4-Stage Zero-Emission Filtration for the Saudi Arabian Market

Industry: Heavy Electrical Equipment Manufacturing
Location: Saudi Arabia (End-User)
Equipment: 2 Sets of Custom Enclosed Industrial Spray Booths
Core Challenges: Strict height limitations, internal material handling requirements, and rigorous environmental & fire safety compliance.

Executive Summary: Engineering Around Constraints

When a major electrical equipment manufacturer in Saudi Arabia required two heavy-duty spray booths for painting large-scale industrial transformers, they faced a complex set of facility constraints. The factory had an absolute ceiling limit of 7 meters, with critical fire-fighting lines running at exactly 6 meters. Furthermore, the handling of massive transformers required a jib crane to operate inside the enclosed booth, all while maintaining zero VOC emissions to the outside environment.

CoatTech Custom Solutions engineered a highly tailored, millimeter-perfect system that maximized internal workspace, seamlessly integrated the client's material handling equipment, and surpassed local environmental and fire safety regulations.

The Challenge: A Three-Dimensional Puzzle

Designing a standard spray booth was impossible due to the site's unique architectural and operational limitations:

1.Height Restrictions: The booth needed a massive 5.5m internal clearance to accommodate the transformers, but the exterior height could absolutely not exceed the 6m fire-fighting line limit.

2.Internal Crane Integration: A heavy-duty jib crane needed to be anchored directly to the concrete floor inside the booth, requiring a specialized foundation and roof design without compromising the cabin's negative pressure seal.

3.Strict Emission & Safety Codes: Exhausting fumes outdoors required navigating a narrow 1.5m-2m backside clearance for ductwork, overcoming increased airflow resistance, and adhering to Saudi Arabia’s stringent fire and VOC emission standards.

The CoatTech Solution: Precision Customization

Our engineering team discarded the standard catalog approach and developed the V2 Custom Enclosed Spray Booth, focusing on structural integrity, aerodynamic efficiency, and unparalleled safety.

1. Millimeter-Perfect Dimensional Engineering
To solve the height paradox, we engineered a ultra-compact plenum and structural frame. We achieved a massive 5.5m internal working height while keeping the absolute maximum exterior height strictly at 5.95m—leaving a safe 50mm clearance below the factory’s fire lines.

2. Seamless Jib Crane Integration
Instead of a compromised "top-open" design, we maintained a fully enclosed, pressurized environment. We engineered customized heavy-duty floor gratings (load-bearing 500 KG/m²) with a precision-cut base slot, allowing the jib crane pillar to anchor directly to the factory floor. The internal lighting and sub-high efficiency ceiling filters were strategically mapped to avoid interference with the crane’s swing radius.

3. Upgraded High-Static Ventilation System
Because the fumes needed to be exhausted outside through tight backside clearances, duct resistance was a major concern. CoatTech upgraded the exhaust system to a powerful 11KW explosion-proof centrifugal motor, delivering an immense 33,000 m³/h airflow. This ensured a rapid air exchange rate of 168 times per hour, instantly clearing paint overspray and maintaining optimal visibility for operators.

4. Ultimate Fire Safety: 70mm Rock Wool & SGS Certification
Understanding the uncompromising safety standards of the Middle Eastern market, we replaced standard EPS insulation with high-density 70mm Rock Wool panels reinforced by a square tube portal frame.

For the filtration media, we utilized SGS-certified F5 ceiling filters that pass the rigorous DIN 53438-3 Class F1 fire retardant standard, ensuring maximum operational safety when dealing with volatile paint environments.

The big challenge:4-Stage Zero-Emission Filtration

To guarantee environmental compliance for outdoor discharge, we implemented a progressive 4-stage filtration architecture:

1.Air Intake (G3): Captures large airborne dust (≥5μm) before entering the system.

2.Ceiling Supply (F5): Ensures 100% sterile, dust-free downward airflow to protect the transformer's specialized coating.

3.Floor Pit Paint-Stop (G3 Fiberglass): Traps heavy, wet paint mist via inertial collision and direct interception.

4.VOC Treatment (M-Type Activated Carbon): High-porosity granular carbon (800-1500 m²/g surface area) chemically adsorbs benzene, xylene, and other harmful VOCs, ensuring the final exhaust air is clean and compliant.

The Result

CoatTech delivered a robust, highly specialized industrial coating environment that fit perfectly into the client's challenging facility footprint. By proactively identifying potential installation bottlenecks—such as rear cabinet clearances and ducting resistance—and engineering specific solutions, we ensured a smooth deployment. The project successfully passed the end-user's rigorous technical and environmental approvals.

Looking for a custom heavy-duty spray booth tailored to your exact facility constraints? Whether you need to integrate complex material handling equipment or meet strict international fire codes, our engineering team is ready to design your solution.