In many facilities, the ventilation system looks quite different after a few years than it did in the original plans. New machinery, additional processes, and more workstations mean that new exhaust points are constantly being added—and the existing system must grow along with them.
This is precisely when a key question arises: How can an existing ventilation system be expanded without shutting down production for days? This article shows how operators of systems for chemically contaminated process air can plan and implement expansions to their existing systems—using saddle pieces, flow-optimized fittings, and Beck’s EffiTech plug-in system.
Why Additions to Existing Buildings Are Becoming the Norm
Hardly any process air system remains unchanged throughout its entire service life. Typical factors include:
- new processes or products,
- additional workstations that require exhaust ventilation,
- stricter requirements for emissions and occupational safety.
In laboratories, electroplating shops, and chemical or pharmaceutical facilities, it quickly becomes clear that simply “building a new system” is not an option. The existing ventilation system must be expanded—ideally where the new process air is actually generated, and ideally without taking the entire exhaust air system offline.
The challenge: Expansion without a long shutdown
In theory, any extension could be handled in the same way as is standard practice on a construction site: cut the pipe, install a new T-fitting, reassemble, and test. In practice, however, this is difficult in an operational process air system, because
- pipes are often difficult to access,
- the modification requires completely shutting down individual lines, and
- and every intervention carries the risk of additional leaks.
That is why many planners and operators rely on components specifically designed to expand existing ventilation systems when retrofitting—with as little disruption to the existing system as possible and minimal downtime.
Retroactive diversion: When the saddle connection is advantageous
Once it is clear where an additional extraction point is to be installed, the question arises as to how best to integrate it into the existing ductwork. One solution has proven particularly effective in existing systems: the saddle fitting.
A typical scenario: The main duct of an exhaust ventilation system is already running along the ceiling of the facility; the system is operational, but an additional exhaust point is needed—for example, for a new tank in the electroplating shop or an additional exhaust vent in the laboratory. This is where the saddle fitting really shines. It is welded onto an existing pipe and creates a retrofitted branch from the main line into a secondary line without having to dismantle the entire line.
The major advantage over a retrofitted T-fitting: Instead of dismantling, realigning, and reassembling the pipe section, only a localized intervention is required. The ventilation system usually only needs to be shut down briefly, the affected area remains manageable, and large parts of the system can continue to operate.
If you’d like to delve deeper into the question of when a saddle fitting and when a T-fitting is the better choice, we recommend our previous blog post “Saddle Fitting vs. T-Fitting: When Is a Retrofit Branch Worth It?”
Best Practices: Three Common Scenarios for Expansion
Anyone looking to expand a ventilation system or retrofit a process air system usually faces one of these three scenarios:
1. New consumption point in the existing system
An additional machine, another tank, or an additional laboratory workstation needs to be connected.
Solution: Retrofitted branch connection with a saddle fitting and a new branch line.
2. Capacity increase in specific areas
Existing processes are being used more intensively—the existing extraction points are no longer sufficient or need to be supplemented.
Solution: Additional outlets on the existing run, expansion with flow-optimized fittings.
3. Layout changes in the lab or production
area Equipment is being rearranged, workstations are moving, and new zones are being created.
Solution: Adapting existing piping, additional branches, a combination of saddle fittings and flexible plug-in connections.
In all three cases, the following applies: The fewer existing lines that need to be dismantled, the faster and more reliably the ventilation system can be expanded.
EffiTech Plug-in System: Expansion without welding or gluing
In addition to traditional welded piping systems, Beck offers the EffiTech push-fit system—a solution specifically designed for quick expansions and modifications, making it ideal for retrofitting existing process air systems.
The principle is simple: The components are assembled by hand without tools, and a 5-layer elastomer lip seal also ensures:
- completely leak-proof, chemical-resistant connections,
- automatic alignment during assembly,
- reconnectable and therefore flexible connections.
So instead of planning welding work in existing systems, new lines can be installed with EffiTech like a modular system. This significantly shortens installation time and reduces downtime to a minimum.
Step by step: How a retrofit typically proceeds
To ensure that an expansion of the existing system runs smoothly, a clear process has proven effective in practice.
1. Define the current system and the goal
First, determine:
- What airflow rates are already in place?
- Where should additional extraction points be installed?
- What materials are used (e.g., PVC, PVC UV, PP, PPs, PPs el, PVDF, PE)?
- How accessible are the existing pipes?
This assessment forms the basis for determining where saddle fittings, where T-fittings, and where the EffiTech plug-in system are the most sensible solutions.
2. Check flow and sizing
Especially when retrofitting process air systems, it is important to keep an eye on flow conditions. Beck provides support here with:
- flow calculations,
- sizing recommendations for new lines,
- selection of flow-optimized fittings.
The goal is to expand the ventilation system without causing undesirable effects such as excessive pressure losses, uneven exhaust, or fan overload.
3. Plan installation with minimal disruption
In the final step, the actual expansion is planned so that operations are disrupted as little as possible:
- Work during scheduled maintenance windows or periods of low production,
- selective interventions using saddle fittings instead of extensive disassembly,
- Use of the EffiTech plug-in system to eliminate the need for welding.
This transforms a complex task into a clearly structured project: expanding the existing ventilation system, but with manageable effort and without prolonged system downtime.
Would you like to plan your retrofit? We’d be happy to advise you!
Materials and Compatibility: Key to Process Reliability
When expanding exhaust air and process air systems, the focus is not only on the mechanical aspects but also on material durability. Beck offers piping components and fittings in a wide range of materials:
- PVC / PVC UV for many standard applications and outdoor use
- PP / PPs for increased chemical resistance
- PPs el for areas with electrostatic discharge requirements
- PVDF for particularly aggressive media
- PE as a robust, versatile solution
The advantage for operators: Expansions can be planned to be compatible with existing piping, both in terms of flow characteristics and chemical resistance.
What sets a good extension apart from a "quick fix"
Expanding a ventilation system involves more than just “attaching an extra pipe.” Effective solutions are meticulously engineered: airflow, air volume, pressure drop, and materials are all carefully coordinated. At the same time, the retrofit is organized in such a way that operations can continue as much as possible and future adjustments remain feasible. Equally important is the documentation, including CAD data, technical documentation, and flow calculations, which make the expansion traceable and verifiable. This is exactly where Beck-Systeme comes in: with precision-manufactured components, suitable materials for process air, and targeted support for planning and design.
Support from Beck: From concept to finished expansion
Whether you need a single new branch for a laboratory fume hood or want to connect an entire production line to your existing exhaust system—the process is always similar: determine your needs, check the airflow, select suitable components, and plan the installation so that operations are disrupted as little as possible.
Beck supports you throughout this process with personalized advice on saddle fittings, piping components, and the EffiTech plug-in system; with flow calculations and sizing recommendations; with CAD data and technical documentation for your planning; and with a product range specifically designed for chemically contaminated process air. This turns the question “How can we expand our ventilation system without shutting everything down?” into a clear, actionable solution—step by step, systematically.
We're here to support you on your next project
If you are considering expanding an existing ventilation or process air system, the experts at Beck will be happy to assist you personally. Together, we will assess your current situation, identify the right technical solution, and support you every step of the way—from planning to implementation.