AHU Burst Coil Replacement

During a spell of freezing weather, three air handling units (AHUs) experienced burst HVAC coils, leaving the building with reduced HVAC performance. The customer needed fast, reliable replacement coils that minimised downtime and on-site rework.

SPC carried out a response covering all three AHUs:

• Rapid on-site survey: Our Area Sales Manager, Chris Ward, carried out detailed surveys to assess damage and capture measurements for each coil
• Bespoke manufacture: Replacement coils were fabricated to the measured dimensions and assembled into galvanised coil housings. All coils were pressure-tested to ensure integrity before dispatch
• Installation: The coils were delivered to site and installed by Dodd Group, ensuring a smooth, professional installation

• Casing: 16g galvanised (16 gauge galvanised steel)
• Pressure test: Coils tested to 22 barg (320 psig) using air under water
• Each AHU contained two water coils: a frost (pre-heat/protection) coil and a main heating coil
• Vent and drain pan included for each coil section

• Type: Water coils (frost + heating)
• Frost coil fins: Aluminium, 25 mm, rippled profile
• Heating coil fins: Aluminium, 15 mm, rippled profile
• Tube diameter: 12 mm
• Duct opening (each AHU): Height 956 mm × Width 1220 mm

Note: The thicker 0.25 mm fins on the frost coils increase robustness and help reduce the risk of damage or icing at the fresh-air intake, while the 0.15 mm fins on the heating coils provide excellent heat transfer for comfort heating.

All three AHUs were returned to full service quickly, with the replacement coils matching existing dimensions to minimise on-site rework. The customer was satisfied with the rapid turnaround and the quality of the replacements.