Custom Fabrication for Industrial Air Handling & Pollution Control Systems

Industrial air handling and pollution control systems face extreme conditions where failure isn’t an option. Northern Manufacturing delivers durable ductwork, scrubbers, and structural components that ensure safety, compliance, and reliability for plant engineers and EPC managers.

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The Technical Challenge: Fabricating for Hostile Airstreams

Industrial air systems must be expertly fabricated to handle extreme chemical and physical stress. For engineers, choosing a fabricator is about mitigating the severe risks of equipment failure.

Chemical Assault

Process gases create corrosive acids that thin metal and cause rapid, localized pitting. The combination of heat, stress, and chlorides can trigger sudden, catastrophic cracking in stainless steel.

Physical Attack

Abrasive particles erode ductwork from within, while extreme heat above 2,200°F (1200°C) demands specialized materials to prevent thermal failure.

System Integrity and Compliance

Leaks are critical failures that waste energy and release hazardous pollutants, risking employee safety. This triggers immediate EPA and OSHA violations, leading to fines and shutdowns.

Northern’s Solution: Precision Fabrication & Verified Quality

We solve complex air handling challenges by combining deep material expertise with certified processes and cutting-edge technology to create assets that perform for decades in the harshest industrial environments.

  • Material & Welding Mastery: Our certified experts specialize in welding high-performance alloys like Duplex and Hastelloy. We use precise heat control and specialized techniques, followed by meticulous post-weld cleaning to ensure maximum corrosion resistance and preserve material integrity.
  • Large-Scale Fabrication Facility: Our expansive 160,000 sq. ft. facility is equipped with heavy-duty machinery to fabricate large and complex structures, including scrubbers, stacks, and ductwork, ensuring robust and total system integrity.
  • Verified Quality & Traceability: Our ISO 9001:2015 certified system guarantees quality. We provide complete material traceability with Mill Test Reports (MTRs) and expert-led Non-Destructive Testing (NDT), offering buyers verifiable proof and absolute certainty.

Examples of Fabricated Air Handling Components

Our capabilities translate into a wide range of custom-fabricated components, each built to solve a specific operational challenge:

FGD Absorber Towers & Ductwork

Key components that house the process for removing sulfur dioxide from power plant emissions.

SCR Reactor Housings & Ammonia Grids

Structures that house the catalyst system used to convert harmful NOx pollution into harmless nitrogen and water.

Large-Diameter Ductwork

Massive ducting engineered to manage the high-volume airflow required in heavy industrial processes.

Abrasion-Resistant (AR) Steel Ductwork

Hardened steel ductwork designed to resist severe wear from abrasive particles in mining and bulk material transport.

Cyclone Collectors & Baghouse Housings

Custom-built structures that house systems designed to capture and filter industrial dust from the air.

High-Temperature Fan Housings

Robust housings built to shield industrial fans from extreme process heat, ensuring reliability and safety.

Key Industries for Air Handling & Pollution Control

Our expertise in fabricating high-performance air handling systems is critical to heavy industries where managing corrosive, abrasive, or high-temperature gas streams is integral to production and regulatory compliance. Our experience is most frequently applied in:

  • Power Generation
  • Chemical Processing
  • Pulp & Paper
  • Mining & Bulk Materials Handling
  • Wastewater Treatment
  • Large power generation facility showcasing custom precision stainless steel fabrication with metallic structures and vents against a clear blue sky.
  • A technician engaged in the process of inspecting a stainless steel fabrication, working on a large, unfinished component with intricate cutouts, showcasing precision metal fabrication quality assurance.

    • Frequently Asked Questions

    We ensure weld integrity through a three-step process: 1) We strictly control heat input using a qualified Welding Procedure Specification (WPS); 2) We use stronger, “over-alloyed” filler metals to match the parent material’s resilience; and 3) We perform comprehensive post-weld cleaning and passivation to remove heat tint and fully restore the material’s corrosion-resistant surface.

    You will receive a complete turnover package with all essential quality documentation. This includes full material traceability with Mill Test Reports (MTRs), all welding procedures (WPS/PQR) and welder qualification records, and all final Non-Destructive Testing (NDT) and quality control reports.

    Food-Grade Fabrications

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    Partner With a Specialist in Complex Fabrication

    Your critical air handling system demands a fabrication partner with a proven track record of solving the toughest challenges in corrosion, abrasion, and temperature. Northern Manufacturing has the expertise, equipment, and certified quality systems to deliver reliable, long-lasting components that reduce your project risk and lower the total cost of ownership. Connect with our team to discuss the specific requirements of your application.

    Discuss Your Project with an Engineer