Lucas Oil Stadium required a large‑scale air distribution system capable of delivering over one million cubic feet per minute of conditioned air to fans. The project included the installation of massive spiral ductwork integrated into the stadium’s roof structure. The solution provided a coordinated, timely, and structurally compatible method for handling the stadium’s ventilation needs.
Key Facts
- Ductwork up to 118 inches in diameter
- Hung from a 3‑piece support system for stability when the retractable roof is open
- 6‑ft‑long duct sections used
- Total airflow: 1,384,000 CFM
- 1,486 linear feet of 2‑inch dual‑wall spiral duct installed
- Interior duct: perforated steel
- Exterior duct: galvanized sheet metal
- Two inches of fiberglass insulation between duct layers
- Duct serves bowl air distribution from supply plenums in all four corners
- Four AHUs serve each quadrant
- Double‑wall plenums: 20,410 sq. ft. for supply; 12,541 sq. ft. for fresh air intake and exhaust
- Custom saddle taps, volume dampers, and accessories factory installed
- Deliveries coordinated in 132 box trailers and 36 dry vans
- Custom spiral machine heads fabricated to produce the duct size
Challenge
Design and install extremely large, highly visible spiral ductwork while maintaining aesthetic requirements and meeting strict construction schedules for a major stadium project.
Solution
FläktGroup SEMCO fabricated custom large‑diameter dual‑wall spiral duct with specialized machine heads. The duct was shipped in precise installation order and delivered just‑in‑time to the jobsite. Saddle taps, flanges, and accessories were pre‑fabricated, and orifice plates were used to achieve balancing without internal dampers.
Results
- Accurate fit and installation ensured despite large duct dimensions
- Just‑in‑time delivery prevented damage and supported strict construction sequencing
- Aesthetic design achieved with minimized duct size reductions
- Improved balancing reliability through use of orifice plates instead of dampers
- Supported overall project completion for stadium readiness
“SEMCO was the only manufacturer I felt comfortable dealing with for a project of this scale.”
Tim Moore
Design Engineer and Principal
Moore Engineers
Products Used
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