Troubleshooting heating and cooling issues can be difficult enough, but when combined with an unusual obstacle, such as not having access to bring in new parts, it’s going to be even harder. Fortunately, we’re no strangers to solving problems like this. We’re used to unique challenges that require unique solutions and this case isn’t any different. Read on to learn how Trimark Mechanical went to new heights, quite literally, to make sure our church client in Springfield could get their equipment fixed and restore comfortability in the Sanctuary and the Nave. 

This isn’t your ordinary problem… 

When we first met this church client in Springfield three years ago they had four large split systems at their facility that were going to need to be replaced. At the time, the four large split systems utilized R-22 refrigerant that needed to be replaced by equipment utilizing R-410A refrigerant, per government regulation. However, there was a pretty large obstacle in the way that made replacing the split systems an extremely difficult task to complete – it was the building itself. We’re not kidding! The air handling units (AHU’s) serving the Sanctuary and the Nave were installed before construction on the rest of the facility was complete. This meant that we couldn’t replace the existing AHU’s because the building’s structure restricted access to do so. We knew that we could upgrade the AHU’s by removing the R-22 refrigerant coils and replacing them with R410A coils but the building’s structure restricted access to even do this. The problem looked kind of something like this:  

Now while you may be saying to yourself, “Who would even think to do that”, you should know this isn’t uncommon. In the past, we’ve seen other facilities where construction teams first set heating and cooling equipment and then built around it. But while this may simplify the initial construction process, it throws a huge wrench in ongoing HVAC maintenance and eventual replacement. Our client understood that better than anyone.    

A brilliant idea strikes! 

Upon our initial on-site visit, we understood that the key to replacing the old R-22 coils was to find a unique entry point to bring in the new parts. That’s when we got creative. During our brainstorming with the Facilities Manager, we noticed decorative louvers towards the roof of the space where the church’s HVAC was located and a light-bulb went off in our heads. If one of those louvers could be temporarily removed, we could hoist the new coils up the side of the building, slip them through hole where the louver was removed, and execute the replacement without needing to make any significant structural changes to the church. The biggest hurdle would be raising the R-410A coils 30 feet in the air, but that was still a better option than cutting a hole in the building. With the plan set, our team got to work.  

We decided it’d be best to spread this project out over a few days to ensure all the necessary parts arrived on schedule and that we didn’t disrupt normal operations. We used a scissor lift to raise the large R-410A coils approximately 30 feet in the air and then slid each coil through the area where the louver was removed, bringing them inside the building. The new R-410A coils were stored in the room with the AHU’s until a day could be scheduled to conduct the replacement. Finally, we reinstalled the louver so it looked like it had never been removed. 

This was one for the books 

We must say, this is one of the more interesting AHU refurbishments we’ve performed. However, it certainly highlights that sometimes you must do whatever is necessary to keep people comfortable and happy.   

At Trimark Mechanical, we have deep experience with church facilities and our expertise allows us to pinpoint the unique solutions to your unique challenges. No matter the obstacle. That’s what’s allowed us to be the trusted partner of this church and several others in the Washington DC Metro area for many years.  

Do you have an out of the ordinary challenge you can’t seem to solve? Contact us today and we’ll figure out how we can help.