CFD-Guided Air Distribution for a Warehouse in Bhiwandi
In Bhiwandi, a major warehousing and logistics area near Mumbai, large warehouse facilities operate under constant pressure to maintain stable indoor conditions across vast volumes of space. One such facility, spanning 110 meters by 100 meters with a clear height of 25 meters, faced the challenge of delivering effective cooling across multiple rack levels, while working within tight spatial and time constraints.
The air distribution solution needed to be powerful, precise, and fast to install. Traditional ducting systems, with their weight and rigidity, were simply not practical for this environment.
Specification
Combi 60
Dark Grey
FabFlow & SonicFlow
Type 1
210,000 CFM
Engineering a Smart Air Distribution System
To address these demands, a fabric-based air distribution system was selected to deliver even, well-controlled airflow throughout the warehouse. This approach ensured that conditioned air reached every level of the racking system evenly, eliminating hotspots and improving overall thermal comfort throughout the warehouse.
Given the scale and complexity of the project, the airflow design was thoroughly validated using Computational Fluid Dynamics (CFD) analysis. This digital modeling phase played a critical role in fine-tuning duct dimensions, airflow rates, and outlet configurations, allowing the system to perform exactly as intended from the moment it was commissioned.
Overcoming Spatial Constraints
One of the most significant challenges of the project was the limited space available between existing support rafters. Routing large duct runs through these narrow zones required a solution that could adapt to the building’s structure without compromising airflow performance.
The lightweight and flexible nature of fabric ducting proved decisive. Multiple duct runs of up to 100 meters in length were installed efficiently, something that would have been extremely difficult using conventional metal ductwork.
Speed of Installation and Project Execution
Despite the warehouse’s size and the complexity of the installation, the entire project was completed within an accelerated 15-day timeline. The reduced weight of the fabric ducts, combined with simplified suspension and handling, allowed installation teams to work quickly and safely, minimizing disruption and ensuring an early handover to the client.
Measurable Results and Operational Benefits
Following installation, the warehouse experienced immediate operational benefits. The fabric ducting system delivered uniform air distribution, improved cooling efficiency, and contributed to significant energy savings during daily operation. Just as importantly, the rapid completion of the project enabled the client to bring the facility fully online without delay.
