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Commercial HVAC — Rooftop Air Handler Replacement
Commercial HVAC

Rooftop Air Handler Replacement

Salt air is undefeated. On an oceanfront high-rise the rooftop equipment corrodes from the outside in, and by the time the cabinet seams are bleeding rust the chilled-water connections behind them are usually worse. This project replaced a bank of Trane air handlers that had reached exactly that point — cabinets rusted through, disconnects failing, and supply and return connections scaled to the point of no longer sealing.

Replacing a rooftop unit on an occupied building is a rigging job as much as a mechanical one. The existing piping was cut out and the old units flown off by crane, the curbs were opened up and prepped, and the new equipment was set, piped, and wired without shutting the building down around it.

The photos below run the job in order — existing conditions, demolition, the lift, and the finished install with new copper and steel piping.

On the Job

Before & After

Before — rust bleeding through every cabinet seam
Before — rust bleeding through every cabinet seam
Before — corroded disconnect and sagging condensate lines
Before — corroded disconnect and sagging condensate lines
Before — chilled-water connections scaled and rotted at the cabinet
Before — chilled-water connections scaled and rotted at the cabinet
Before — failed unions at the supply and return
Before — failed unions at the supply and return
Survey — assessing the units before demolition
Survey — assessing the units before demolition
Demolition — old piping cut out and staged on the roof
Demolition — old piping cut out and staged on the roof
Rigging — slings and chains set on the old unit
Rigging — slings and chains set on the old unit
Lift — breaking the old unit off the curb
Lift — breaking the old unit off the curb
Lift — the old air handler clear of the roof
Lift — the old air handler clear of the roof
Curb prep — duct openings exposed after removal
Curb prep — duct openings exposed after removal
After — new Trane air handler set and level
After — new Trane air handler set and level
After — new unit, full length
After — new unit, full length
After — new copper riser and brass isolation valves
After — new copper riser and brass isolation valves
After — new steel supply and return on painted stands
After — new steel supply and return on painted stands
After — piping complete and supported
After — piping complete and supported
Scope

What's Involved

  • Existing-conditions survey and corrosion assessment
  • Chilled-water isolation and demolition of failed piping
  • Crane lift planning, rigging, and removal of the old units
  • Curb prep and new air handler set
  • New copper and steel supply/return piping with isolation valves
  • Electrical disconnects, condensate, and startup

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