Custom Size Return Air Grille

Standard Return Air Grille Sizes

Return air grilles are typically made in standardized sizes. However, upon request, many grille suppliers do provide custom-made sizes at a higher price.

Return air grilles are standardized by 2 per size increase. The smallest return air grille is usually starts at 4 inches by 4 inches. So, the next corresponding return air grille size includes 4×6, 6×6, 6×4, 8×6, 4×8 and so on.The largest return air grille is typically stops at 48 inches by 24 inches.

Below is a list of standard return air grille sizes:

Standard return air grilles typically stop at around 48 inches by 24 inches as subsequent sizes are too large for standard applications in homes and commercial buildings. Certain places like factories and production plants may call for larger grille sizes but they are mostly custom-made.

How To Properly Size A Return Air Grille For Capacity

The capacity of your HVAC system determines the amount of air moving through your system, usually measured in cubic feet per minute . This dictates the total amount of return air grill area you need in your home.

There are two ways to determine this BTU output of the furnace or the tonnage of your air conditioner unit. These ratings can be found on the units themselves, typically as a sticker or newer models or a riveted plate on older models.

When using British Thermal Units to calculate your need:

• If you divide your furnaces BTU rating by 50, that tells you how much CFM your furnace blows. For example, a furnace rated at 100,000 BTUs pushes out 2000 cubic feet of air per minute.
• One square inch of filter grille area can handle 2 CFM, so in the example above, you would need 1000 a of total square inches of return grille area.
• Use the length and width of common grille or filter sizes 20 X 20, 25 X16, etc. to calculate their area, and that will tell you the number and sizes of return air grilles you need.

When using the tonnage of your cooling unit to calculate your need:

• As a general rule, you need 200 square inches of return air grille area per ton of your air conditioning equipment. For example a 3-ton residential cooling unit requires 600 square inches of grille area.

Return Air Grille Size Calculation

Return air grille size is calculated using the following formula:

Grille Area = Airflow ÷ Face Velocity ÷ Grille Free Area x 144

From the above formula, using 500 fpm with 70% free area, we get:

Grille Area = Airflow ÷ 500 ÷ 0.7 x 144

Let’s say we have an HVAC unit with 1050 CFM of airflow, then:

Grille Area = 1050 ÷ 500 ÷ 0.7 x 144Grille Area = 432 sq.in

Using the CFM chart for horizontal grilles, the 18 inches by 24 inches grille has a grille area of 432 which is suitable for the HVAC unit with 1050 CFM of airflow.

If you don’t prefer to use a horizontal grille, you can use the CFM chart for vertical grilles to find the 24 inches by 18 inches grille or the 36 inches by 12 inches grille. Both grilles are suitable for the HVAC unit with 1050 CFM of airflow.

However, for an airflow of 1050 CFM, we can actually use a more optimal grille size. For example, the 16 inches by 25 inches grille which only has a grille area of 400 sq.in.

The reason why we can use a smaller grille for the 1050 CFM is because of the assumption about the free area of the grille.

When calculating for the 1050 CFM, we assumed that the free area of the resulted grille is 70%. However, that’s not always the case.

A typical grille with about 16 inches by 25 inches size has a free area of around 80%. So, if we recalculate the grille area based on 80% free area, the result is as follow:

Grille Area = Airflow ÷ Face Velocity ÷ Grille Free Area x 144Grille Area = 1050 ÷ 500 ÷ 0.8 x 144Grille Area = 378 sq.in

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Custom Return Air Grilles For When Previous Hvac Contractors Or Builders Left Some Challenges For Future Homeowners Solutions For Uncommon Return Air Grille Sizes

Nobody seems to have a duct opening with standard specifications, and no amount of manipulations will make a standard size fit satisfactorily, so we have equipped ourselves to custom make many different sizes, depending upon whatever style you choose. Generally, custom air return grilles that are cast in a mold are less likely to be good candidates for customization, but most other styles may be workable. If you need custom return air grilles be sure to call us for advice and consultation as there are multitudinous avenues to misconfiguring.

Custom Size Handmade Solid Cast Bronze Air Return Grate Cover

Looking for a rich looking air return grill for your heritage home? Checkout our custom-made Air return Grill in Royal design

The custom made Air return Cover in Traditional design is Handmade in Solid Cast Bronze and comes with a LIFETIME WARRANTYThe beauty, strength and forever lasting feature of Bronze makes it the most desirable metal.Architectural bronze is a metal alloy that consists of 85% copper and other metal alloys . The higher the level of copper the higher will be the resistance to corrosion.The natural bronze finish is a LIVING FINISH that changes over time with the environment, climate, surroundings, and level of use. The finish ages naturally resulting in a unique patina and an overall ultimate finish.A textured surface of casted bronze architectural hardware is offered with natural bronze and bronze patina finish The color of weathered/aged finishes will continue to evolve over time and can verdigris in different climatic conditions. You should be aware that in most natural environments, verdigris is to be expected and results from the chemical reaction of sweat, dust, or changing weather conditions on metal. If this is not the result you want on your hardware, please discuss with us for giving more information on the advantages or disadvantages of other alternatives.*Bronze is a classic material timeless and yet so changeable.INSTALLATION:For Floor: Select Registers without holesFor Wall and Ceiling installation: Select Registers with countersunk holes

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Return Air Grille Sizes: 3 Cfm Charts + Grille Size Calculator

In HVAC, we have to choose the right return air grille size. Everybody knows that an adequately sized grill will ensure smooth airflow . However, not everybody knows what return grill size to choose.

What size return air grille do you need?

There are two ways how to figure out what return grille size you need:

What happens if the grill size is not appropriately sized?

• Choosing a grille that is too small will basically suffocate your HVAC system. The airflow HVAC system needs will not be sufficient if we choose a return grille size that is too small. Small grills can increase the noise levels as well due to increased sucking of air.
• Choosing a grille that is too big is less problematic. The HVAC system will have sufficient airflow but we will unnecessarily have to sacrifice additional space for the grille. This will also increase the overall cost of our HVAC system.

Return Air Grilles Made For Melbourne Conditions

Our sturdy aluminium louvre grilles can be adapted for both internal and external applications. When placed externally we will incorporate a bird wire mesh to guard against nesting birds or vermin.

• Manufacturing grilles since 1980
• Serving wholesale trade and retail customers
• Superior service at a competitive price

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Update Your Home With New Floor Registers And Grilles

Whether youre updating the look of your home with decorative floor registers or adding practical floor vent covers over air ducts, you have plenty of options. From lightweight plastic to warm wood and durable metal, floor vents come in a range of materials and colours. Looking for a simple white floor diffuser for the laundry room? No problem. Want to spruce up your living room floor vents with an intricate wooden cover? You got it. Todays floor registers and grilles can complement a variety of decors and blend in seamlessly with any flooring finish.

When choosing your floor registers or grilles, there are a couple of things to keep in mind. A register covers air duct holes in walls or floors and often features adjustable louvers or dampers to direct airflow. Grilles, on the other hand, do not have adjustable louvers. They simply cover the vents where air is blowing between the room and the central heating or cooling unit.

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Categories

• 3″ X 10″, 4″ X 10″

Eggcrate Grid Return Air Grilles A Common Element In Vintage Homes From The Late Eighteen Hundreds Until The Mid Nineteen Hundreds

Acquiring a vintage charmer house you may have existing eggcrate style registers, which is something you may want to emulate for historicity. Repeatedly over the last one hundred years the wooden slats may have disintegrated. It is exceedingly rare to discover one in satisfactory condition. Our restoration quality eggcrate style returns are made in a superior quality manner than those from generations ago. It is difficult not to appreciate the fashionable yet functional look of the eggcrate style. You may even retain a sense of responsibility to preserve the same style. Eggcrate style units are an admirable choice for illuminating in a floor. You can see our matching eggcrate heat registers by visiting heatregisters.com.

What is a return air grill?

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Some Things To Consider:

What do the terms grille and register mean? A grille is a vent that does NOT have a damper. A register on the other hand is a vent that does have a damper.

What is the difference between wall and floor grilles/registers?Floor grilles/registers can support the weight of a person while wall ones cannot.

When sizing grilles remember:

• Supply or exhaust application? It matters for some grilles.
• Dayus grilles are sized by the hole they fit into. We call the hole size the List Size. They are typically slightly undercut to make sure they fit the hole.
• Filter grilles are openable, should you need access or want to install a filter.

Vertical Return Air Grilles Cfm Chart

Vertical return air grilles are the most common type of grille used in single-family homes with a central air conditioning system. Following are tables showing the CFM of vertical grilles:

12 to 18 Tall Return Air Grilles

Honestly, I did spend a lot of unproductive time searching for the best grille size when I was working as a junior project engineer. Why did I never think of creating a whole table for myself?

Anyway, let’s see how to calculate return air grille size in a manual way.

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How To Calculate Return Grille Size

Lets presume that our HVAC system requires 400 CFM airflow. The grille size has to be big enough to allow for 400 CFM airflow.

Now, to properly calculate the return grille size, we have to make these two assumptions:

With these two concepts in mind, we can look at this return grille size formula:

Grille Area = Airflow ÷ Face Velocity ÷ Free Area × 144

In this equation, we see that we have the desired airflow , the face velocity , free area , and the 144 factor that converts the grille size into square inches.

Grille Area = 400 CFM ÷ 500 FPM ÷ 0.7 × 144 = 164 Sq In

That means we will need a grill with at least 164 square inches of area to accommodate for a 400 CFM airflow.

10×10 grille, for example, has a 100 sq in area it will be too small. 14×20 grille has a 280 sq in area it will be too big. The closest grille with at least 164 square inches area are 18×10 grill with 180 sq in area and 6×30 grille with 180 sq in area.

The Benefits Of The Right Return Air Grille

Whether you are building a new home, upgrading or renovating an older home, or just performing maintenance and upkeep, the right return filter grille coverage can make a big difference.

It may seem like a small consideration, but attention to this detail means greater comfort, lower energy bills, and less unnecessary wear and tear on your heating and cooling system.

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Return Air Grilles That Feature The Best In Filtering Technology

Our return air grilles all come with the option of a electrostatic air filter. These filters come with a lifetime warranty, and the user-friendly design of our grilles allows you to easily remove the filter when needed for inspection or cleaning to ensure that your filter continues to provide a lifetime of service as it filters out dust, allergens, and pollutants.

Return Air Grille Units An Opportunity To Incorporate Some Stylistic And Functional Improvements

Return air grilles are generally preponderantly larger than supply registers and are a prominent architectural element of structures both contemporary and historical. Consequently, considering they are substantially more prominent they are more noticeable and are not a secondary consideration. Regrettably, a typical return air grille is just a little bit on the unattractive side. Unfortunately, most contractor grade grilles are particularly inadequate from an aesthetic standpoint. We think our selection of hvac return air grilles represents just about any style in which a person might be interested.

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What Is A Return Air Grille

Grilles are designed to pull air out of a room, ensuring energy efficiency and relative comfort while also providing circulation back to the central heating or air conditioning unit. In other words, grilles bypass the inefficiency of sealed ducts while also supplying sufficient heating/cooling to every room in the house, without over pressurizing the house. They are normally installed in a wall, ceiling, or an opening in the floor, and are a major part of home and HVAC design. In fact, without return air grilles, circulation is nearly impossible, as you need both registers and air grilles to work in tandem to guarantee proper temperature control.

What Happen If You Use A Smaller Return Air Grille

Using a smaller return air grille will result in a higher face velocity with the same type of grille . With a higher face velocity, the grille may create audible noise. The smaller the grille, the greater the noise.

If you really need to use a smaller return air grille, I recommend you don’t exceed 800 fpm of face velocity. Alternatively, you can seek return air grilles with a larger free area. Otherwise, use more than one grille if possible.

Different grilles have different applications. If you want to learn about the different types of grilles used in HVAC, feel free to check out my blog post 4 Types of Grilles in HVAC .

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Custom Hvac Grilles In Aluminium

Our custom HVAC grilles in sturdy, modern aluminium provide homes and businesses with the solution they need. We can manufacture internal and external grilles with customisation options that are purely practical. If the area where the grille is to be placed is an unusual shape or size, then you can count on us to provide the perfect fit.

Of course, we can also provide customisation options that transform a grille into a thing of beauty, without compromising on its function. From decorative panels to unique colours and finishes, let us know what you have in mind and we will make it a reality.

Return Grille Size Calculator

You just insert the airflow your HVAC system needs , and you will get the minimal area of the grille size you need:

Example: Try calculating the minimal grille area for 600 CFM. You just slide the calculator to 600 and you get the calculate grille size 247 square inches. This means you need a grille size with at least 247 sq in area.

How to match the grille area to the actual grille size in inches?

You can use the following return grille CFM chart. There are 3 charts, namely:

• Horizontal grille size CFM chart. Horizontal grilles have a longer width dimension than the height dimension.
• Square grille size CFM chart. Square grilles have the same width and height dimensions.
• Vertical grille size CFM chart. Vertical grilles have a shorter width dimension than the height dimension.

Lets look at each of these CFM charts in turn:

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