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The duct layout also had to change to accommodate the oversized duct required for the media room. Because sound was such a big consideration in the design, specialty products were used for every aspect of the duct installation. The insulation was 1-in. thick internal acoustic insulation, the duct hangers were an L-bracket that eliminated all vibration, and then a wrap was put around the duct. "This wrap could have stopped a bullet," Sigman says. "It was very heavy; screws with washers were used to hold it to the duct. In addition, all this work had to be done from scaffolding because the media room sits above the gym and the gym ceiling is more than 20 feet high."

Sigman designed the media room with 15 cfm of fresh air per person and 165 total cfm fresh air. At seven air exchanges per hour times 9,000 cu.ft., that meant an airflow of 1,050 cu ft/min, and 250 ft. per minute at each register. This design allows for slow air movement to avoid any air noise while supplying a lot of volume for the small space and good air exchange. Sigman provided a fan with a silencer to move air across the projector to help keep it cool as it runs.

Needless to say, in a home of this size and complexity, there were numerous other facets that brought everything together. The gymnasium and pool area presented their unique challenges, as did the controls and snow melting system. The homeowner, for example, wanted the controls for the system to be as close to invisible as possible.

"The controls were going to be tied to the home automation system," Sigman says. "The automation company had said that our Aprilaire controls were compatible with their system. Since we were unfamiliar with their communicating controls we had commercial reps to the shop to go through their controls and explain how the controls worked and what would be needed to satisfy the needs of the homeowners."

Ultimately, however, solutions were found to all the challenges, and the creative and talented team from Sigman Heating and Air Conditioning/ Sigman Indoor Climate Solutions — which includes nine technicians certified by North American Technician Excellence (NATE) — brought it all together for the client in a remarkable comfort system that came in at just under $1 million.

"A system this size requires a great deal of teamwork and coordination," Sigman says. "The men did a great job making sure that nothing was missed. The design is only as good as the craftsman installing the system, and the team did a great job of making sure that the highest level of quality went into every part of the job."

The only concern for Sigman is where to go from here. "I don't know how we'll top this one," Joel Sigman says, "but don't worry, we'll keep trying to come up with something interesting."

PRODUCT KEYS TO SUCCESS

Forced Air System:

• 13 ClimateMaster Tranquility 27 geothermal heat pumps; 3 ClimateMaster ClimaDry Tranquility 27 geothermal heat pumps
• 3 Bryant variable speed air handlers with auxiliary heaters
• Unico advanced blower module; Unico blower module with advanced control board
• Unico R-410a heat pump coil
• Unico 5 kW auxiliary heater
• 4 Grundfos loop pumps
• 13 P.C.I. geothermal flow controllers
• BGM supply flow controller
• Spirotherm VSR500 5-in. air eliminator

Controls:

• 5 Honeywell HZ432 TrueZone panels
• 10 Honeywell dampers
• 3 ClimateMaster ClimaDry thermostats
• 19 Aprilaire thermostats
• 34 Aprilaire temperature sensors
• 11 Aprilaire humidity control
• 11 Aprilaire humidity sensors

Indoor air quality:

• 10 Fantech CM 3000 HEPA filters
• Fantech pool heat recovery unit
• 9 Fantech heat recovery ventilators
• 16 Fantech inline bath fan kits
• 3 Fantech dryer boosters
• 3 Fantech inline fans and silencers
• 10 General Aire steam humidifiers
• 1 Honeywell steam humidifiers

Radiant floor heat/ pool heat:

• 4 GeoComfort 10-ton water-to-water units
• 4 120 gallon storage tanks
• 6 Grundfos circulators
• 26 Taco circulators
• 50,000 ft. Viega ½-in. oxygen barrier tubing
• 24 Viega stainless steel manifolds
• Amtrol expansion tank
• Spirotherm air eliminator
• Weil-McLain pool plate exchanger
• 8 Taco zone control panels, 2 to 6 zones
• 18 Honeywell Pro 8000 thermostats
• 18 Honeywell remote sensors
• 4 Penn Johnson Controls

Snow melt/water heating:

• 2 Knight 500,000 Btu boilers
• 2 Lochinvar 120-gal. indirect storage tanks
• 2 Tekmar snow melt controls
• 8,000 ft. of Viega ¾-in. oxygen barrier tubing
• 8 Taco pumps
• 2 Amtrol expansion tanks
• 2 2-in. Spirotherm air eliminators