Custom One Inch Lined Plenum Boxes and Plenum Sleeves

Depending on the job, commercial or residential, there may be a need for fiber glass acoustical lining on the inside of the duct work. Duct liner, in it’s simplest form, is there to help reduce noise and provide a minimal R-value—much less than duct wrap—to provide more consistent temperatures and energy efficiency.

K&E Sheet Metal’s morning was full of duct liner, one inch thick to be exact. The thickness can range from 1/2” to 2”. Our shop mostly deals with half-inch and one-inch. Occasionally, we will get a spec (specification) for 1 1/2” or 2”, but it’s rare for the size jobs—commercial vs. Industrial— we fabricate for. In future, as the shop grows, that could change.

The liner is cut to size, adhered to the metal with glue, and then secured with corresponding weld pins.

Plenum Sleeves with liner glued; waiting for pins to be welded down.

Plenums and Sleeves in multiple stages of the lining process

Steve finishing up weld pinning some plenum sleeves

Joe placing pins for the next step

Finished and ready for pickup

Square to Round Monday

Happy Monday! The humidity has arrived in the fabrication shop, as the rains continue here in the Northeast. The floors are coated with a perfect glaze of condensation from the annoying Spring weather patterns. Rain is getting tiresome. Frustrating, but not something to get worked up over. Air conditioning to the rescue!

We move on. HVAC sheet metal fabrication stops for no weather! The square to rounds must go on!

We are busy and the name of the game today is square to round fabrication. Our shop is limited in the fact that we don’t currently have a spot welder for assembling our square to round fittings. We rivet them. Why not weld? Valid Question. One that many of you fabricators may be asking.

Truth be told, I’ve had different spot welders over the years and have never been thrilled with the results. Collars were continually popping off in the field, making it harder for our customers to get their job done efficiently. So we began riveting, which does take longer, but there is no worrying about failure in the field.

I am aware that a water cooled spot welder would be the way to go. However, it’s just not in the budget at this time. We invested heavily in equipment over the last few years and the focus is on managing that debt. We will get there.

The picture below shows multiple flat stock body patterns of square to round duct fittings after being cut on the plasma table. They are marked to start the bending process.

Collars for the round portion of the fittings have been built, ready for installation after the guys have assembled the main body of the custom fittings. We usually fabricate the collars first so they are ready to go!

Custom Collars for Square to Rounds

We had a minor issue with the hand beader for the square to rounds. Below, Steve is working diligently to fix the problem.

We use the manual bead roller to crimp the top—the round end—of the fitting body. The crimp helps to make easier the installation of the collar on the fitting. We then switch out the crimping dyes for the bead dye, which helps to secure the collar to the square to round body. We finish the job with a few rivets.

Crimping

Final Bead with Rivets

We are currently fabricating an order of 75 square to rounds. They take time and we want to make sure each one is done to the best of our ability. Occasionally, that means sacrificing some speed. I think the trade-off is worth it.

Next on the docket…Custom plenum drops for a couple rooftop heating and cooling units!! Joe is starting that process this afternoon. Sheet number one has finished cutting; next we clear the table, cut the remnants for recycling and use the scrap for other items in the shop. Possibly another square to round!

Joe clearing the plasma table.

SaraSpa Rod & Gun Club Duct Fabrication

After installing the filter boxes and elbows shown in my previous post, it is now time to fabricate the next set of duct and transitions that will run up the wall. There are three total units and each will need a 90" drop. Below are the in-progress fittings lined up in a pretty little row.

Our next task is to cut and install the Ductmate Flange System on each section of duct for easy installation when we get to the jobsite.

Wolla!

We finished up a few 90 elbows with turning vanes for the job as well. Probably could have managed a better photo but I had to assist my helper uncle with that tub of screws :)...JK

SaraSpa Rod & Gun Club Duct Installation Photos

Here are a couple pics from our most recent duct installation at the SaraSpa Rod and Gun Club in Greenfield Center, NY.

Installation of the Exit Air Unit ductwork and filter cabinet.

Installation of Make-up Air Unit duct.

The job has been progressing nicely with a lot of custom duct and fittings. Each section is fabricated with 24 gauge metal and secured together with the Ductmate Flanging System.

There is a light at the end of the tunnel regarding finishing up the installtion and fabrication. I hope to get all the photos gathered together and share them after the project is completed. With our move to a new fabrication shop space and other jobs, time has been at a premium. We are finally getting back to a somewhat normal schedule.