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Case Study |
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Independent Sheet
Metal, New Jersey, USA |
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Cost effective corrosive fume
exhaust system |
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Completed building project with
60" diameter PSP® installed |
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vertically on the facing side of the building
and then runs |
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horizontally to wrap around
to the middle of the other side |
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of the
building. |
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Background |
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Independent Sheet
Metal, a northern New Jersey firm engaged in the fabrication and
installation of sheet metal ductwork for heating, ventilation
and air conditioning (HVAC) systems had a customer give them a
tough assignment. A large pharmaceutical manufacturer
requested a recommendation for a cost-effective corrosive fume
exhaust system for their multiple scale organic building
project. The request called for several lengths of
60" diameter duct with a long horizontal run located ten
stories up on the side of the building. Independent was
also told the overall project was over budget and behind
schedule! |
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Challenge |
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Careful analysis of
all the products available led Independent and their client to
the belief that a cost effective solution existed, without
sacrificing the corrosion resistant qualities required for the
duct. |
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Research showed
that many types of material have been used for corrosive exhaust
ductwork, with the most common being plastic. However only
a few of the plastic duct products are accepted by the various
insurance and code authorities for installation without
sprinklers inside the duct. Of the approved plastic duct
alternatives, the time needed to prepare, glue and heat-cure
each joint (including grinding, sanding, and use of epoxies)
would be extremely time consuming and labor intensive for
assembly. |
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Solution |
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Independent's quest
for a solution ended with a conversation with a Fab-Tech
representative. Fab-Tech's product called PermaShield Pipe
(PSP®) has been in use for over a decade in the semiconductor
sector as the premier product for exhausting corrosive fumes.
Their stainless steel duct with proprietary fluoropolymer integrally
bonded to interior surfaces delivers exactly what is needed;
unparalleled corrosion protection, structural integrity and ease
of installation without the need for internal sprinklers. |
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A critical factor
in selecting PSP® was its FM rating. FM (Factory Mutual)
is an affiliate of FM Global, the world's largest insurance
company. FM is specifically devoted to reducing commercial
and industrial property losses. PSP® has earned the FM
Approval mark as stipulated in Factory Mutual Research Standard
No. 4922.
Independent Sheet
Metal project manager, Vincent J. Reitano, worked closely with
Fab-Tech to present to the client a bidder's alternative
proposal, bringing in PSP® as a "Value Engineering"
solution. The savings of installation expenses versus
furan fiberglass pipe was dramatic, amounting to "tens of
thousands of dollars." |
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60" PSP® duct prepared for
shipment from Fab-Tech. |
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Over 300 feet of
60" diameter coated stainless steel duct was delivered
on schedule and quickly installed by Independent's professional
crew. Several segments were pre-assembled on the ground
and then lifted into support saddles 100 feet above the ground.
The aerial bolted assembly went together much quicker than
expected. |
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Conclusions |
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So impressed was
the client that a second application was purchased and installed
inside the multiple scale process building. These 8"
through 24" diameter exhaust lines are used to vent
reactors, filter presses, distillation units and laminar flow
booths. Duct up to 16" diameter use Fab-Tech's
proprietary PSP-EZ™ single bolt band clamps - resulting in
even faster installation times. Three additional benefits
of PSP® were also realized: |
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- The PSP-EZ™
clamps and bolted van stone flanges can be quickly disassembled
for duct inspection, cleaning or replacement. |
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- If
manufacturing suites are reconfigured in the future, no cutting
or removal of entire duct systems would be necessary.
Simply unbolt the segments to be changed and reuse or quickly
add to the existing system. |
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- The
stainless steel exterior presents a pristine
"sanitary" appearance that never needs painting. |
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Independent's
Vincent Reitano added, "PSP® helped us as the HVAC/Sheet
Metal Contractor to propose an effective and cost saving
alternative to our client, demonstrating our commitment to them,
as a valued team member." This is an excellent
example of supplier and contractor working closely together to
provide a superior product to enable valued clients attain their
corporate goals. |
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