The Challenge
Across the healthcare industry, aging mechanical systems present a growing challenge. In older facilities, building designs often placed air handling units (AHUs) deep within hospitals, rarely with HVAC system upgrades in mind. For facilities like Ben Taub Hospital, shutting down entire systems to perform replacements can be cost-prohibitive and logistically difficult to execute without disrupting patient care.
Innovation through Expertise – The 'Aha' Moment
For the HVAC system upgrades, instead of tearing out and replacing the aging AHUs, the project team opted for a creative and cost-effective alternative: AHU refurbishment. While this method required precision and intense coordination, it eliminated the need for structural demolition and allowed patient services to continue uninterrupted.
To support each refurbishment phase, we installed 2 temporary rooftop AHUs, delivering 140,000 cubic feet per minute (CFM) of conditioned air to maintain operations. The team reimagined the design strategy, bypassing the original, scaffolding-heavy plan, and instead installed over 1,500 linear feet of 72-inch temporary ductwork, connecting them to the AHUs through targeted openings.
Over the course of 20 shutdowns, supported by the temporary cooling system, we completely refurbished the interior and exterior of each AHU. Each unit took 6–8 weeks and included updates to components such as:
- Supply and return air fans
- Pre-filter and final filter banks
- Digital controls
- Reinforced steel flooring
- Insulation and coating
After the AHU refurbishment, a power surge caused a return riser duct to collapse. Over one weekend, the team demolished and replaced the entire vertical riser, which spanned multiple floors. This unexpected challenge serves as a valuable lesson learned for future clients considering the refurbishment of existing units to consider other HVAC system upgrades to support their AHUs.
Watch the project highlight reel here.
The Bottom Line
By implementing a complete AHU refurbishment, these projects have proven that long-term equipment maintenance is possible without the need for full system replacement. This approach offers a practical alternative to purchasing and installing new AHUs, particularly in existing buildings where access is limited. It challenges the industry norm and empowers facility managers to view AHU refurbishment as a viable, cost-effective solution for HVAC system upgrades.
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