Where can sheet metal ductwork fabrication go wrong? It starts with improper material selection. If an abrasive particulate such as silica isn’t matched with an abrasive-resistant duct material, the duct will not withstand wear and tear over time. Incorrect thickness can also lead to premature wear when the duct is too thin for the application’s pressure or abrasiveness. Poor welding can also affect the structural integrity of the duct, which causes premature failure.

Inferior ductwork fabrication comes with hidden costs

Problems often arise when sheet metal duct fabrication doesn’t meet quality standards. Time may pass before leaks and corrosion are identified, leading to more extensive damage and frequent repairs. Risky, expensive and time-consuming issues may include:

• Structural failure: Ductwork could fail and fall out of the ceiling causing damage to buildings, equipment, and creating safety risks
• Subsequent costs: Wasted materials and downtime needed for repairs result in material replacement costs and lost revenue.
• Potential health issues: When ductwork is faulty, employees may be exposed to dangerous particulates that lead to hazardous health problems.
• Increased energy costs: Improper ductwork may not be able to handle necessary air flow, causing energy inefficiency.
• Compliance violations: Faulty ducts may cause noxious fumes to be released into the air or harmful particulates to remain in employee work areas. These compliance violations may result in costly fines.

Expensive system replacement may be needed when these issues go by undetected for long periods of time. When dust settles within ductwork, it can decrease the capture effectiveness of the hood, resulting in costly replacements.

How to ensure quality for your application

A quality industrial ventilation partner will conduct a thorough evaluation of your industry, products and air stream condition to help ensure proper sheet metal ductwork fabrication. The right ductwork material and design will be determined by whether your product is sticky, moist, dry or in vapor form. An assessment of the speed of materials passing through the ductwork also determines the proper design requirements.

Common ductwork materials per industry include:

• Foundry: Mild steel (hot/cold rolled)
• Paper: Aluminum and stainless steel
• Mining: Abrasion-resistant or stainless-steel
• Silica: Abrasion-resistant steel

Materials may vary based on individual applications.

Enjoy the lasting benefits of ductwork fabrication done right

Properly fabricated ductwork helps ensure employee health and stringent regulation compliance. On-target ductwork fabrication stands the test of time to minimize issues, repairs and downtime. It also delivers a low-maintenance solution and energy efficiency for industrial ventilation.

���ձ�’s unmatched craftsmanship delivers excellence

With 30 years of expertise, ��һ��ݶ�brings knowledge learned from numerous projects to industrial ductwork fabrication, including design, engineering, fabrication, installation and maintenance. ���ձ�’s trained sheet metal workers complete an apprenticeship program with hands-on application and written classwork to achieve a journeyman position. ��һ��ݶ�journeyman continue to train in and be tested on numerous weld processes to meet the fabrication needs of our customers. Plus, laser-cutting and other CNC controlled equipment delivers more exact cutting and better welds during
fabrication.

Get started with quality sheet metal duct fabrication

Contact IVI for proper duct fabrication that lasts.

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Benefits of proper industrial airflow by dust collection type

• Dust collection systems: Proper airflow contributes to high air quality and a clean work environment.
• Fume collection systems: Proper airflow helps mitigate hazardous airborne particles (HAPs).

Design methods for industrial airflow

• Blast gate/orifice plate method: This method is somewhat flexible. Flow rates can be changed, and it’s easier to make additions and changes using this method. The location of blast gates depends on the location of elbows, hoods, straight duct and access. This is the most common method of design.
• Balance by design method: This method achieves a “balanced” airflow system without blast gates or orifice plates. The method calls for calculating static pressure of airflow in each segment. Factors that influence static pressure include duct sizes, elbow radius and hood design. This method is best for hazardous materials. Adding, removing or adjusting a collection point requires a complete system redesign.

Duct Network Design

Either the blast gate or balance method can be used to design the industrial duct network.

• Tapered system: The ductwork gets larger closer to the collector as additional airflows are added. Tapering the ductwork helps ensure the velocity at each branch is constant.
• Plenum system: The ductwork is generally larger, the airflow velocity is lower and there’s low resistance for airflow to the air cleaner or fan. A plenum system is typically used on supply air systems.

Distributing airflow in duct routing

Ductwork design plays a big role in improving and maintaining airflow. Ductwork designed for maximum airflow efficiency:

• Minimizes pressure drop across the system
• Is routed to reduce potential wear spots
• Takes aesthetic appeal into consideration

For more details on optimized airflow design and duct network design, reference . Learn more about how to maintain proper airflow with ���ձ�’s blog: “Maintain proper industrial airflow for dust collection systems”

���ձ�’s Experience and Innovation

At IVI, We help design, build and install industrial dust collection systems for any operation. Read more about ���ձ�’s fume collection systems and dust collection systems. Start on these pages to answer basic questions, and contact  IVI, Inc. to dive deeper into industrial ventilation solutions.

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Hood Types

Enclosing hoods:

An enclosing hood will completely or partially surround the point where contaminants are generated. An enclosing hood is typically preferred but may not be practical due to potential interference with employee workstations.

• A partial enclosing hood has two to three sides where an inward flow of air through the opening will contain the contaminant within the enclosure and prevent its escape. Examples include paint spray booths or grinder station.
• A completely enclosing hood has all sides and is preferred whenever possible. A laboratory hood is an example of this use.

Exterior hood:

Exterior hoods are placed next to the point where contaminants are generated without creating an enclosure. An exterior hood may be an opening on a welding table or slots on the side of a tank. The exterior hood should be located in the path of the emission if transferring larger particulates such as sand.

There are four main types of exterior hoods:

• Canopy: A one- or two-sided overhead hood that receives upward airflow from hot air or gas.
• Close-capture: Mounted directly over the source of a contaminant.
• Push-pull: A hood placed on the side of a push-pull ventilation system.
• Side-draft (also called lateral exhaust hood): This is not as efficient as other containment or down-draft hoods.

Hood Velocity Considerations

A specific velocity is required, depending on the type of contaminant being captured. To achieve the required velocity, carefully consider the hood’s shape, size and location.

• Face velocity: Velocity right at the hood opening.
• Capture velocity: Velocity at the dust generation source to capture the contaminant and transfer it into the hood.

Ergonomic Considerations:

An industrial ventilation system hood is one of the most important components of an individual’s workstation. A worker will be more likely to use the hood and the ventilation system properly if ergonomic elements are considered. Among these considerations are:

• Accessibility to parts within the hood
• Size, design and weight of objects handled
• Safety cables
• Overhead clearance
• Sharp edges
• Lighting
• Ease of cleaning

���ձ�’s engineering and design team has years of experience designing and sizing industrial ventilation systems.  ��һ��ݶ�can assist in the design of a new system or the redesign of an existing system.

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Types of Industrial Ductwork

• Tapered systems: The velocities are nearly constant as the airflow is merged together and the duct becomes larger. Tapered systems are typically used for dust collection systems.
• Plenum systems: The velocity is usually lower and generally is larger than a tapered system. Plenum systems are typically used for HVAC systems and occasionally used for fume extraction.

Industrial Ductwork Sizing

Determining the size of the ductwork for an industrial dust collection system requires a few key pieces of information:

• What exhaust volume is required at each duct collection point?
• What are the sand, dust and/or particulates being collected?
• What are the conveying velocity requirements?

Exhaust Volume

It is best practice to first check with the equipment supplier for the recommended exhaust volumes. Calculating the size of the duct segments can be done using a series of calculations known as the Velocity Pressure Method consisting of two primary variables:

• Q = Airflow (sometimes referred to as volume)
• SP = Static Pressure

Calculations for determining the appropriate airflow (Q) are provided in the . Air is also required to overcome the resistance of the duct and other parts of the industrial dust collection system. This resistance is referred to as the total system static pressure (SSP).

Collecting Sand, Dust and Particulates

The type of contaminants being carried through the industrial ventilation system should be understood while determining the size of its ductwork. Various contaminants have different characteristics including:

• Size
• Size distribution
• Shape
• Density
• Surface

Contaminant variations for sand, dust and particulates

There are large varieties and sources of contaminants that may be transported  through an industrial dust collection system, including:

• Vapors, gasses and smoke
• Fumes and metal smoke produced by welding
• Light or fine dusts such as cotton or flour
• Average dusts produced by grinding, buffing, material handling and foundries
• Heavy dusts such as sawdust, sandblast dust, boring dust and lead dust
• Heavy and moist dusts such as most cement, asbestos and lime dust

Conveying Velocity Requirements

It is also key to consider the minimum conveying velocity, referred to as Transport Velocity, that is required to move the dust with particulates (dust, condensable vapors) without creating build-up, static or other obstacles to the airflow.  Learn more about how the velocity varies by dust types by reading Control Costs by Carrying Dust at the Right Speed.

Other Velocity Considerations:

• What size of material is being transported?
• Does it have any specific qualities, such as high moisture content, abrasiveness, corrosiveness or combustibility?

Calculating Ductwork Size

Upon a final understanding of the exhaust volume, the contaminants being collected and the velocity requirements, sizing the ductwork for an industrial ventilation system can be determined with the Flow Rate Equation Q=VA.

Volume = Velocity X Area

���ձ�’s engineering and design team has years of experience designing and sizing industrial ductwork. ��һ��ݶ�can assist in the design of a new system or the redesign of an existing system.

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