Gresham Smith provided an engineering design study for a hot mill fume exhaust upgrade for a world leader in aluminum rolling and recycling. The client had previously determined the need to increase fume exhaust volume in its production facility to meet both current and future demand. We managed and executed the study—from project chartering through field investigation and planning to the preliminary design package and capital project planning—providing recommendations for the replacement of the facility’s existing fume exhaust equipment that had been in service for close to 30 years.

The first phase of the project involved the challenge to significantly improve fume-capture efficiency and volume capacity while maintaining full production with limited downtime at the plant. Our multidisciplinary team worked closely with the client to develop five options for new and more effective fume capture technology. The options included design items such as fume exhaust equipment sizing, layout arrangement and specifications; coiler/exit end hood and supports; mill enclosure improvements; aerodynamic analysis; fire protection; oil piping and structures; and electrical power and distribution controls.




Northeast , U.S.


year-old existing fume exhaust equipment


comprehensive study


options for new fume capture technology

An Exhaustive Evaluation

An Exhaustive Evaluation

Gresham Smith carefully evaluated the top three options for feasibility for constructability, fume-capture effectiveness, and impact on capital cost and schedule. To facilitate these evaluations, our team developed layout drawings, capital cost estimation, construction scheduling, and major equipment specifications. We also engaged in pre-procurement services to obtain quotations from fume exhaust system suppliers. The end result was a preferred option that not only met the plant’s performance criteria but was lower in cost than the projected capital budget.

Over the years, Gresham Smith has provided engineering and front-end planning on multiple projects for the client including coil handling, coil cooling, and wastewater filtration and treatment.

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John Wharton, P.E.
John Wharton, P.E.
Senior Vice President