage AI, including in areas like tool manufacturers that are tracking data on use and repair needs. “Everything is quick and easy to access for a project — the drawings, submittals, specifications, cut sheets, change orders,” he says.‘There Will Be A Change’Perennial industry challenges aside from recruitment often center on labor-management relations and market share.Martin is a strong collaborator. He says that SMART and SMACNA share a strong national alliance, and addressing in-the-weeds communications issues can begin with “low-hanging fruit,” Martin says. This could include focusing on a market to convene the parties for recruitment. Everyone’s on the same team concerning attracting talent and introducing the industry’s opportunities. Martin suggests that the megaprojects that blew up headlines and fueled tremendous industry growth aren’t going away but will slow. “With the new administration, I believe there will be a change from cell battery and EV projects to data rooms, big healthcare and any type of energy and municipal work like jails and water treatment plants,” he says. Martin says there is a promise of less regulation for more expedited projects. Looking forward, he sees the potential for increased private-sector investment in large projects. In fact, there’s potential all around. “The word is opportunity,” Martin says, “and we’re going into the market resourced with SMACNA’s backing.“Be prepared, be engaged, and talk to us about your best practices and challenges,” Martin continues, “so we can succeed together.”
by John Crowley | Apr 15, 2025 | Uncategorized
Lowering Carbon Footprints In 2022, SMACNA member United Mechanical, headquartered in Rockland, Massachusetts, helped a Massachusetts pharmaceutical production facility lower its carbon footprint and increase the energy efficiency of its building. United Mechanical partners with general contractors and property managers to devise economical solutions to meet HVAC needs and aggressive construction schedules. The company offers a range of services, including sheet metal, coordination and fabrication, as well as in-house BIM capabilities and managing projects with VDC. Its growth to a full-service fabrication facility since 1991 is a result of a focus on details, as well as a commitment to service and craftsmanship. United Mechanical prides itself on the fact that 80% of its business comes from repeat clients. This pharmaceutical facility needed complex mechanical solutions, and United Mechanical had 30 years of experience to bring to the job.SOME BENEFITS OF USING PHENOLIC DUCTThis pharmaceutical production facility required more than 8,000 square feet of Thermaduct’s Thermaround outdoor round ductwork to give the application’s HVAC system a smooth aluminum interior with an R-12 phenolic insulated value. By using phenolic materials in this application, the medical facility was able to see the following benefits at its new location:Lower Embodied Carbon Materials – The use of phenolic materials and fabrication practices allowed for a reduced carbon HVAC system when compared to traditional metal and insulation alternatives.Weather Resistant Cladding – United used Thermaround’s 1000-micron vinyl cladding and its assembly process to ensure a continuous cladded surface with minimal seams. Phenolic duct is fully sealed in each corner with a continuous bead of sealant supplied by the manufacturer in all four corners of the duct section. Longitudinal seams can be secured on the exterior with panel fasteners, which are metal clips with teeth that grip into the phenolic and are sealed with UL 181 approved tape.Closed Cell, High R Value Insulation – Using phenolic materials with high-insulated values helped the facility meet energy code requirements, using less space.Low Leakage Flanged Connections – United Mechanical had a relatively easy installation process using offset couplings and flanged connections. The manufacturer offers online training for tips on proper installation of these connections.DUCTWORK’S ROLL IN LOWERING EMBODIED CARBONLowering embodied carbon of HVAC systems is a growing conversation in the HVAC industry.With such a heavy dependence on high carbon producing materials such as rolled steel and glass insulation, ductwork has many times been left out of that conversation. In 2004, when phenolic materials entered the U.S. Market, a true low carbon alternative became available to contractors and building owners. This material offers less embodied carbon during manufacturing of the insulated panels and lower energy usage for fabrication into ductwork.United Mechanical’s teamwork philosophy enabled its project team of designers, engineers, subcontractors and vendors to work cooperatively, ensuring that the end results exceeded the customer’s expectations.
by John Crowley | Apr 15, 2025 | Uncategorized
Expanding Horizons As the HVAC and sheet metal industry continues to evolve, adding commercial services has become a pivotal growth strategy for businesses looking to diversify their revenue streams, stabilize cash flow and attract top-tier talent. Thomas Montgomery, North Regional Director of Mesa Energy (dba EMCOR Services Mesa Energy), shared his expertise during SMACNA’s 81st Annual Convention in Palm Desert, California, providing invaluable insights into why and how businesses should take the leap into commercial services.About Mesa EnergyAs a licensed, full-service HVAC, building automation and retrofit contractor, Mesa Energy combines high-quality consulting services with efficient, cost-effective customized energy solutions. The company’s experience spans nearly every major industry. Mesa Energy targets quality and innovation in projects like the Molina Healthcare office towers in Long Beach, California, where a complete mechanical system retrofit led to a reduction in annual operating costs by $250,000.Building a Sustainable FutureMontgomery began his convention talk by highlighting the shift in market dynamics happening in the commercial space. “In 2024, the U.S. mobile service market is projected to hit $80 billion, and by 2034, it’s expected to soar to $146 billion,” he notes. This growth isn’t just a number; it represents opportunities for HVAC businesses willing to adapt.Adding commercial services allows HVAC businesses to tap into recurring revenue streams. Montgomery compares it to the utility industry. “When you build up a customer base with automatic billing, it becomes a continuous revenue-generating machine,” he says. This stability is particularly attractive in industries prone to seasonal fluctuations, offering a consistent buffer against downturns.The Value of Service Over ConstructionOne of Montgomery’s key points was distinguishing between mobile service work and traditional construction projects. He emphasizes that service operations require a unique approach. “Service is a reactive business,” he explains. “Your technicians need to be prepared to tackle unexpected challenges, often with limited lead time.”The financial upside is clear. Montgomery cites that while construction projects may yield a gross profit margin of 15% to 20%, well-optimized service operations can achieve margins upwards of 35% to 40% on average, with some repair work hitting 60% or more. “The numbers don’t lie,” Montgomery says. “Service work not only commands higher markups but also builds a loyal customer base that leads to repeat business.”Laying the Groundwork for SuccessTransitioning into commercial services requires careful planning and investment in the right tools, people and processes. Montgomery outlines several key steps:Leadership Expertise: “Having someone on your leadership team with a strong service background is critical,” he says. This ensures the operation is managed efficiently and aligns with the company’s long-term goals.Tech Training and Tools: Commercial service technicians require advanced training to handle computer-driven systems, injection tools and complex diagnostic equipment. Montgomery emphasizes investing in versatile technicians who can adapt to various scenarios.Operational Systems: From billing to dispatching, robust systems are essential for managing the fast-paced nature of service work. Montgomery recommends exploring modern solutions like Microsoft Dynamics to streamline operations.Customer Relationships: Building trust is crucial. “Your best technicians are not just good at their trade; they excel at customer service,” he remarks, sharing stories of technicians who became indispensable to clients through their dedication and relationship-building skills.Challenges and StrategiesExpanding into commercial services is not without its challenges. Montgomery acknowledges common hurdles such as pricing pressures, competition and the difficulty of finding and retaining skilled technicians. He stresses the importance of a well-thought-out compensation plan, including rewards for securing maintenance contracts. “It’s hard to be mad when you see those commissions rolling in,” he jokes.For businesses looking to fast-track their service division, Montgomery suggests acquisitions as a viable option. “Find a solid operation with good systems and people already in place,” he advises. This approach minimizes the growing pains associated with starting from scratch and offers immediate access to an established customer base.A Winning FormulaThe long-term benefits of adding commercial services go beyond financial gains. It positions businesses as full-service providers, increases valuation and creates opportunities for internal growth. “This isn’t just about making money; it’s about building a legacy,” Montgomery says.As businesses look ahead, the message from Montgomery is clear: Adding commercial services is not just a strategy; it’s a necessity for those aiming to thrive in an increasingly competitive industry.
