Daylighting in Manufacturing Sectors of Industrial Buildings. Case Studies in the Metropolitan Region of Campinas, Brazil

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1 Daylighting in Manufacturing Sectors of Industrial Buildings. Case Studies in the Metropolitan Region of Campinas, Brazil Maíra Vieira Dias #1, Paulo Sergio Scarazzato #2 # School of Civil Engineering, Architecture and Urban Design, University of Campinas Cidade Universitária Zeferino Vaz, Barão Geraldo - Campinas, São Paulo, Brazil 1 mairavd@yahoo.com.br 2 paulosca@fec.unicamp.br Abstract Although daylighting is a renewable resource, support to energy efficiency and promoter of wellness state and health, there is a huge number of projects, in Brazil, that do not use it efficiently, probably because architects and its clients ignore its principles, resources and possibilities. In the industrial sector, even observing an increasing interest related to the environment conditions improvement, focused on greater productivity, few attention is devoted to the project. Thus, this research analyzed in qualitative terms the performance daylighting systems used in industrial buildings at Metropolitan area of Campinas, São Paulo, Brazil, where the luminance s distribution in the production area was taken by photographs taken in loco, with image s creation of High Dynamic Range (HDR). After that, computer based sequences were simulated using DIALux software, in comparison with HDR images, in order to have a better understanding about light distribution. This research concluded that the main problems related with daylighting in manufacturing areas of the industries analyzed are due to the lack of maintenance of daylighting capture systems and lack of integration with the artificial lighting, which clearly states that those buildings are created for simple warehouses to place industrial activities, without regard to human needs and comfort of users. Keywords - daylighting; HDR images; industrial buildings 1. Introduction Nowadays working environment in industrial buildings is not designed considering environmental conditions, employees health, performance and wellbeing. Daylight is not conceived aiming those aspects, but a costs economy. However, lighting improvements reduce the number of accidents, improves employees self-esteem and consequently increases productivity ([1]). Besides that, when it comes to industrial lighting, most common failures are about insufficient lighting and lack of the system s maintenance ([2]). Those practices actually are false economies, since the lack of maintenance and cleanliness of the systems will contribute to an irregular illumination and increase the possibilities of accidents.

2 The daylight project must be balanced with additional artificial illumination at dark areas and not provide light excess at brighter zones. Location from both sources and their integration with other working places must be planned and quite defined, as well as the lamps arrangement and luminaries on the ceiling ([2], [3]). Metropolitan Region of Campinas (MRC) 1 registered industries in 2009, in which 59 firms are associated with the Center of Industries of the State of São Paulo - CIESP ([4]) and 56 of them are multinationals ([5]). The city of Campinas/SP presents industries as its main economic activity, representing 43% of the mobilized resources by the city s economy. Even with these numbers being significant, they illustrate only part of the country industries, which have no regulation, legislation or specific code about lighting for industrial buildings. Thus, by performing a project, judgment must prevail to provide the industrial production spaces with a uniform luminance distribution. Besides the light, it is also necessary to think on the interaction of it with the objects and the space layout ([6]). Thus, the present research purpose is to make a qualitative evaluation on daylight in production sectors of MRC s industries, selected according to different typologies. Therefore, photographic registers in real spaces were made, which were processed into High Dynamic Range (HDR) images, and computer simulations with the validated DIALux software ([7]). Computer simulations were used in order to compare the correlations between both procedures and also to enable a better space perception of the environments. 2. Method Two industries were selected according with size and lighting systems applied, and these will be identified by the alphabet letters. After that, a data collection of the daylight and artificial lighting systems was made, besides the type of glazing and solar protection; material, roughness and color of walls, ceiling and floors; possible external interferences; types of lamps and luminaires used; and systems maintenance. To evaluate qualitatively the light distribution, HDR images were taken. Through traditional measuring instruments levels of illuminance and luminance can be measured point by point, however these measures requires more time and are leaning to errors due to measurement uncertainties and can generating an erroneous analysis of the light distribution. In this sense, the use of photographs makes it an excellent tool for capturing the luminance values in the environment, on a quick and economical way ([8]). Even without photometric calibration, an HDR image gives a reasonable accuracy (with a 10% margin of error when compared with physical measurements 1 MRC consists in a 19 cities, namely: Americana, Arthur Nogueira, Campinas, Cosmópolis, Engenheiro Coelho, Holambra, Hortolândia, Indaiatuba, Itatiba, Jaguariúna, Monte Mor, Nova Odessa, Paulínia, Pedreira, Santa Bárbara D Oeste, Santo Antônio de Posse, Sumaré, Valinhos and Vinhedo.

3 [8]) on the light distribution in the visual environment and can be used to assess the environments ([9]). In addition, previous experiments using HDR images ([10], [11], [12], [13], [14]) showed reliability on indicating values of luminances beyond the perception of light in three-dimensional space. Thus, the Sony Cyber-Shot DSC-S730 camera was calibrated ([9], [10]) and the pictures were shot with it supported by a Greika WT 3770 trivet. The ranges of exposure values (EV) taken varied from -2 to +2, with intervals of 1.0. The photographed images were overlapped in the Picturenaut software ([15]) to create the HDR image, which was processed in the RadDisplay ([16]) to obtain its correspondent in false colors (FC). The RadDisplay ([16]) also allowed the luminance assess at the chosen points. Computer simulations were performed through the DIALux software ([7]), which provides data to both quantitative and qualitative evaluation. Quantitative evaluations are obtained from the values of luminance and illuminance generated by calculations performed by the software, based on inputs that are provided according to each case study. However qualitative evaluations allow to understand the light distribution in space through images in FC. For this, the ceiling, walls and floors reflectances were fixed according with the existing case studies and the simulations were made for the time in which the HDR images were collected, in order to compare with the results of them. The chosen sky conditions were clear sky, for being the same condition of the visits dates. 3. Results and Discussion The results obtained by the HDR images and the simulations in DIALux ([7]) were analyzed according with the researcher perceptions and confronted, based on the variables proposed by IESNA ([17]) lighting quality model. In the images, the values in each scale are not absolute, but relative, since both can be manipulated to color adjustment. Industry A Represented by the German multinational Mann+Hummel Brazil Ltd., placed in Indaiatuba/SP in a m² area, in which m² are built area. The production sector is divided in two, according with the productive process and the storage sector is located at the space s peripheral zone, along the production sector. As the production process from the first production sector generates a higher number of pollutants, there s a greater particles accumulation over the roofing and surfaces, making the environment darker. The sheds have 3 m high and due to the particles accumulation on them, they look yellowish. This fact has brought the firm to replace some sheds. In the second sector, in addition to the shed, there are translucent sidings.

4 The artificial lighting system has 400 W metal halide lamps that are being replaced by 40 W Philips TL5 lamps. The new luminaries were installed in a closest high from the working place and remains switched on during all the firm s business hours, except in the storage sector. The shot HDR images were performed on August 12 th, 2010, from 10h30 to 11h30, in 23 points inside the building, under clear sky. The point 03, placed in the first production sector, illustrates the lack of sheds maintenance, where the particle accumulation creates a barrier to light incoming (Fig. 1). The luminance levels found in this point ranged from cd/m² to cd/m² (Fig. 2). Fig. 1 FC in point 03, scale 0 to 350cd/m² Fig. 2 Luminances values at point 03 The point 06 refers to the new sheds area, which allows a more uniform light distribution and, through the roofing it can be perceived how daylight reaches the space in deepness terms (Fig. 3). Closest to the sheds the luminance reaches cd/m² while in further distant places this value drops to cd/m² (Fig. 4). Fig. 3 FC in point 06, scale 0 to 350cd/m² Fig. 4 Luminances values at point 06 The point 18 represents the second production sector sheds, which presents less particles accumulated in its surface (Fig. 5). The task lighting has cd/m² luminance and causes reflection on the equipments surface. This reflection in the field of view presents cd/m² and in long

5 terms it can contribute to cause damage in the operator s visual system (Fig. 6). Fig. 5 FC in point 18, scale 0 to 100cd/m² Fig. 6 Luminances values at point 18 The simulation for daylight condition created in DIALux ([7]) shows the surfaces color influence to provide an environment with a greater sensation of luminosity, as well as the systems maintenance significance, to provide a lighting of quality and with uniform distribution (Fig. 7). Fig. 7 Difference in lighting levels between the production sectors As the particles block light incoming at the first section, most part of the environment has an average of 300 lx illuminance. At the second sector, where the sheds are less compromised, a greater light amount is captured and its reflection on the lighter roofing provides a brighter environment. The average illuminance levels are 600 lx, reaching values above 800 lx close to the translucent sidings (Fig. 8). Fig. 8 Illuminance levels found in the sectors of production, scale 0 to 850 lx

6 Industry B The Torwell Mechanical Industry Ltd., at Indaiatuba/SP, has an 1 800m² production area and daylight is represented by skylight through translucent tiles and translucent sidings along the building. This is a recent system, with only 1 year of installation. There are still 19 luminaries to general lighting and 20 to task lighting each one with two fluorescent lamps of 40 W. Only the task lighting is switched on during the day. The HDR images were taken on August 12 th, 2010, from 15h to 16h in 17 points inside the building, also under clear skies conditions. At the 03 point it can be noticed that the used daylight system provides a good light amount, allowing the activities to be developed and at the same time, creates a greater contact with outside environment. As the maintenance system, it is found in good conservation state for being recent and operates with efficiency in light transmission (Fig. 9). The luminance values found in the zenithal reached cd/m² (Fig. 10) and the roofing area is underused to its installation, since there was never been an enhanced study to for placement of these zenithal, which where only randomly arranged. Fig. 9 FC in point 03, scale 0 to 350cd/m² Fig. 10 Luminances values at point 03 As this industry has equipments that generates sparks, greater attention must be given to the production line layout, since the produced sparks added with the light intensity that comes in the environment can cause visual discomfort on the employees. This situation can be seen at the equipment portrayed in point 07 (Fig. 11 and 12).

7 Fig. 11 FC in point 07, scale 0 to 350cd/m² Fig. 12 Luminances values at point 07 Through computer simulation the zenithal and translucent sidings behavior could be observed in relation to the admitting light and its distribution on the environment. Differently from the sheds placed in Industry A, at the zenithals and translucent sidings light propagates in a punctual way, with brightness and/or glare incidence, and occurrence of shadow areas (Fig. 13). Fig. 13 Punctual incidence of light in the environment Since light can t reach deep into the environment, at the shadow areas the illuminance maximum found was 150 lx. At the central plant area, there is more uniformity in light distribution and this value was 400 lx. Where there is punctual light incidence, the values found were over 400 lx (Fig. 14). Fig. 14 Illuminance levels found in the sectors of production, scale 0 to 350 lx

8 4. Conclusion From the HDR images and computer simulations in the DIALux software ([7]) it was possible to make diagnosis lighting quality in the shown study cases. Both Industry A and B presented good light distribution, however some considerations must be made. In Industry A the absence of daylight system maintenance is set as a major fault. The particles accumulated on the sheds, besides making it get a yellowish surface, block the light incoming. If a proper maintenance was made a greater amount of light would have been transmitted to the inside environment, what would contribute on decreasing the use of artificial lighting. On the other hand, Industry B exhibits good maintenance conditions of daylighting devices, but the lack of a previous study can be noticed by the randomly arrange of skylights. There is no integration among lighting system and machines layout. Skylights are concentrated at central part of the plant, resulting in shadows in peripheral portion of the building. Both industries presented task lighting with luminance levels that in long terms can compromise employees visual system, performance and safety, since those sources are found in a height close to the field of view. With this study it could be seen that there still are industries that assumed the rational project, in which the biggest concern is related with building costs but not with providing a proper working environment that appreciates for environmental conditions. The use of technical platforms on the roofing to daylight systems cleanliness and maintenance is not considered at the architectural design, and this planning fault makes the maintenance to be done by switching the glazing sheets. Even daylight being abundant the most part of the day, few are the projects of industrial buildings in Brazil that use it in an efficient way. As the tools adopted in this study are simple and easy to handle, they can be incorporated in the design process to change this reality. Thus, in addition to thematic literature, this research aims to show that the potential of daylighting systems in industrial buildings in Brazil, suggests the necessity of a guideline for such building typology. It should be mentioned that this research has unfolded in another study, ongoing, in which will be verified the influence of luminances and illuminances distribution in the employees visual field, in addition to perception of them. Acknowledgment The authors thanks to Foundation for Research Support of the State of São Paulo - FAPESP for the financial resources used to finance the project through the Masters Program, Case No. 2009/ and visited industries and colleagues for allowing this work.

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