When specifying a linear bar grille or heavy-duty grille for a high-traffic environment, all-welded construction is the way to go. This technique welds face bars to support bars, resulting in strong, sturdy grilles that can be manufactured in large single pieces. All-welded grilles are ideal for rugged environments such as gymnasiums, warehouses, and parking garages.
How are All-Welded Grilles Made?
Face Bars: Face bars are laid face down in an upside-down fixed core jig to maintain consistent bar spacing intervals with tight tolerances.
Support Bars: Notched support bars are slid into place underneath and between the upside-down face bars.
Welding: Welds are applied at the intersection of every face bar and every support bar. Since the welding is done while the core is upside-down, the welds are not visible on the finished product.
Framing: The completely welded core assembly is turned right side up and welded to its frame, unless the grille is specified as a removable core type grille.
Are All-Welded Grilles Stronger than Pressed Grilles?
All-welded grilles are stronger than pressed grilles due to differences in the manufacturing process. Pressed grilles use a hydraulic press to force face bars and support bars together. In contrast, all-welded construction places welds where the face bars and support bars meet, creating a strong physical bond. This results in grilles that are more resistant to impact, gravity, foot traffic, and torsion while requiring fewer support bars.
What Are Other Benefits of All-Welded Grilles?
Alongside superior strength, all-welded grilles offer the following benefits.
Large Single Size: Thanks to their increased strength, all-welded grilles can be manufactured in far larger sizes than pressed grilles. They can be built to exact size specifications to cover very wide and/or very long ductwork openings.
Custom Shapes: The flexibility of all-welded construction allows grilles to be built in custom shapes that maximize space and airflow.
Ease of Installation: As all-welded grilles are sized to fully cover openings, they can be installed as-is—no on-site joining or bolting of multiple grilles required.
How to Specify an All-Welded Heavy-Duty or Linear Bar Grille
All-welded grilles are offered in a variety of tough materials, mounting options, and finishes to maximize performance and aesthetics.
Materials
Painted Steel: A commonly used, cost-effective material.
Aluminum: A mid-cost material that is lighter and more corrosion-resistant than steel.
Stainless Steel: A high-cost, heavy-duty material, chosen when environmental factors could impact the longevity of coated steel or aluminum.
Frame Type
Flanged Frame: The all-welded grille frame material forms a flange that overlaps with the wall or floor opening.
Band (or Straight) Frame: The all-welded grille frame contains no outward flange and is flush with the wall, creating a clean look.
Mounting Options
Face Mounting: The all-welded grille is mounted to the wall or floor with screws/fasteners that are visible on its face.
Concealed Mounting: The all-welded grille is mounted inside the wall or floor opening between the blades, concealing the fasteners.
Core Options
Fixed Core: The core, or the part of the all-welded grille inside of the frame, is welded directly to the frame.
Hinged Core: A section of the core is on a hinge, which can be lifted up to allow hand access to the inside of the duct.
Removable Core: The core is fully removable from the frame.
Finish
Painted: Steel or aluminum can be painted to match a desired color.
Satin: A polished look for aluminum or stainless steel.
Anodized: Aluminum treated for a durable finish.
Why KEES
KEES specializes in all-welded construction. We offer the largest single-size all-welded heavy-duty and linear bar grilles in the industry, packed and shipped from our manufacturing facility directly to you in one piece. Whether you need a long, thin floor grille for a narrow walkway, a wide rectangular grille for a gymnasium wall, or a small, trapezoidal grille just the right size for a cramped stairwell, the expert manufacturers at KEES will ensure a perfect fit.
