Background
Companies like SpaceX value partners who are responsive, responsible, budget-conscious, and easy to work with throughout the life of a project.
SpaceX is one of the most recognized aerospace manufacturers in the world, known for designing and building rockets, spacecraft, and launch systems that operate under extremely demanding conditions. In environments like these, fabrication, welding, grinding, and blasting operations all have to support high production standards.
Because of that, companies like SpaceX typically look for suppliers that can deliver more than equipment alone. They value partners who are responsive, responsible, budget-conscious, and easy to work with throughout the life of a project. Strong customer service, practical engineering support, competitive pricing, and the ability to adapt as project requirements evolve all matter.
At its Cape Canaveral, Florida location, SpaceX contacted Baghouse.com for a budgetary proposal as it planned to move a sandblasting operation into a new building next to its fabrication and weld shop. At the time, the project was still taking shape. SpaceX had a rough outline of the building, a general idea of the blasting equipment size, and a vision for how the new space would be used, but it needed help translating that concept into a workable dust collection system.
Working from those early layouts and discussions, Baghouse.com helped determine the airflow requirements for the space. That evaluation led to a target of approximately 60,000 CFM, which became the foundation for the system design.
Scope of Work
This project involved designing a complete dust collection solution for the new facility, including the main equipment, ductwork, return air system, and the custom wall vent arrangement required for the building.
Using rough photos and preliminary layouts provided by SpaceX, the team at Baghouse.com developed an initial concept for the system and then refined it over several design iterations as the project changed. This included creating duct layouts, 3D models, and 2D drawings so the customer could better visualize how the system would fit into the building and function in real-world operation.
As the design progressed, Baghouse.com delivered an engineering package defining the duct routing, equipment location, duct sizes, and general system arrangement. That package gave SpaceX a clear path forward and ultimately served as the basis for approval and installation.
Solution
Based on the required airflow, process conditions, and the building layout, Baghouse.com recommended an ACT cartridge-style dust collector with a ground-mount fan. The final design centered on a downflow cartridge collector paired with a large New York Blower-style fan arrangement, giving the facility the airflow capacity needed to support both grinding and blasting operations.
A key part of the design was SpaceX’s request to return filtered air back into the building. This helped maintain more neutral building pressure and supported better airflow balance inside the new workspace.
Baghouse.com also designed and supplied the ductwork for the system, including the return air distribution. One of the more unique features of the project was the use of four large wall vent panels, each roughly 6 feet by 6 feet, that had to be carefully sized and integrated with the duct system to maintain the proper velocities for production needs.
Equipment installed
- • Dust Collector: Model ACT 5-100 cartridge collector
- • Filters: 100 cartridge filters, totaling 25,400 sq-ft of filter media
- • Filter Media: Nano-Elite nano-fiber filters, MERV 15
- • Air-to-Cloth Ratio: 2.36:1 at 60,000 CFM
- • Collector Footprint: 200” x 86” x 183”H
- • Hopper Clearance: 45” under hopper discharge
- • Cleaning System: Pulse control timer board with built-in DP gauge and venturi-assisted pulse cleaning
- • Construction: Fully welded heavy 7 and 10 gauge carbon steel
- • Valves: Goyen diaphragm and solenoid valves
- • Warranty: Made in the USA with 10-year manufacturer’s workmanship and materials warranty
Ground-mount fan
- • Fan: AirPro Blower BIHS Size 490 – New York Blower
- • Width: 95%
- • Speed: 1,180 RPM
- • Performance: 60,000 ACFM @ 9.00” WC static pressure
- • Air Density: 0.0734 lb/ft³
- • Outlet Velocity: 4,397 FPM
- • Motor: 150 HP, 3/60/460V
Ductwork and return air
- • Ductwork: 16–18 ga. galvanized steel, flanged
- • Wall Vent Hoods: Qty. 4 custom 6’ x 6’ side wall vent hoods
- • Return Air Trunk Line: 48” diameter, 16 ga. galvanized, flanged
- • Fittings: Qty. 1 90-degree elbow, Qty. 1 45-degree elbow
- • Branching: 48-30-30-30 flanged double branch
Installation Challenges
The most significant challenge came from the building itself. To make the return air design work, the team had to create large rectangular openings in the concrete wall so the custom vent panels and connecting ductwork could be installed. What looked straightforward on paper became more complex once structural limitations were taken into account.
Baghouse.com had to work through how to size the vents correctly, fit the ductwork into the available space, and maintain the proper air velocities for the process, all while working around the structural realities of the building. This required engineered header designs and some adjustments to the placement of components so everything could fit and function as intended.
Despite those challenges, the project moved forward successfully. From the first conversation to final completion, the overall timeline was about a year, much of which involved planning, layout development, revisions, and coordination. Once the project was approved and under contract, the pace accelerated significantly. Equipment was delivered in roughly seven to ten weeks, and the installation team was on site shortly after that. Final installation took about 10 days, and the project was completed in summer 2025.
In the end, the finished installation gave SpaceX a clean, high-capacity dust collection system that supported its grinding and blasting operations with plenty of airflow, a well-integrated return air arrangement, and a professional final appearance. Just as important, the project met expectations on speed, support, and competitiveness.
Outcome and Conclusion
This project is a good example of how successful dust collection work often starts long before equipment is built. SpaceX came to Baghouse.com with an emerging plan, rough building information, and a need for budgetary guidance. From there, Baghouse.com helped define the airflow requirement, developed the system concept, produced the engineering package, supplied the equipment, and completed the installation.
For customers looking for a supplier that is technically capable, responsive, cost-conscious, and committed to service, this project shows the value of working with a partner that can support the entire process.
