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Decarbonisation of HVAC systems is frequently discussed in strategy documents and long-term roadmaps. Applying it within a live, permanently occupied building is a different challenge altogether. At Mansfield Pollard’s Bradford headquarters, two modular HP Series air handling units have now been installed as a permanent upgrade to the building’s core services, providing full mechanical ventilation, heating, and cooling to a 10,000 ft² open plan office.

This project forms part of Mansfield Pollard’s wider programme to electrify its estate and reduce operational carbon intensity through measurable, repeatable actions. It was not delivered as a demonstration or trial installation. The systems are operating daily under normal working conditions and were selected using the same engineering criteria applied to client projects.

Why HVAC was targeted

Air handling systems remain one of the most energy intensive components within commercial buildings. Legacy gas-fired AHUs present a clear opportunity for carbon reduction when replaced with all electric alternatives, particularly when heat recovery and modern control strategies are applied correctly.

At Bradford, HVAC was identified as a high impact building services asset. Replacing the existing system offered a direct route to removing fossil fuel dependency while maintaining internal environmental conditions suitable for a modern office environment.

Real world constraints

The conditions at Mansfield Pollard’s headquarters are representative of many retrofit projects across commercial, education, healthcare, and public sector estates. The installation was required to proceed with the building fully occupied, limited plant space available, and no tolerance for operational disruption.

The systems were located externally at ground level and connected into the existing internal distribution network. Delivery, installation, and commissioning had to be completed efficiently and predictably, without reliance on complex site logistics or extended shutdown periods.

System selection and technical rationale

Two HP Series modular air handling units were selected to meet these requirements. Each unit provides mechanical ventilation, heating, and cooling within a single factory integrated system. All major components, including the reverse cycle heat pump, heat recovery, fans, and controls, are contained within the AHU casing.

Each unit delivers a nominal airflow of 2.15 m³/s through a five fan EC plug array. This configuration supports stable airflow control, acoustic performance, and redundancy across a range of operating conditions. Heat recovery is provided via a rotary thermal wheel with both sensible and latent energy transfer. System effectiveness exceeds 86 percent under EC 1253 reference conditions, supporting reduced heating demand during seasonal transitions.

Heating and cooling are delivered via an integrated reverse cycle heat pump. A supplementary electric heater battery provides frost protection and performance stability during periods of low ambient temperature. The casing meets BS EN 1886 classifications for air leakage, thermal transmittance, mechanical strength, and thermal bridging, ensuring long term durability in an exposed external environment.

Importantly, the units were supplied to standard specification. No bespoke engineering or additional external plant was required.

Installation and commissioning

Both units were delivered in sectional format and installed onto a preformed concrete base using standard pallet handling equipment. No cranes or specialist lifting equipment were required. External duct penetrations were formed directly through the building façade and connected to predefined internal interfaces.

Controls and power connections were factory integrated, enabling rapid connection on site. Commissioning was completed on the same day using the native HP Series web interface. Airflow rates, temperature setpoints, schedules, and operating modes were configured through standard visualisation tools without the need for third party software or additional programming.

Performance management and control

The HP Series units are monitored and managed using Mansfield Pollard’s native control platform. The browser based interface provides direct access to all operational parameters, including airflow, temperature, humidity, CO₂ levels, fan speed, and electrical load.

Three standard operating modes are available, Eco, Optimum, and Comfort, each with configurable thresholds aligned to occupancy patterns and internal conditions. Real time monitoring is supported by historical trend data, enabling continuous performance optimisation as seasonal and usage profiles change.

The same control architecture is deployed across Mansfield Pollard’s modular AHU range, supporting consistency and repeatability across multi site estates.

Quantifying energy, carbon, and cost outcomes

Performance modelling for the Bradford installation applies a like for like comparison against a conventional gas heated AHU operating at 90 percent efficiency. All calculations are based on 1,500 annual heating hours and derived from real operational data.

Declared assumptions include fan power, heating duty, system efficiencies, current energy tariffs, and the UK grid carbon factor. Fan energy savings are calculated separately from heating energy reductions, reflecting the efficiency gains delivered by EC fan arrays when compared with belt driven systems.

Under these assumptions, the installation delivers an annual energy saving of 231,450 kWh. This equates to a projected annual cost saving of £20,325 and an estimated reduction in operational carbon of 61.9 tonnes CO₂e per annum. Based on capital outlay, the projected return on investment is approximately 2.5 years.

These figures are presented transparently to allow informed technical scrutiny. They are intended to reflect typical retrofit conditions rather than best case scenarios.

Why assumptions matter

Assumptions are unavoidable in any decarbonisation model. What matters is whether they are realistic, declared, and repeatable. By publishing the basis of comparison and the operational parameters applied, Mansfield Pollard aims to support informed decision making rather than headline claims.

This approach mirrors the methodology applied across client estates, where performance modelling is used to assess carbon impact, energy reduction, and financial return before systems are selected or replaced.

Relevance beyond Mansfield Pollard

The conditions, constraints, and outcomes observed at Bradford are not unique. Many organisations face similar challenges when upgrading building services within live environments. Modular air handling units, when applied correctly, provide a practical route to electrification, reduced carbon intensity, and improved operational control without extensive disruption.

This project demonstrates how applied decarbonisation can be delivered through standardised system selection, modular deployment, and transparent performance evaluation. While not a complete solution in isolation, it represents a decisive step within a coordinated approach to estate wide carbon reduction.

The full project profile, including technical specification and detailed performance modelling, is available to download here.