Custom Mesh Filter, Aluminum, 4 Inch Thick

Description

Product Overview

The HIAS40 Custom 4″ Washable Mesh Air Filter is a made-to-order heavy-duty industrial air filtration solution engineered for equipment requiring a 4-inch nominal depth filter (3-3/4″ actual depth) with non-standard dimensions and maximum dust-holding capacity. This permanent washable filter provides exceptional flexibility through three material construction options—aluminum (HIA), galvanized steel (HIG), or 304 stainless steel (HIS)—allowing you to match your filter to your specific operating environment and temperature requirements. Each HIAS40 filter features robust 9-ply media construction that delivers industry-standard 43% dust arrestance with superior dust-holding capacity, providing extended cleaning intervals and reduced maintenance frequency for HVAC systems, industrial equipment, and specialized air handling units in demanding applications.

Built to your exact specifications through our online configurator, the HIAS40 eliminates the frustration of discontinued filters and hard-to-find sizes for older or European equipment requiring deep-bed filtration. Whether you need a direct OEM replacement for legacy industrial air handlers with 4-inch filter banks, a high-temperature solution for industrial ovens and dryers requiring extended media life, or a corrosion-resistant filter for harsh chemical or marine environments with heavy particulate loading, the HIAS40’s three material options provide the versatility to meet your requirements. The aluminum option (HIA) offers lightweight, cost-effective performance up to 275°F, the galvanized steel option (HIG) provides enhanced durability up to 325°F, and the 304 stainless steel option (HIS) delivers maximum environmental resistance in extreme conditions up to 900°F continuous operation.

Every HIAS40 filter is precision-manufactured with material-matched components throughout—frame, media, face grids, and rivets—ensuring structural integrity and optimal performance across the filter’s 5-10 year service life. The 4-inch nominal depth (3-3/4″ actual) makes the HIAS40 ideal for equipment requiring maximum dust-holding capacity with custom face dimensions, fitting filter tracks and housings that accept nominal 4″ filters while providing the non-standard length and width measurements specified during ordering. The 9-ply media construction offers the highest dust-holding capacity in our custom filter line, extending cleaning intervals from months to potentially a full year in moderate-duty applications and dramatically reducing maintenance frequency in heavy-duty industrial environments.

As a permanent washable filter, the HIAS40 eliminates recurring replacement costs and reduces environmental waste through years of reliable reuse. Simple water washing restores filtration efficiency to like-new performance, making the HIAS40 a sustainable, economical choice for facilities seeking to reduce operating costs and environmental impact in applications where deep-bed filtration is required. Once you’ve ordered your custom HIAS40 filter, your exact dimensions are saved in your online account for effortless reordering—no need to re-measure or re-enter specifications. This streamlined reordering process ensures you’ll always have the right filter size on hand, with consistent performance across multiple orders in your most demanding filtration applications.

Material Selection Guide

HIA: Aluminum Construction (Standard Grade)

The HIA aluminum option represents the most cost-effective choice for standard industrial and heavy-duty commercial HVAC applications requiring 4-inch depth filtration. Constructed with a .030″ aluminum frame, 9-ply aluminum media, and 24-gauge aluminum face grids, the HIA configuration provides excellent performance in typical operating environments up to 275°F continuous temperature. Aluminum’s lightweight characteristics (approximately 30% lighter than galvanized steel) simplify installation and handling of these larger, deeper filters, while the natural oxide layer provides moderate corrosion resistance in normal humidity conditions. The HIA option is ideal for manufacturing facilities, warehouses, large commercial buildings, and industrial applications where temperature and corrosive exposure remain within normal ranges but extended cleaning intervals from 4″ depth are required. Expected service life with proper maintenance: 5-10 years.

HIG: Galvanized Steel Construction (Enhanced Durability)

The HIG galvanized steel option offers enhanced mechanical durability and improved corrosion resistance compared to aluminum, making it suitable for more demanding industrial environments requiring 4-inch depth filtration. Built with a 24-gauge galvanized steel frame, 9-ply aluminum media, and 30-gauge galvanized face grids, the HIG configuration handles higher temperatures up to 325°F continuous operation and provides superior frame rigidity for applications with higher static pressures or mechanical stress common in deep-bed filter installations. The zinc coating on galvanized steel delivers better protection against moisture and mild chemical exposure than uncoated aluminum, extending filter life in warehouses, manufacturing facilities, outdoor installations, and semi-industrial environments. The HIG option balances performance and cost for industrial users requiring moderate temperature and corrosion resistance with maximum dust-holding capacity. Expected service life with proper maintenance: 5-10 years.

HIS: 304 Stainless Steel Construction (Harsh Environment Grade)

The HIS 304 stainless steel option is specifically engineered for extreme environments where harsh conditions would rapidly degrade aluminum or galvanized alternatives, while also requiring the extended cleaning intervals that 4-inch depth provides. Featuring a 24-gauge 304 stainless steel frame, 9-ply stainless steel media, and 30-gauge 304 stainless face grids, the HIS configuration handles continuous temperatures up to 900°F and provides maximum resistance to corrosive chemicals, salt spray, high humidity, and aggressive cleaning agents. The HIS is the required choice for industrial ovens, dryers, powder coating operations, food processing facilities, coastal/marine environments, chemical processing plants, and applications involving frequent washdown with caustic cleaners—all while providing the longest possible cleaning intervals from 9-ply media construction. While the HIS option represents a higher initial investment, its ability to withstand conditions that would destroy other materials makes it the most economical long-term solution for harsh environments requiring maximum dust-holding capacity. Expected service life with proper maintenance: 5-10 years in extreme conditions.

Industrial Applications

Discontinued and Legacy Equipment

The HIAS40 provides the perfect solution when OEM filters for older industrial HVAC systems and process air equipment are no longer available from the original manufacturer. Many legacy industrial air handlers, large fan coil units, and process air systems require 4-inch depth filters in non-standard face dimensions that have been discontinued or are prohibitively expensive through OEM channels. By ordering custom HIAS40 filters manufactured to your exact specifications, you maintain optimal filtration performance without costly equipment replacement or modification. Your custom dimensions are saved for easy reordering, ensuring consistent fitment across multiple replacement cycles. The 5-10 year washable design combined with extended cleaning intervals from 9-ply construction reduces total cost of ownership compared to disposable alternatives, even for equipment with odd or obsolete filter sizes requiring deep-bed filtration.

European and International Equipment

European industrial manufacturers and international equipment suppliers often specify metric filter dimensions and non-standard depth combinations that don’t align with U.S. standard sizes. The HIAS40 accommodates these unique dimensional requirements by manufacturing filters to your exact metric or imperial specifications, eliminating forced-fit installations and air bypass issues in deep-bed filter applications. Whether your equipment requires 600mm × 800mm dimensions, unusual aspect ratios, or metric depths with imperial face dimensions, the HIAS40 configurator converts your measurements into a precision-manufactured filter that fits properly the first time. The three material options ensure compatibility with European temperature specifications and environmental requirements across diverse climates and industrial processes requiring 4-inch depth filtration.

High-Temperature Industrial Processes

Industrial operations involving elevated temperatures demand filtration solutions that maintain structural integrity and performance under thermal stress while providing extended service intervals. The HIAS40’s three material options provide temperature flexibility from 275°F (aluminum) to 900°F (304 stainless steel), accommodating pre-filters for industrial ovens, dryers, heat treating furnaces, powder coating booths, and high-temperature process air systems. The 9-ply media construction maintains mechanical strength and filtration efficiency at elevated temperatures while providing maximum dust-holding capacity to extend cleaning intervals, while material-matched rivets and frame construction prevent thermal expansion mismatches that cause frame warping or media separation. For applications between 275°F and 325°F, the galvanized option provides cost-effective performance. For sustained temperatures above 325°F or intermittent spikes approaching 900°F, the 304 stainless steel construction is essential for maintaining the deep-bed filtration advantages.

Heavy Particulate Loading Applications

Facilities with extremely high particulate loading rates benefit dramatically from the HIAS40’s 9-ply deep-bed construction, which provides the highest dust-holding capacity available in custom washable filters. Woodworking facilities, metalworking operations, cement plants, bulk material handling facilities, and other high-dust industrial environments can extend cleaning intervals from weekly or monthly (with thinner filters) to quarterly or even annually (in moderate-duty cycles) with 4-inch depth filtration. The HIAS40’s 304 stainless steel option (HIS) delivers maximum corrosion resistance for chemical processing plants, coastal industrial facilities, marine applications, commercial kitchens, car wash installations, food processing plants, and pharmaceutical cleanrooms requiring frequent washdown with caustic agents—all while providing extended service intervals between cleanings. The aluminum and galvanized options serve heavy-particulate applications cost-effectively where corrosive conditions are not present.

Construction Features

Precision-Engineered Deep Frame

Each HIAS40 filter features a precision-mitered deep frame constructed from your selected material—.030″ aluminum (HIA), 24-gauge galvanized steel (HIG), or 24-gauge 304 stainless steel (HIS)—manufactured to your exact custom length and width specifications with ±1/8″ tolerance. The frame corners are joined with material-matched pop rivets (aluminum, galvanized, or stainless steel respectively) that provide superior strength compared to spot-welded or glued construction, maintaining structural integrity through hundreds of wash cycles and years of thermal expansion/contraction. The 3-3/4″ actual depth (4″ nominal) is held to ±1/16″ tolerance, ensuring proper fitment in filter tracks and housings designed for standard 4″ filters. The deep frame geometry accommodates the 9-ply media pack while maintaining smooth airflow transition from inlet to outlet, with reinforced corners to handle the additional weight and stress from deep-bed filter construction.

9-Ply Expanded Media Construction

The HIAS40’s filtration effectiveness comes from its robust 9-ply expanded screen wire media, offering the highest dust-holding capacity available in custom washable filters and extending cleaning intervals far beyond thinner configurations. For HIA and HIG options, the media is constructed from crimped aluminum wire mesh that creates turbulent airflow patterns to trap particulate while maintaining low pressure drop across nine distinct filtration layers. For the HIS option, the media is constructed from 304 stainless steel wire mesh that provides the same filtration characteristics with added corrosion resistance for harsh environments. The expanded media design increases effective filtration surface area beyond the nominal face dimensions, enhancing dust-holding capacity and extending cleaning intervals dramatically. Multiple media layers are precisely stacked and secured to the frame, preventing media shifting or compression that would create air bypass channels. The 9-ply configuration balances filtration efficiency, pressure drop, and mechanical durability for the most demanding industrial applications requiring maximum dust-holding capacity.

Corner Drain System

All HIAS40 filters incorporate a corner drain system that facilitates water drainage during washing and prevents moisture accumulation during operation. Small drain holes located at the frame’s bottom corners allow water to exit freely when the filter is positioned vertically for washing, accelerating drying time and preventing water pooling that could lead to microbial growth—particularly important in deep filters where water can be trapped in the 3-3/4″ depth. In vertical installation orientations, these same drain holes prevent condensation buildup that might otherwise accumulate in the frame channels, particularly important in high-humidity environments or applications with significant temperature differentials. The corner drain system is integrated into the frame design without compromising structural strength or creating air bypass paths, with proper sizing to handle water drainage from the larger media pack.

Material-Matched Face Grids

The face grids on each HIAS40 filter are fabricated from the same material family as the frame and media to ensure consistent thermal expansion characteristics and prevent galvanic corrosion at contact points. HIA filters feature 24-gauge aluminum face grids, HIG filters use 30-gauge galvanized steel face grids, and HIS filters incorporate 30-gauge 304 stainless steel face grids. These face grids provide upstream and downstream protection for the 9-ply media layers, preventing mechanical damage during handling, installation, and removal—critical for deep filters with higher weight and more fragile extended media packs. The grid pattern is engineered to maximize open area (typically >70%) to minimize additional pressure drop while providing adequate structural support for the deep-bed construction. Face grids are permanently attached to the frame during manufacturing, ensuring they remain properly positioned throughout the filter’s service life and extended cleaning intervals.

Maintenance & Cleaning

Washing Instructions

The HIAS40’s permanent washable design enables hundreds of cleaning cycles throughout its 5-10 year service life, with cleaning required far less frequently than thinner filters due to the 9-ply media’s superior dust-holding capacity. When pressure drop reaches 0.50″ w.g. (or per your facility’s maintenance schedule), remove the filter from the equipment and rinse both sides with water pressure between 40-60 PSI—standard garden hose pressure is ideal. High-pressure washers exceeding 1000 PSI can damage the media and should be avoided. For filters with heavy grease loading or stubborn particulate (common after extended service intervals), pre-soak the filter in warm water with mild detergent for 30-60 minutes before rinsing to allow deep penetration through the 9-ply media. Industrial facilities may use commercial parts washers or automated filter cleaning systems sized for deep filters. After washing, shake excess water from the frame and allow the filter to air dry completely before reinstallation—this typically requires 4-8 hours in ambient conditions or 60-120 minutes with forced air drying due to the 3-3/4″ depth. Never reinstall a wet filter, as trapped moisture can promote microbial growth and accelerate corrosion even in stainless steel components.

Inspection & Service Life

During each cleaning cycle, visually inspect the HIAS40 for signs of mechanical damage, media separation from the frame, bent face grids, or compromised frame corners—particularly important for deep filters that experience higher mechanical stress. Minor dents in the frame that don’t affect fitment or sealing are generally acceptable. However, torn media, missing rivets, or separated frame corners indicate the filter should be replaced. The 304 stainless steel option (HIS) exhibits virtually no corrosion in properly maintained installations and typically reaches end-of-life due to mechanical damage rather than material degradation. The aluminum option (HIA) may show white oxide formation over time, which is normal and doesn’t affect performance. The galvanized option (HIG) may show red rust spots after several years in high-moisture environments, indicating the zinc coating has been compromised in those areas. With proper maintenance and appropriate material selection for the operating environment, expect 5-10 years of reliable service across all material options with extended intervals between cleanings compared to thinner filters.

Installation

Installation Guidelines

Installing your custom HIAS40 filter ensures optimal performance when proper procedures are followed. Note that 4-inch depth filters are heavier and bulkier than thinner configurations, potentially requiring two-person installation for larger custom sizes, particularly in stainless steel construction. Verify that the filter track or housing is clean and free of debris before installation—old gasket material or dust buildup can prevent proper seating. Confirm the HIAS40’s custom dimensions match your ordered specifications by measuring the filter before installation; the dimensions should be within ±1/8″ of your order. If your equipment uses filter tracks, slide the HIAS40 into the tracks with the upstream face (typically marked with airflow direction arrows) oriented toward the incoming airflow. For equipment with filter frames or holders, ensure all sides of the HIAS40 seat evenly against the gasket or seal surface. The 4″ nominal (3-3/4″ actual) depth should fit snugly without forcing—if the filter binds or requires excessive force, verify the ordered dimensions against the actual filter opening.

Airflow Direction & Orientation

The HIAS40 is bidirectional in terms of filtration performance—airflow can pass through either face with equivalent dust arrestance and pressure drop. However, for ease of maintenance and optimal dust release during cleaning of the deep 9-ply media pack, install the filter with the airflow direction arrow (if marked on the frame) pointing in the predominant airflow direction. In horizontal airflow applications (side-to-side), orient the frame’s drain holes downward to facilitate condensation drainage through the 3-3/4″ depth. In vertical upflow or downflow applications, position the drain holes toward the downstream side to prevent water accumulation during operation. If your HVAC system experiences bidirectional airflow due to economizer operation or reversing fans, the HIAS40 will perform effectively in both directions, though cleaning may be slightly more challenging with dust embedded from both sides.

Sealing & Bypass Prevention

Proper sealing around the HIAS40’s perimeter is critical to prevent air bypass, which allows unfiltered air to pass around the filter rather than through it—particularly important in deep-bed filtration where the investment in 4″ depth is wasted if air bypasses the filter. If your equipment uses compression gaskets (typically 1/2″ to 3/4″ thick neoprene or foam for 4″ filters), verify the gaskets are in good condition and replace them if compressed, hardened, or torn. The HIAS40’s rigid deep frame provides an excellent sealing surface for gasket-based systems. For filter track systems that rely on frame-to-track contact for sealing, inspect the tracks for damage, warping, or debris buildup that might create gaps. The HIAS40’s ±1/8″ dimensional tolerance ensures proper fitment in correctly-sized filter openings—if gaps larger than 1/4″ exist around the filter perimeter, your filter opening dimensions may have been measured incorrectly when ordering. Contact technical support to verify proper sizing for replacement orders.

Frequently Asked Questions

How do I choose between aluminum, galvanized, or stainless steel for my HIAS40?

Select based on your operating temperature and environmental conditions rather than service life, as all three materials offer 5-10 years of reliable performance with proper maintenance. Choose aluminum (HIA) for cost-effective performance in standard industrial and commercial applications up to 275°F with normal humidity and no corrosive exposure where 4″ depth extends cleaning intervals. Choose galvanized steel (HIG) for enhanced durability and moderate corrosion resistance in industrial settings up to 325°F with moderate moisture or outdoor installations. Choose 304 stainless steel (HIS) for maximum environmental resistance in harsh conditions up to 900°F, including corrosive chemicals, salt spray, high humidity, aggressive cleaning agents, or extreme temperatures. The stainless option’s higher cost is justified when harsh conditions would rapidly degrade aluminum or galvanized alternatives, not for extended service life.

What is the difference between 4″ nominal and 3-3/4″ actual depth?

The 4″ nominal dimension represents the industry-standard sizing convention for filters in this thickness range, while the 3-3/4″ actual dimension is the precise depth of the manufactured filter. This 1/4″ difference allows proper fitment in filter tracks and housings designed for “4-inch filters,” which typically have 4″ wide channels that must accommodate the filter plus clearance for insertion and removal. If your equipment specifies a 4″ filter depth, the HIAS40 with 3-3/4″ actual depth is the correct choice. If your equipment requires an exact 4″ depth (unusual), specify this requirement when ordering so manufacturing can adjust the depth accordingly.

Can I order different materials for the same dimensions?

Yes. Once you’ve ordered an HIAS40 filter in specific custom dimensions, your account saves those dimensions permanently for easy reordering. When placing subsequent orders, you can select a different material option (HIA, HIG, or HIS) while maintaining the same length and width specifications. This flexibility allows you to upgrade from aluminum to stainless steel if operating conditions change, or to order multiple filters in different materials for comparison testing. The frame depth remains 3-3/4″ actual (4″ nominal) regardless of material selection.

How does the 4″ filter compare to 1″ and 2″ filters in dust-holding capacity?

The HIAS40’s 9-ply construction provides dramatically higher dust-holding capacity compared to the HIAS10’s 5-ply (1″) and HIAS20’s 7-ply (2″) configurations. This increased capacity can extend the time between cleaning cycles from weeks or months (with thinner filters) to quarterly or even annually in moderate-duty applications, dramatically reducing maintenance frequency and labor costs. However, the HIAS40’s initial pressure drop and weight are higher than thinner filters. The 4″ depth is ideal when maximum dust-holding capacity and extended cleaning intervals are priorities, while space and weight constraints may favor thinner configurations.

Does material selection affect filtration efficiency?

No. All three material options (aluminum, galvanized, and stainless steel) deliver identical 43% dust arrestance because filtration occurs in the 9-ply expanded media, which maintains the same layer count and geometry across all configurations. The primary differences between materials are temperature rating (275°F/325°F/900°F), corrosion resistance, and frame weight. Filtration performance, pressure drop, and dust-holding characteristics remain constant regardless of whether you select HIA, HIG, or HIS construction.

How often should I clean my HIAS40 filter?

Cleaning frequency depends on your specific operating environment and dust loading, but the 4″ depth with 9-ply media extends intervals dramatically compared to thinner filters. Monitor pressure drop across the filter using a differential pressure gauge (magnehelic gauge), and clean when pressure drop reaches 0.50″ w.g. or per your facility’s preventive maintenance schedule. In light-duty applications, cleaning may be required only 1-2 times per year. In moderate industrial environments, quarterly cleaning is typical. In heavy-duty applications with high particulate loading, cleaning every 2-3 months may be necessary. The HIAS40’s superior dust-holding capacity generally extends cleaning intervals 2-3 times longer than 1″ filters in equivalent applications.

Will the HIAS40 fit in my existing 4″ filter housing?

The HIAS40 is manufactured to the exact custom dimensions you specify during ordering, so fitment depends on accurate measurement of your existing filter opening. Measure the length and width of your current filter or the filter track/housing opening. The HIAS40 should be ordered slightly undersized (typically 1/4″ to 1/2″ smaller in each dimension) to allow for insertion and removal. For filter track systems, measure the internal dimensions of the tracks. For filter frame systems, measure the frame opening. If you’re uncertain about proper sizing, contact technical support with your measurements before ordering. The 3-3/4″ actual depth (4″ nominal) fits equipment designed for standard 4″ filters.

Can I use the stainless steel HIAS40 in a standard commercial HVAC system?

Yes. The 304 stainless steel option (HIS) functions perfectly in standard commercial HVAC systems and provides identical filtration performance to the aluminum option. However, the stainless configuration costs significantly more than aluminum and is engineered for harsh environments that would damage aluminum filters. Unless your application involves high temperatures (above 275°F), corrosive chemicals, salt spray, or aggressive cleaning agents, the aluminum option (HIA) is the more economical choice and will deliver the same 5-10 year service life in normal commercial environments. Reserve the stainless steel option for conditions that specifically require its superior environmental resistance.

What happens if I order the wrong dimensions?

Because each HIAS40 is custom-manufactured to your specifications, filters cannot be returned or exchanged due to incorrect dimensions. We recommend the following to ensure accurate sizing: (1) Measure your existing filter if available, (2) Measure the filter housing or track opening in multiple locations to verify consistency, (3) Account for clearance—order 1/4″ to 1/2″ smaller than the housing opening to allow insertion/removal, (4) If uncertain, contact technical support before ordering to verify your measurements. Once your order is placed, you’ll receive a confirmation email listing the exact dimensions that will be manufactured—review this confirmation immediately and contact customer service if corrections are needed before production begins.

Why Choose the HIAS40 Custom Washable Filter?

The HIAS40 Custom 4″ Washable Mesh Air Filter represents the ultimate solution for equipment requiring non-standard filter dimensions with maximum dust-holding capacity and extended cleaning intervals. By offering three material construction options—aluminum, galvanized steel, and 304 stainless steel—the HIAS40 provides unmatched flexibility to match your filter to your specific operating environment, from cost-effective performance in standard industrial applications to maximum environmental resistance in extreme conditions. Every HIAS40 is precision-manufactured to your exact specifications, eliminating the frustration of discontinued OEM filters and hard-to-find sizes while providing direct replacement capability for legacy equipment requiring deep-bed filtration.

The permanent washable design delivers exceptional value through 5-10 years of reliable service across all material options, dramatically reducing total cost of ownership compared to disposable alternatives. With 9-ply media construction providing superior dust-holding capacity and 43% dust arrestance, the HIAS40 protects your valuable industrial equipment while extending cleaning intervals from months to potentially a full year in moderate applications and dramatically reducing maintenance frequency in heavy-duty environments. The robust construction—precision-mitered deep frames, material-matched pop rivets, and integrated corner drain system—ensures structural integrity through hundreds of wash cycles and years of thermal cycling in demanding industrial applications.

Once you’ve placed your initial order, your custom dimensions are permanently saved in your online account, making reordering effortless—no need to re-measure or re-enter specifications. This streamlined reordering process ensures you’ll always have the right filter size on hand, with consistent performance across multiple replacement cycles in your most demanding filtration applications. Whether you’re replacing filters in discontinued industrial equipment, accommodating European metric dimensions, requiring specialized materials for high-temperature or corrosive environments, or simply need the maximum dust-holding capacity available in custom washable filters, the HIAS40’s custom manufacturing capability and three-material flexibility provide the exact solution you need.

Choose the HIAS40 Custom 4″ Washable Mesh Air Filter for permanent, sustainable air filtration that’s engineered precisely for your equipment, manufactured to your exact specifications, and built to last 5-10 years through hundreds of cleaning cycles. Experience the peace of mind that comes from custom filters that fit perfectly, perform reliably with extended service intervals, and deliver exceptional value throughout their extended service life in your most demanding industrial filtration applications.