Duct Balloons
Reduce Maintenance Cost
How is it installed in the duct work?
Bring the duct balloon and blower to a location near the access door. Remove it from the storage bag. Carefully feed the balloon through the access door opening to the work to the area where you want to install it. Run the inflation tube back out the access door near the blower. The balloon has anchor rings sewn into the top corners for lifting it in place if required. Most balloons less than 20’ high can be maneuvered in place during the inflation process without hoisting. Connect the inflation tube to the blower and then turn the blower on. As the balloon starts to inflate, it can be maneuvered into position by using the supplied grab handles. Installation time is usually less than 20 minutes, depending on balloon size. To see a short video clip of an 18’ high x 10’ wide x 3’ deep duct balloon being inflated, click here.
How accurate must my dimensions be? The duct balloon is designed by using the existing duct work dimensions that you provide. It is designed to inflate slightly larger than the dimensions you provide in order for it to create a tight seal. While actual field dimensions are preferred, dimensional information can be taken from plant drawings, or taken outside of the duct work when the unit is operating. Be sure to take into consideration the thickness of any existing insulation that maybe present on the outside of the duct work.
How is it deflated when you're done? Turn off the blower. Remove the inflation tube from the blower discharge by opening the Velcro attachment and safety strap. Then pull open the deflation zipper on the balloon and it will quickly deflate.
What temperature is the material rated to?
The balloon material is rated to 485°F (251°C).
Where does the blower need to be located?
The blower can be located a few feet from the balloon, or it can be 100' or more away from it. It is preferred to locate it in a clean area on grating outside of the duct work away from any fly ash that maybe present. By cutting a 7” diameter hole in the duct work, the inflation tube can be run from the balloon to a clean area where the blower is located. You can see actual photos of how this has been done by clicking here. Care should be taken to keep the blower intake clear of any foreign matter or objects. The blower can be left outside on grating as it’s weather resistant but not waterproof.
Can I inflate the balloon once and then remove the blower?
No, the blower system must remain on at all times to keep the balloon fully inflated.
What voltage blowers do you offer?
We can supply the blowers in 120V, 208V or 220V.
If the blower must always remain on, is it very expensive to run?
Electric rates vary by location, but overall the cost is minimal. The 120V motor that powers the blower draws between 6 to 11 amps.
What if the blower loses power, will the balloon start to deflate?
There is a small louver damper on the blower discharge which will keep it from deflating immediately, but the balloon will soften and eventually deflate. In areas where this could cause concern, we can supply a two blower setup for redundancy. Due to its design, the balloon cannot become over pressurized by using two blowers simultaneously. In the event of a power loss to the one of the blowers, the balloon will remain fully inflated by the backup blower, as long as the blowers are connected to different circuit breakers. This has been done in the past on SCR or FGD applications .
Can I use my own inflation tube, and what size is it?
No, the inflation tube we provide is actually made from the same material as the duct balloon. It inflates to 8” in diameter at full inflation pressure. We normally furnish 25’ of inflation tube for use between the blower and the balloon, but any length can be provided at the customer’s request. If there are numerous 90º turns between the blower and the balloon, we can supply spiral wound Flex-Duct inflation tube. Care should be taken to determine the correct length of either type of inflation tube. Too long of an inflation tube can become a tripping hazard or it can get kinked which reduces air flow to the balloon and affect its sealing performance. Also, be sure to let us know if there are structural steel supports in the duct which could be in the way where the inflation tube is attached to the balloon so we can move it accordingly.
How much does one of these balloons weigh? A 12’ x 12’ x 3’ size duct balloon weighs about 32 lbs. An 18’ diameter x 5’ thick disc shaped balloon weighs about 50 lbs. The blower weighs about 40 lbs. We furnish estimated weights for the duct balloons in our quotations. To see a weight chart of various sizes, click here
Can I use station air to inflate the balloon?
No, each balloon must use its own 120V, 208V or 220V positive pressure blower.
What if the balloon gets torn, will it deflate?
Small tears won’t cause the balloon to deflate as the balloon is always pressurized as long as the blower remains on. The balloon can be temporarily repaired with duct tape if necessary to keep it inflated. We can also furnish a repair kit that includes 5 square feet of material and adhesive for small on site repairs. The balloon can be sent back to the factory for a more permanent repair.
Can I use a larger size balloon for an opening that is slightly smaller?
Yes, it is OK to use a slightly larger balloon in a smaller size existing duct work. It should still seal tightly, but you will need to be careful with the extra material getting in the way of your work space.
How does it compare in cost to other types of temporary barriers installed by our plant personnel or contractors?
Labor rates vary by location, but many customers have told us that the duct balloons will usually pay for themselves in the first installation and removal, and they are reusable.
What if I have structural supports in the area I want to install the balloon?
You may have to look at installing it in a different location. Most expansion joints are about 2’6” wide, and a 3’0” deep balloon will fit nicely in this area and provide a tight seal. Click here for more information.
How large or small can these balloons be made?
While there are no size limitations for very large balloons, the weight of the balloon can become prohibitive, as well as the access door it must go through. Balloons for very large duct work openings can be supplied in sections that mate together to make them easier to install and remove. Small balloons can be made for pipe sizes from 20” in diameter and larger.
How much differential pressure will it take before it begins to move?
All duct balloons are supplied with a high pressure blower rated at 8” w.c. They are also provided with anchor rings in the corners and grab handles around the perimeter that can be used as attachment points to tie the balloon off to keep it from moving. If the differential pressure in the duct work where the balloon is to be installed is more than 8” w.c. then using the anchor rings on the balloons as a tie down point is recommended in order to keep it in place.
We may be grinding or welding near the balloon, so how can we protect it?
The balloon can be supplied with additional anchor rings sewn into it at 24” centers so that a fire retardant blanket can be hung from it.
Do you need to erect a support structure in order to keep it in place?
Normally the balloon will hold tightly against the wall of the duct if sized and installed properly and the operating environment is only a natural draft. If the balloon is installed in front of a malfunctioning damper that has a negative pressure on one side of it, then it has nowhere to go. If the balloon can be installed near existing structural steel in the duct as shown here, then movement can be prevented. If there is no support steel present, then pad eyes should be installed in the duct work prior to the installation of the balloon. Nylon rope or straps can be attached between the tie down point and the anchor rings on the balloon to assure no movement can take place. A layout drawing is provided with all quotations that shows anchor ring and grab handle locations on the duct balloon.
Does it come in a storage box so I can safely store it until my next outage?
The balloon, blower and inflation tube are shipped in a heavy duty vinyl storage bag with a draw string top. Knock down type storage boxes are available for an additional cost.
Can the balloon be exposed to sunlight or high humidity conditions?
The material that the balloon is manufactured from is UV resistant and is also impregnated with a mildewcide to inhibit mold growth, so sun or high humidity conditions won’t affect it.
Bring the duct balloon and blower to a location near the access door. Remove it from the storage bag. Carefully feed the balloon through the access door opening to the work to the area where you want to install it. Run the inflation tube back out the access door near the blower. The balloon has anchor rings sewn into the top corners for lifting it in place if required. Most balloons less than 20’ high can be maneuvered in place during the inflation process without hoisting. Connect the inflation tube to the blower and then turn the blower on. As the balloon starts to inflate, it can be maneuvered into position by using the supplied grab handles. Installation time is usually less than 20 minutes, depending on balloon size. To see a short video clip of an 18’ high x 10’ wide x 3’ deep duct balloon being inflated, click here.
How accurate must my dimensions be? The duct balloon is designed by using the existing duct work dimensions that you provide. It is designed to inflate slightly larger than the dimensions you provide in order for it to create a tight seal. While actual field dimensions are preferred, dimensional information can be taken from plant drawings, or taken outside of the duct work when the unit is operating. Be sure to take into consideration the thickness of any existing insulation that maybe present on the outside of the duct work.
How is it deflated when you're done? Turn off the blower. Remove the inflation tube from the blower discharge by opening the Velcro attachment and safety strap. Then pull open the deflation zipper on the balloon and it will quickly deflate.
What temperature is the material rated to?
The balloon material is rated to 485°F (251°C).
Where does the blower need to be located?
The blower can be located a few feet from the balloon, or it can be 100' or more away from it. It is preferred to locate it in a clean area on grating outside of the duct work away from any fly ash that maybe present. By cutting a 7” diameter hole in the duct work, the inflation tube can be run from the balloon to a clean area where the blower is located. You can see actual photos of how this has been done by clicking here. Care should be taken to keep the blower intake clear of any foreign matter or objects. The blower can be left outside on grating as it’s weather resistant but not waterproof.
Can I inflate the balloon once and then remove the blower?
No, the blower system must remain on at all times to keep the balloon fully inflated.
What voltage blowers do you offer?
We can supply the blowers in 120V, 208V or 220V.
If the blower must always remain on, is it very expensive to run?
Electric rates vary by location, but overall the cost is minimal. The 120V motor that powers the blower draws between 6 to 11 amps.
What if the blower loses power, will the balloon start to deflate?
There is a small louver damper on the blower discharge which will keep it from deflating immediately, but the balloon will soften and eventually deflate. In areas where this could cause concern, we can supply a two blower setup for redundancy. Due to its design, the balloon cannot become over pressurized by using two blowers simultaneously. In the event of a power loss to the one of the blowers, the balloon will remain fully inflated by the backup blower, as long as the blowers are connected to different circuit breakers. This has been done in the past on SCR or FGD applications .
Can I use my own inflation tube, and what size is it?
No, the inflation tube we provide is actually made from the same material as the duct balloon. It inflates to 8” in diameter at full inflation pressure. We normally furnish 25’ of inflation tube for use between the blower and the balloon, but any length can be provided at the customer’s request. If there are numerous 90º turns between the blower and the balloon, we can supply spiral wound Flex-
How much does one of these balloons weigh? A 12’ x 12’ x 3’ size duct balloon weighs about 32 lbs. An 18’ diameter x 5’ thick disc shaped balloon weighs about 50 lbs. The blower weighs about 40 lbs. We furnish estimated weights for the duct balloons in our quotations. To see a weight chart of various sizes, click here
Can I use station air to inflate the balloon?
No, each balloon must use its own 120V, 208V or 220V positive pressure blower.
What if the balloon gets torn, will it deflate?
Small tears won’t cause the balloon to deflate as the balloon is always pressurized as long as the blower remains on. The balloon can be temporarily repaired with duct tape if necessary to keep it inflated. We can also furnish a repair kit that includes 5 square feet of material and adhesive for small on site repairs. The balloon can be sent back to the factory for a more permanent repair.
Can I use a larger size balloon for an opening that is slightly smaller?
Yes, it is OK to use a slightly larger balloon in a smaller size existing duct work. It should still seal tightly, but you will need to be careful with the extra material getting in the way of your work space.
How does it compare in cost to other types of temporary barriers installed by our plant personnel or contractors?
Labor rates vary by location, but many customers have told us that the duct balloons will usually pay for themselves in the first installation and removal, and they are reusable.
What if I have structural supports in the area I want to install the balloon?
You may have to look at installing it in a different location. Most expansion joints are about 2’6” wide, and a 3’0” deep balloon will fit nicely in this area and provide a tight seal. Click here for more information.
How large or small can these balloons be made?
While there are no size limitations for very large balloons, the weight of the balloon can become prohibitive, as well as the access door it must go through. Balloons for very large duct work openings can be supplied in sections that mate together to make them easier to install and remove. Small balloons can be made for pipe sizes from 20” in diameter and larger.
How much differential pressure will it take before it begins to move?
All duct balloons are supplied with a high pressure blower rated at 8” w.c. They are also provided with anchor rings in the corners and grab handles around the perimeter that can be used as attachment points to tie the balloon off to keep it from moving. If the differential pressure in the duct work where the balloon is to be installed is more than 8” w.c. then using the anchor rings on the balloons as a tie down point is recommended in order to keep it in place.
We may be grinding or welding near the balloon, so how can we protect it?
The balloon can be supplied with additional anchor rings sewn into it at 24” centers so that a fire retardant blanket can be hung from it.
Do you need to erect a support structure in order to keep it in place?
Normally the balloon will hold tightly against the wall of the duct if sized and installed properly and the operating environment is only a natural draft. If the balloon is installed in front of a malfunctioning damper that has a negative pressure on one side of it, then it has nowhere to go. If the balloon can be installed near existing structural steel in the duct as shown here, then movement can be prevented. If there is no support steel present, then pad eyes should be installed in the duct work prior to the installation of the balloon. Nylon rope or straps can be attached between the tie down point and the anchor rings on the balloon to assure no movement can take place. A layout drawing is provided with all quotations that shows anchor ring and grab handle locations on the duct balloon.
Does it come in a storage box so I can safely store it until my next outage?
The balloon, blower and inflation tube are shipped in a heavy duty vinyl storage bag with a draw string top. Knock down type storage boxes are available for an additional cost.
Can the balloon be exposed to sunlight or high humidity conditions?
The material that the balloon is manufactured from is UV resistant and is also impregnated with a mildewcide to inhibit mold growth, so sun or high humidity conditions won’t affect it.
