When the EPA tightened its emissions limits for hexavalent chromium, an aerospace engineering facility in New Hampshire, had a choice: act quickly or face significant fines. The stakes were high—not just for compliance but also for the safety of its employees and the environment.
Hexavalent chromium, a chemical compound created when chromium metal oxidizes at high temperatures, is notoriously hazardous. Exposure can cause respiratory irritation, kidney and liver damage, and long-term health conditions like cancer. It also poses an environmental risk, as it doesn’t biodegrade and can contaminate soil and water.
The facility’s existing industrial ventilation system wasn’t up to the challenge of meeting these new standards. To keep operations running smoothly and protect their air permit under the EPA’s Clean Air Act, they needed a modern solution.
That’s where Macy Industries came in.
A Two-Part Project to Tackle Toxic Emissions
Hexavalent chromium is a byproduct of two key processes at this facility: welding and electrochemical machining (ECM). Addressing emissions from both sources required a comprehensive, two-part solution.
Part One: Fume Collection for Welding Cells
One of the facility’s buildings houses dozens of welding cells, all generating hexavalent chromium fumes. To keep these emissions under control, Macy Industries designed a fume collection system to capture the dirty air directly at each welding station.
From there, the air would travel through custom ductwork to the roof, passing through HEPA filters to trap the hexavalent chromium particles. After filtration, the system safely emits clean air back into the atmosphere. This part of the project also included the installation of a new rooftop fan and filter system.
Part Two: Mist Collection for ECM Machines
ECM machines, which use an electrochemical process to shape metal, produce hexavalent chromium as a mist during operation. The second part of the project focused on capturing and filtering this mist. Macy designed a system that directed the emissions through custom stainless steel ductwork into a scrubber equipped with a ULPA filter.
The scrubber used a high-surface-area filtration method to trap contaminants, with any remaining particles captured by the ULPA filter, which offers even higher filtration efficiency than HEPA filters. The result? Clean air leaving the building and a safer work environment for employees.
Solving Complex Ventilation Challenges
At Macy Industries, we take pride in being more than an industrial sheet metal fabrication shop. From the earliest stages of design to the final installation, our expert team handles every step of the process to ensure we meet our clients’ needs with precision, efficiency, and care.
Designing for Compliance and Efficiency
The design phase of this project required careful collaboration between Macy Industries, our client, and an outside engineer. While the engineer provided the initial plans, the facility’s on-the-ground realities—the obstacles, tight spaces, and precise clearances—meant those plans needed fine-tuning.
Our team worked closely with the engineer, reviewing drawings and conducting site walks to ensure the designs were not only compliant with EPA regulations but also practical for the facility’s layout. Using CAD software, we created detailed models of the system, including the custom ductwork, fan skids, and supports, to ensure everything would integrate perfectly.
Fabrication Built for Durability and Precision
With the designs finalized, we began fabricating the components for their industrial ventilation system in our sheet metal fabrication shop. Our experienced team handled every part of the process—from cutting and shaping ductwork to welding and assembling fan skids.
- Stainless Steel Expertise: This project’s custom ductwork included components made of 316 stainless steel. This corrosion-resistant alloy is ideal for harsh conditions such as hexavalent chromium filtration.
- Custom Fabrication: Using plasma cutters, press brakes, and welding equipment, our team fabricated each part to our client’s exact specifications. For more complex pieces, we rolled and hand-fitted components to ensure a perfect match.
- Attention to Detail: Whether polishing joints for a seamless finish or ensuring every fitting was leak-proof, we focused on creating an industrial ventilation system that would perform reliably for many years.
Managing all aspects of the project allowed us to respond quickly to adjustments and unforeseen challenges. For example, if this client needed a custom piece to solve an unexpected issue, we could have had it ready in days, not weeks.
Installing with Precision and Care
The installation process brought its own set of challenges, from coordinating crane operations to working at heights with fall protection equipment. Macy’s team handled it all.
- Weekend Work: Some installations were completed over weekends to minimize disruptions to the facility’s production schedule. With fewer employees to work around, our team was able to work more efficiently and avoid interfering with day-to-day operations.
- On-Site Welding and Assembly: Large components like ductwork and rooftop systems were welded and assembled on-site to ensure a perfect fit. The rooftop fan and HEPA filter system required precise alignment and coordination with other trades, including electrical and roofing teams.
- Effective Collaboration: Throughout the process, Macy worked closely with the facility’s team, as well as other contractors, to ensure everything was installed on time and to specification.
By the time the project was complete, the facility had a modern, efficient ventilation system that met EPA standards and created a cleaner, safer environment for employees.
Why Choose Macy Industries?
With over 40 years of experience, Macy Industries is uniquely positioned to tackle projects like these. Our ability to design, fabricate, and install complex systems under one roof gives us—and our clients—a distinct advantage.
- Responsiveness: When you call Macy Industries, you’ll speak with a real person who’s ready to help. Our project managers are hands-on, ensuring every detail of your project runs smoothly.
- Expertise: From welded stainless steel ductwork to custom fan skids, our team has the knowledge and skills to handle even the most challenging projects.
- Flexibility: Do you need weekend work or a last-minute adjustment? Macy adapts to your needs and delivers solutions on your timeline.
When you choose Macy Industries, you’re not just getting a contractor—you’re getting a partner dedicated to your success.
Do you have a tough ventilation challenge you’re ready to discuss? Contact Macy Industries to learn how we can deliver practical, reliable solutions that are customized to your needs. From start to finish, we’re here to help.