Airflow from HVLS fans helps sheet metal processor eliminate condensation problems

Situation

The word condensation brings to mind beads of dew forming on a cold soda can on a warm summer day. The same forces are at play in fabrication shops.

Condensation occurs because cold air cannot hold as much water vapor as warm air. When warm, humid air meets a cold surface like metal, the surface draws heat from the air, warming the surface a little while cooling the air a lot. When the air reaches the dew point, the water vapor turns into water droplets that are deposited on the cool surface. In fabrication facilities, that’s most often coiled metal or stacks of metal sheet; however, it also can be the concrete floor.

Condensation leads to rust, and rust leads to cleaning, wasted labor hours, and product loss. When condensation forms on floors, it creates slippery surfaces and puddles that threaten workers’ safety.

O’Neal Flat Rolled Metals, a sheet metal processing and distributing company, experienced repeated issues with condensation at its Garland, Texas, facility. The area’s abrupt temperature changes, particularly in spring and fall, along with the constant high humidity, caused substantial condensation buildup. Every year the company had to write off about $28,000 worth of rusted product, not to mention the wasted resources spent cleaning up puddles.

Resolution

To combat the issue, O’Neal installed four high-volume, low-speed (HVLS) overhead fans from Big Ass Fans in its 84,000-sq.-ft. facility.

An HVLS fan creates facilitywide airflow with their large diameters (up to 24 ft.) and airfoil-inspired blades. As the fan spins, it pushes a large column of air downward; this column hits the floor and then spreads horizontally. As this air passes over the floor or cold rolls of metal, it whisks away the cooled, stagnant air surrounding the cold surface and replaces it with warmer air. This reduces the amount of time that air is in contact with cold surfaces, thereby reducing the likelihood of condensation. And when condensation does occur, the airflow from an HVLS fan speeds up evaporation, reducing the time in which corrosion can form. On concrete slabs, this helps puddles dry more quickly and saves time previously spent mopping up.

For O’Neal, the added airflow created more uniform conditions throughout the space and on the surface of the products, eliminating its condensation issues almost immediately. Phil Cavender, senior vice president, said that it was “an investment well worth the money; the payback was almost instantaneous,” before adding that the fans “surpassed our expectations, eliminated condensation issues, and saved us a tremendous amount of money.”

In addition to saving the company tens of thousands of dollars annually, the fans also improved workplace safety, as the condensation had previously turned O’Neal’s floors “into a skating rink.” Plus, the giant fans move more than enough air to keep employees cool and comfortable during the sweltering Texas summers.

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