What if you could improve indoor air quality, eliminate filter headaches, and lower energy costs, all without investing in heated makeup air? That’s exactly what Air Solutions helped a Mid-South manufacturer achieve in their welding shop.
The Challenge: High Costs and Heavy Maintenance
This manufacturer’s weld shop was enclosed with soft vinyl curtain walls and relied on cartridge dust collectors to filter and recirculate air. While effective at capturing fumes, the system created major problems:
- High operating costs from constant filter changes
- Maintenance headaches and production interruptions
- Wasted energy from heated air trapped overhead
They needed a solution that improved weld shop air quality, safety, and comfort while protecting the bottom line.
The Solution: Non-Heated Makeup Air
Air Solutions designed a balanced airflow system using roof-mounted exhaust fans to remove weld fumes and supply fans with fabric distribution ducts to deliver fresh outdoor air directly to the weld shop.
This approach delivered:
- Continuous inward airflow beneath the curtain enclosure
- No migration of fumes into adjacent plant areas
- Effective air exchange rates to keep the space safe
- Even distribution of clean air across the weld shop
Smart Use of Existing Heat
With a 27-foot roofline, the facility already had warm, stratified air overhead. Instead of wasting it, the new design for improving weld shop air quality mixed incoming outdoor air with the heated ceiling air, reducing temperature swings while reusing energy already in the building.
Key Benefit: No heated makeup air required.
Reliable Equipment, Long-Term Performance
- Americraft Manufacturing Co., Inc. provided the roof exhaust and supply fans
- FabricAir, Inc. supplied the flexible air distribution ducts around the shop perimeter
Together, these solutions created a robust system with less maintenance and consistent results.
The Results
- Cleaner Air – Safer, healthier environment for welders
- Lower Energy Costs – No need for heated makeup air
- Reduced Maintenance – Fewer filter changes and downtime
- Improved Comfort – Balanced temperatures across the facility
Why It Matters for Plant Managers
For operations leaders, this project proves that ventilation doesn’t have to be expensive or complicated. By leveraging non-heated makeup air and smart airflow design, facilities can:
- Avoid surprises from constant filter replacement
- Improve worker satisfaction with a cleaner, quieter space
- Reuse energy already in the building
Non-Heated Makeup Air Helps with OSHA Standards
OSHA’s welding, cutting, and brazing standard (29 CFR 1910.252) requires employers to provide adequate ventilation, air replacement, and protection for workers. The non-heated makeup air approach addresses these requirements directly:
- Adequate Ventilation: Roof-mounted exhaust fans maintain constant fume removal from the weld shop, ensuring airborne contaminants don’t exceed OSHA limits.
- Air Replacement: Supply fans with fabric air ducts introduce a consistent volume of outdoor air, satisfying the OSHA requirement for replacing exhausted air.
- Protecting Adjacent Areas: The inward draft created by balanced airflow prevents weld fumes from escaping into other parts of the plant, keeping neighboring work zones compliant as well.
Ready to Lower Energy Costs and Improve Air Quality?
Air Solutions represents trusted manufacturers of fans, air distribution systems, and soft wall enclosures. We understand plant operations and partner with you from design through installation to ensure results that last.
Contact Air Solutions today to schedule a consultation.
