Q&A: Can you tell me more about curving?

We recomend a custom submittal drawing be used for curved diffusers when you have a custom curving need.  The submittal files are used both by a curving vendor and at receiving plants to ensure accuracy.

Custom curving requires that the customer specify the border style, direction of curve (whether plan - ceiling or floor installs or face curves - arches), radius and length.

Custom curving is best performed using precision stretch-forming techniques developed for the aeronautical industry.  They are generally more accurate and faster than roll-forming techniques.

How Exactly Does s Stretch Forming Work?

Stretch forming allows material to be formed along a custom template while eliminating wrinkling along the inside edges of the curve.

Aluminum is the most commonly used, but other metals can be stretch formed. Stretch forming is a process that permanently bends metal into a desired shape using heat to treat it then press it over a die while the metal is held at a tension beyond the yield point.

When the metal is held just beyond the yield point it will permanently retain the desired contour and shape. Some materials may require multiple stretching operations to permanently alter the memory of the metal.

A. Both ends of the work material are inserted in gripper jaws that are mounted on a swing-arm.

B. The material is then stretched outward to its yield point.

C. Then wrapped around the form die while maintaining the stretch force.

D. When the metal has taken shape, the force is released and the finished curved product is removed. The material’s memory has been permanently altered to the desired shape.

Mark Costello - GRD Application Engineering Manager

Active Chilled Beam Design - Occupant Comfort

Active chilled beam systems offer design consultants an effective means to create a comfortable space while offering numerous opportunities for energy savings. There are several critical aspects of the design that must be addressed to ensure occupant comfort in addition to meeting the load requirements in the space. These include primary airflow supplied to the beams, placement and sizing of the beams.

The first tem that should be addressed in design of a chilled beam system is the volume of primary air supplied to the space. In chilled beam systems the primary air is the only source for both ventilation air and removal of latent heat gains in the space.

In order to determine the primary air requirements for the space in an active beam system, two separate items need to be considered. The minimum ventilation rate for the space must be compared to the amount of conditioned air required to maintain control of the humidity level in the space. Guidelines for determining the minimum ventilation requirements are given in ASHRAE standard 62.1-2010. The required flow ate to meet the latent load is determined by the following equation:

It follows that the required flow ate to maintain control of the humidity will rapidly increase as the difference between the room air and primary air humidity ratios decrease. As a result, designs seeking to maintain relatively low humidity ratios will need a high primary flow ate if the dew point temperature of the supply air is close to the design dew point in the room. Criteria for maximum dew point temperature in the space is set in ASHRAE Standard 55-2010; for a room design temperature of 75BF the maximum relative humidity is 63.5%. The larger of the two flow rates calculated will dictate the requirements in the space.

Once the required supply flow ate has been determined the beam throw pattern and unit size can be selected.

While there are many factors affecting the size/length of the chilled beam, the appropriate throw pattern should be determined based on multiple room considerations, e.g., shape/layout, intended use of the space, and windows.

In open office spaces as well as internal offices two-way or four-way beams are typically used. The flexibility provided by two-way and four-way beams, due to multiple sizes and nozzle configurations, allow them to be appropriately applied in most applications. One-way beams are typically used in perimeter zones and small spaces such as individual offices and hotel rooms.

After the throw pattern has been decided, placement of the beam within the space can be determined. Active chilled beams, because of their design, share throw characteristics with conventional slot diffusers. Placement and orientation of active beams is critical for thermal comfort due to long throw values associated with active beams.

In open office plans t is typically more cost effective to use several longer beams that are installed parallel in space, instead of numerous smaller beams the length of the module division. However in an open office the number and size of beams used will be determined by balancing the cost per beam, cost of air side operating pressure, and water side pumping power to achieve optimum energy efficiency. When applying two-way and four-way beams in small offices and individual offices the recommended location is directly above the occupants. This will result in the lowest velocities within the occupied space. It is also recommended that two-way beams are installed lengthwise in the space. This will allow for the use of longer beams, reducing the cooling requirements per linear foot which will in-turn lower total air flow per foot and the resulting velocities in the space ensuring occupancy comfort. If placement is required near a wall use of one-way throw beams are recommended. One-way beams can also be effectively used in perimeter zones for cooling applications; however they should be supplemented with baseboard heating to address window loads during the heating season. Two-way beams can be effectively applied in perimeter zones for both heating and cooling. Care must be taken if two-way beams are installed parallel to windows. In intermediate seasons when internal cooling is required and window surfaces are cool an acceleration of the air can occur in the space creating drafts and potential discomfort.

Once the primary air requirements, type, and orientation of the active beams in the system have been determined an iterative approach should be used to determine unit size/length and final placement of the beam based on operating conditions. In addition to providing latent cooling, supply air will deliver sensible cooling. Location for final placement should take into consideration the allowable average air speed in the occupied space in accordance with ASHRAE Standard 55-2010. Accounting for the air side sensible capacity will allow for reduced capacity requirements of the water coils in the beams.

Designing with this in mind will reduce airflow requirements per linear foot, which will help to meet the requirements for thermal comfort. When placing two beams in the same space as shown in Figure 2, care must be taken to ensure that the colliding air streams do not result in velocities over 50 fpm causing discomfort. A general guideline to achieve air velocities of 50 fpm or less in the occupied space is to ensure the velocities of colliding (V collisions) airstreams are below 100 fpm. If velocities at the point of collision are greater than 100 fpm, the distance from the ceiling for the airflow to slow to 50 pm is noted in the equation below:

Buildings and systems utilizing active chilled beams can achieve significant reduction in energy usage through optimization of the active beams selected, and the equipment selected for providing primary air and chilled water to the units. While savings may be obtained through reduced energy usage, the cost of reduced productivity resulting from worker discomfort can quickly erode the realized energy savings. Therefore it is critical that the appropriate considerations must be made to ensure thermal comfort is maintained in the space.

Matt McLaurin - Senior Design Engineer

Application: Options for Surface Mounting Ceiling Diffusers

One of the more frequently asked questions we receive in application engineering is in regards to surface mounting Titus diffusers. When a ceiling grid is not present, surface mounting is specified and the installation questions arise. Linear diffusers are available with concealed mounting, square and rectangular diffusers with square or round inlets are not.

The most important thing to know about surface mounting is that it normally requires additional framing to which the units will be secured. We often receive calls for mounting instructions after the sheet rock has been installed which is too late to provide framing without removing the installed surface.

Framing requirements will vary from one job to the next, but there are some general guidelines and terminology we use.

Obviously installing screws in the face of a diffuser will work as it does for grilles but the duct return flanges behind diffuser edges are generally not available to provide a secure mounting base for screws. Also, many surface mount frames do not have a flat surface nor is there a screw hole fastening option available. Furthermore, screw fastening certainly does not enhance the aesthetics of the installed diffuser.

All sheet rock is mounted to ceiling joists. Joists are usually parallel to each other and spaced at two to three feet apart depending on local building codes, and in most cases, the framing for the diffuser can be mounted to the top of, and perpendicular to the joists. Screws are then used to mount the back pan to the framing. Framing members should be centered on the diffuser location to allow sufficient clearance for the diffuser inlet and associated duct. Additional care must be taken so as to avoid any protrusions or features that will occupy the space necessary for the framing on the rear side of the diffuser. Framing should also be at a depth that will allow the diffuser to firmly seat against the sheet rock. Most diffuser back pan heights are less than the depth of the joist. The sheet rock or ceiling surface is installed into an opening provided for the diffuser.
The diffuser core should be removed prior to installation to allow for screws to be installed in the top of the back pan transition; this is the flat portion on the rear of the back pan. Screws are then used to secure the back pan to the framing. It is helpful to use washers to prevent the screw heads from being driven through the back pan if the framing is not flush to the ear of the pan. In most cases the screws can be placed in a manner to not be visible from the occupied space after the diffuser core or face is re-installed.

As an alternative to the framing process, and one that we suggest if the ceiling surface has been installed without prior framing for the diffuser mounting, is to use our rapid mount frame. The TRM frame can be installed in the space between the joists following the installation of the ceiling.

The TRM replicates a standard ceiling grid module and a lay-in (type 3) frame diffuser. The diffuser can then be laid in the TRM frame. The TRM frame does add a border to the finished appearance of the diffuser, but also can be utilized as an access port to the space above the ceiling by simply pushing the diffuser up and out of the opening.

While the TRM does represent additional diffuser cost, the reduced labor requirement and flexibility of the installation sequence offers a distinct advantage.

The TRM is available in steel and aluminum and is ordered as a separate line item. Remember, when using the TRM frame, the (type 3) diffuser frame must be used instead of the (type 1) diffuser frame.

Mark Costello - GRD Application Engineering Manager