By methodically replacing aging infrastructure and equipment over the past eight years, Columbia Metropolitan Airport (CAE) in West Columbia, SC, managed to shave $1.2 million off its annual budget. The project team made a strategic plan that included upgrading handlers and chillers, lighting systems and escalators, starting with the pieces that cost the most in both energy and ongoing maintenance.
Around 2010, CAE was grappling with issues that highlighted the need to create a roadmap within its Master Plan. “We started to experience some pretty significant mechanical issues,” recalls CAE Vice President of Facilities and Planning Frank Murray. “The focus of that plan became inventorying all the old systems and developing a strategy for replacement.”
The 2012 Master Plan developed a detailed schedule of components and building systems that had reached the end of their useful life, and also identified opportunities for efficiency upgrades. That data was then refined through a mechanical system design project into a logical sequence for construction phases. Work on the most critical systems was prioritized, followed by systems that were closest to the point of disruptive failure. This strategic approach ensured that the most pressing issues were addressed promptly, preventing potential system failures that could disrupt airport operations.
The project team also placed priority on the central systems for the terminal itself. “The systems are somewhat linear, so you want to take care of the central plant before you worry about anything in passenger spaces,” says Dave Carpenter, project manager at Foth. “Otherwise, you replace those and then your central plant is still kind of gumming everything up because it’s got inefficiencies or it’s bottling things up. So we definitely went from the center out.”
The airport is using the name “ECOproject” for its current and near-future capital improvements. “ECO” stands for Enhanced Construction Opportunities, emphasizing the airport’s dual commitment to ecological friendliness and economic efficiency.
Financial constraints played a significant role in the planning and execution phases, but subdividing the project in phases allowed the airport to right-size the program to the available funding, Murray notes. Completing critical airfield infrastructure first allowed CAE to use back-to-back years of Airport Improvement Program grants on terminal projects.
System Updates
| facts&figures
Project: Infrastructure & Equipment Upgrades Location: Columbia Metropolitan Airport, in SC Cost: $7.4 million for mechanical systems updates; $1.4 million for upgraded lighting; $1.8 million for new escalators; $2 million for solar array Construction: 2014–2023 Architecture: Miller Dunwiddie Program Management: Foth Mechanical Designer: MECA Inc. Building Automation System: Honeywell Alerton Chillers: Trane Ice Storage System: Calmac Cooling Towers: Evapco; Reymsa Variable Air Volume Systems: Nailor Key Benefits: Reduced energy & maintenance costs; reduced carbon footprint through clean energy usage; more comfortable temperatures & new escalators for travelers |
The first phase of updates addressed the mechanical system, which was installed in 2016. It is split between two central plants, concourse and terminal, and includes additional thermal storage built in the concourse.
CAE committed to using the Alerton building management system in 2015 to help monitor and control the HVAC systems, Murray notes. “As new physical infrastructure was updated, its various data points were added to the software, which controls the sequencing of how the equipment operates together,” he comments.
Implementing a unified and non-proprietary control system was a pivotal decision when overhauling the HVAC operations. Prior to this upgrade, managing equipment across different systems posed significant challenges. “The programming was complicated and hard to control,” Murray recalls. By using an open-source binary system, the airport ensured compatibility across all components, regardless of supplier. This approach not only simplified CAE’s control interface, it also simplified implementation.
Testing for the new control system was meticulous, with sections of the terminal undergoing rigorous checks to verify functionality before going live. To support ongoing maintenance and operational continuity, CAE recruited personnel with hands-on experience from the project implementation. “That’s been really helpful,” Murray says. “They had that familiarity with the installation process, but also the technology and how we keep it running.”
Having additional control and visibility of what the systems are doing has been crucial to helping manage energy consumption more effectively, he adds. This not only aligns with the airport’s sustainability goals, but also enhances comfort and reliability across the terminal.
Minimizing Disruptions
By expanding into previously unused areas, the teams could install new equipment and systems without interfering with daily operations or negatively affecting the passenger experience. For instance, space under the terminal that housed a flight kitchen years ago was developed into a new chiller plant before any systems were taken out of service. This allowed heating and cooling to continue throughout the renovation work. It also allowed designers to create new mechanical rooms that are more efficient and spacious, Murray notes.
Construction occurred behind the scenes or after hours, and contractors had contingencies at the ready. “We had temporary systems there for us to bring on site if we had any outages,” Murray says.
This proactive approach meant that passengers were largely unaware of the ongoing work. “For the public, it’s probably news to them that we did some of these because it was really, really seamless, in a lot of ways,” he adds.
The new building automation system and variable frequency drives have already greatly improved temperature regulation across the terminal. Murray interprets a lack of feedback from customers as an indication that they are comfortable. “A lot of the time, when you don’t hear from travelers, you’re winning,” he says.
New Tech, Less Energy
One of the most significant benefits of CAE’s recent upgrades has been increased energy efficiency. A new thermal storage system allows the airport to produce chilled water at night when electricity is cheaper, which led to substantial savings. More efficient air handlers and chillers, paired with improved mechanical control systems to more effectively handle the heating and cooling demand, have also significantly reduced energy consumption.
The introduction of variable frequency drives into HVAC components will improve system efficiency, reduce power surges and prolong system and equipment lifespans—a combination that will enhance reliability and save energy. Previously, CAE had a 550-horsepower motor that used a hard start, which spiked power usage and the airport’s energy bill. Project designers changed out that single motor for a nine-fan array for higher efficiency and a slow, soft start.
The team also replaced variable air volume systems across the airport that had been in place since 1996—and installed them in areas where they had not been added during prior terminal renovations. Variable air volume systems allow better on-demand regulation of temperature across the facility, providing a more comfortable environment for travelers and tenants, while using less energy.
The Power of LED
Lighting upgrades, the second major phase of updates at CAE, began in 2014. Again, the goals were reducing energy consumption and improving efficiency. Murray reports that installing advanced lighting controls and energy-efficient LED fixtures yielded a 50% reduction in energy usage. Improvements were particularly evident in the parking garage, where the annual electrical bill fell from $160,000 in 2012, to less than $80,000 in 2022. Based on early successes, the transition to LEDs eventually extended to all areas of the airport, including terminal spaces, roadways and ramps, leading to a considerable reduction in energy consumption and costs.
| Total Terminal Program Benefit:
Clean Energy Produced: Nearly 29 million KwH (solar offset of consumption & energy savings through efficiency) Energy Equivalence: About 22.2 million lbs. of coal burning avoided Carbon Reduction: 20,216 Metric Tons |
Motion-sensitive lighting systems save energy during off-peak hours, though those results have not been as dramatic as expected. “There’s very few areas that will dim down and can go very low consumption for maybe an hour, or an hour and a half at night,” Murray says. “There’s always people moving around.”
Smaller airports with longer gaps between flights may see more significant savings, he adds.
New Escalators
More recently, CAE updated its escalators. Units from the 1990s had outlasted their expected lifespan of 15 to 20 years and had become increasingly costly to maintain. When frequent breakdowns began disrupting operations and annual maintenance bills reached $60,000, the airport replaced them with a more modern system for $1.8 million.
The new escalators, installed in 2021, use motion sensors to reduce speed when not in use and automatically return to full speed when passengers approach. Additionally, an auto stop feature enhances safety by eliminating the need for manual emergency stops in case of accidents.
Investing in Solar
The fourth phase of upgrades at CAE was a solar array. Initially, airport leaders hoped to build another covered parking deck with solar panels on the top to power the terminal and create shaded parking, a sought-after amenity in sunny South Carolina. “People like their cars to be covered and will pay a little bit more for that opportunity,” Murray notes. “So that was something we were looking to deliver.”
However, when the idea was first explored in 2015, costs were too high for an adequate return on investment. Instead, the airport added a 5-acre, 1.38 MW ground-mounted solar array on the airfield in 2016. The system, which was backed by a 10-year incentivized net metering agreement, has successfully reduced the airport terminal’s energy bill by an average of 32%, or $257,922 annually.
| Airfield Solar Farm
Clean Energy Produced: More than 11 million KwH Energy Equivalence: About 8.5 million lbs. of coal burning avoided Carbon Reduction: 7,722 metric tons |
The array is located southwest of where CAE’s runways intersect. The site has southern exposure for better energy collection, but the reflective panels do not create glare issues for air traffic controllers or approaching pilots. Moreover, the sloping tract was not attractive for other future development.
The airport had a maintenance agreement with the system installer for the first six years, but it recently issued a request for proposals for future maintenance and performance monitoring.
“The airport’s project investment (approximately $2.5 million) will be returned within the 10-year incentive period and will continue to produce an annual energy bill offset of around $160,000 for another 15 years,” Murray explains. The array is designed to last more than 20 years.
As energy demand continues to grow throughout the state, utility companies are coming up with ways to generate more clean energy, he adds. “We’re getting a decent amount of support and encouragement to do a project like this, because it lessens the burden of energy they need to make up elsewhere.”
To complement South Carolina’s increased manufacturing related to electric vehicles, the airport may add more onsite charging stations.
New Staff Member
After making so many incremental gains in efficiency over the last eight years, airport leaders wanted to make sure that updated terminal systems operate at optimum levels for years to come. So CAE recently created a new position: project and asset manager.
“Things do have a tendency to just sort of creep back up,” Murray comments.
The airport’s new employee provides continued oversight of system performance and is expected to go above and beyond traditional maintenance practices. Duties include establishing preventive maintenance procedures and contracts when contractors turn over new projects or equipment to the airport.
Overcoming Challenges
Navigating complex retrofit and renovation projects required quick adjustments in the field during construction or installation. “Those are always tricky, because you run into things that nobody remembers doing from historical projects,” Murray says.
When encountering unforeseen obstacles, crews used flexibility and effective communication to create solutions and minimize disruptions, he adds.
One particularly memorable challenge was shutting down power to the entire terminal to interconnect new high-voltage systems to the switchgear—a feat that required significant planning and coordination among the operations teams and project contractors. For example, security staff had to be posted at every door until automated systems came back online.
“We put a lot of thought into the first time that happened and then as things went along, you can get the process down and everything just gets a wee bit easier,” Murray recalls. “People get more comfortable with it.”
Looking Ahead
With technology advances, cost reductions and new incentive programs to encourage energy resilience, the airport will continue looking for ways to increase its efficiency. The idea of developing a solar farm over a parking garage and creating a microgrid is still very much on the table.
“The big goal is for us to be as self-sufficient as possible,” Murray comments. “So when we do these projects that directly benefit the public, they’re also helping the airport be more efficient and more productive.”
