Mr. Steinhauser, besides being a tennis pro, an active athlete, and long-term manager for the club, was also a practicing conservationalist and outdoors person. As he shopped for better building options, he learned of WERC and contacted David Winkelman in 2001. While doing a sight visit, Mr. Winkelman noticed the relatively large areas of wetland surrounding the club and realized that this may be a good installation for horizontal earth loop for geothermal heating and cooling energy.

The city officials were willing to entertain the concept, so Mr. Winkelman and Mr. Steinhauser set about designing an energy efficient tennis court building that would be heated and cooled from the earth. Further suggestions were discussed for aligning the building rooftop for photable-tag building integrated solar generator as well as the possibility of putting up a wind turbine on the premises. To put it simply, White Bear Lake Racquet and Swim Club's short term objective is to be "fossil-fuel-free" by 2010, and, beyond that, to become a fully sustainable company. “That means,” he explains, “that we’d use only renewable energy and other renewable resources, and would add only nontoxic biodegradable materials to the waste stream…" .

In 2002, WBRS replaced an aging five-court tennis bubble with a permanent, highly insulated, five-court metal building. The old bubble was heated with gas at a cost of approximately $40,000 per winter, required 60,000 watts/hour of electricity (12 fixtures per court) to achieve “poor” lighting, and was oppressively hot and humid during the summer.

Last October-December, with the newly installed heat pumps, the building’s efficient insulation produced a heating bill of $0. In January, when temperatures plummeted to –10 degrees, it was $60 (versus $5,590 for January ’01). WBRS expects to save $40,000 in fuel costs per year. The new light fixtures require 20,000 fewer watts/hour, saving an estimated $2,000 a year, and provide “superb” illumination.

In a liquid or "Hydronic" radiant heating system, a heat source such as a heat pump or a boiler, produces warm water. These systems generally operate from 80°F to 120°F. Warm liquid is circulated through PEX tubing in the floors which heats the room evenly. Since the liquid has to transfer some of it's heat to the room, by the time it reaches the end of the loop, it's temperature has dropped. The cooled liquid is then re-circulated through the heat source and the cycle continues. Installation of a liquid system needs to be done by a trained (certified) installer because the tubing must be protected from hazards (like punctures or freezing) and the system must be pressurized, checked for leaks and air-purged properly. See Hydronics Tour

HERE WAS THE PROCESS

When the club installed the loop field for its new ground source heat pumps in a wetland, it worked with the Minnesota Department of Natural Resources to remove invasive plant species, replant with native species, and deepen several ponds. “The project increased the diversity of the wetland,” Steinhauser points out, “and produced an attractive water feature on our property.”

Bullen Construction of McGrath, Minnesota who has had extensive experience in geothermal for many years, installed the heat source pumps and horizontal loop field that consists of 42 ground loops buried 12 feet deep in the wetland.

In the building itself the entire floor is covered with a rigid styrofoam insulation barrier. Some insulation products absorb and hold water which reduces insulation performance and is one of the necessary conditions for mold growth. Styrofoam extruded polystyrene insulation resists water absorption and does not provide a nutrient source for molds. It offers the highest moisture resistance of any foam plastic insulation, provides long-term insulating performance while reducing the potential for mold growth within the insulation. Pictured at left.

When the barrier was complete, the warm water will be circulated through Wirsbo PEX tubing which was put into place using a pre designed pattern for even distribution of heat. Pictured at right.

After all the tubing is secured into place, the next step was to bring in a special clay mixture that was recommended in the professional tennis court specifications. Pictured below left.

The "clay" base is then leveled and packed down or tamped to tennis court specs. Pictured below.

Heat exchange pump has been installed and connection to the loop field outside has been completed. The circulator pump connects to the header which distribute the heated water through the Wirsbo tubing.

A finished project. Warm, dry tennis courts. But this is only the beginning for Paul Steinhauser who wants to be fossil-fuel-free by 2010.