HeatEX Techologies

How Aging Infrastructure is Challenging Commercial Buildings

Thu, 18 Jun 2026 14:43:11 GMT

As a building gets older, it becomes much more likely to experience several different types of HVAC failure, which results in decreased efficiency and reliability in the system. Considering the fact that most commercial buildings in the US were built between 1970 and 2000, this aging infrastructure is becoming increasingly problematic in the world of HVAC.

To increase difficulty, many organizations postponed renovation and retrofit projects during COVID and during times of economic uncertainty and inflation. Those decisions extended HVAC equipment beyond its initial design life in many cases, and now that it is finally time to renovate, there are significant challenges to doing so in those buildings. With today’s rising equipment costs, aging building stock, high energy costs, sustainability pressures, and limited budgets, many facility managers are burdened with attempting to keep their equipment running smoothly.

As HVAC systems age, they experience coil degradation, efficiency losses, corrosion, and increased failures and downtime in general. Coils are usually one of the first parts to deteriorate, as they are exposed to plenty of different weathering aspects in the air, such as salt, moisture, and pollutants, to name a few. When a coil deteriorates, it reduces system capacity as a whole. Efficiency losses in older units are common as well, since with time, the unit has to work harder and harder to remain operating at the same capacity as it was when it was new. Reliability decreases for units due to increased unexpected failures and downtime, along with it becoming harder to source parts for repairs as technology advances and changes.

Unlike common belief, most of the time failure in commercial HVAC systems resides in just one aspect of the entire unit. Different components in different systems age differently, leaving many parts in a failed unit perfectly fine and replaced unnecessarily. For example, an HVAC system in a 25-year-old building may have corroded coils, but the fans, cabinet, and structural components are perfectly fine.

The solution to issues such as these is answered through retrofitting instead of full equipment replacement. While many facilities managers assume that they will have to fully replace entire systems, it’s much easier to replace specific parts of the system. Retrofitting makes projects cheaper, easier, and much quicker overall. Because it's only specific components of full systems that need replacement, you can extend the life of entire HVAC systems and buildings with smaller projects. This is much more sustainable in the long run.

When facing issues with aging HVAC infrastructure, HeatEX Technologies offers many different solutions. HeatEX manufactures custom coils and heat exchangers of all kinds, fit specifically to the specifications of each individual project and retrofit job. For aging buildings with different dimensions and challenges, HeatEX Technologies helps lower costs and time while raising efficiency and reliability.

Works Cited

Guckes, Bill. “The Who, What and Why of Replacing Aging Cooling Systems.” FacilitiesNet, 1 Oct. 2018, www.facilitiesnet.com/hvac/article/The-Who-What-and-Why-of-Replacing-Aging-Cooling-Systems---17882. Accessed 17 June 2026 .

Long, Jordan. “Retrofitting Aging Buildings Requires Strategic Tech Integration.” Buildings, 28 Jan. 2025, www.buildings.com/architecture/renovation-adaptive-reuse/article/55295290/retrofitting-aging-buildings-requires-strategic-tech-integration . Accessed 17 June 2026.

YCAV Air-Cooled Chiller Conversion Case Study

Thu, 11 Jun 2026 14:34:11 GMT

Location: Hotel – Fort Lauderdale, Florida

Overview:

A 6-year-old York YCAV air-cooled chiller serving a hotel experienced premature condenser coil

failure. Out of 10 total coils, 4 had already failed (40%), with the remaining coils showing active

corrosion. The unit operates continuously, making reliability critical for guest comfort

Challenges:

- Coastal environment (humidity, salt air, pollutants)

- Microchannel aluminum coils susceptible to corrosion

- Thin wall design prone to leaks

- Continuous 24/7 operation accelerating deterioration

- Vibration from fans and compressors causing fatigue and cracking

Solution:

A full conversion from microchannel to copper tube / aluminum fin coils was performed:

- Replaced all 10 coils with custom-engineered coils

- Designed to match original chiller performance

- Factory-applied protective coating for corrosion resistance

Benefits:

- Increased durability and resistance to corrosion

- Copper tubes better withstand vibration and mechanical stress

- Coils are repairable (unlike microchannel)

- Improved reliability for continuous operation

- Restored heat transfer and system efficiency

Results:

- Eliminated refrigerant leaks

- Restored system performance

- Reduced compressor strain and energy use

- Avoided full chiller replacement

- Extended equipment life by 10+ years

Key Takeaway:

In coastal, high-runtime applications, microchannel coils can fail prematurely due to corrosion and

vibration. Converting to coated copper tube/aluminum fin coils provides a long-term, reliable

solution

HVAC's newest Refrigerants

Mon, 08 Jun 2026 20:44:41 GMT

New refrigerant requirements from EPA mandates aimed at reducing greenhouse gas emissions are shaking up the HVAC industry. These requirements are causing a shift from R-410A refrigerant to A2L refrigerants R-454B and R-32. A2L refrigerants are low in toxicity and flammability. The shift is based around a metric called GWP, standing for Global Warming Potential, which measures how much heat a gas traps in the atmosphere compared to carbon dioxide. R-410A has a GWP of around 2,088, which means that 1 pound of R-410A released into the atmosphere has the same warming effect of 2,088 pounds of CO2.

The primary replacement for R-410A currently is R-454B, which has a GWP of around 466, which is 78% lower than the old refrigerant. It offers similar performance characteristics as R-410A, which makes it a valid choice to transition to. The other popular replacement is R-32, which yields higher energy efficiency at a GWP of 675. Both R-454B and R-32 are very similar, with a practical difference in GWP. Most manufacturers are choosing R-454B because regulations are tightening over time, which gives R-454B more time before it faces new regulatory restrictions.

These refrigerants are not drop-in replacements, and need specialized new coils engineered specifically around them. Because coils and heat exchangers are engineered for specific refrigerant properties, manufacturers are having to redesign their systems around these new refrigerants. These changes may shift aspects such as efficiency targets and pressure drops, as well as coil circuitry. In addition, the demand for coils is increasing and pushing HVAC prices up. When replacing the refrigerant in already existing projects, custom coil solutions are needed to match old equipment with the new requirements.

This change also brings about new installation procedures for contractors to learn, and training for technicians on A2L refrigerants. Because old and new equipment in certain projects cannot be used jointly, this makes inventory management more complicated as well.

HeatEX Technologies is in a terrific position to handle this change, offering specialized coils that can be used in adapting to R-454B and R-32 refrigerants. As the industry adapts to this transition, the need for engineered heat transfer solutions grows larger and larger. HeatEX Technologies helps support new equipment designs and retrofit applications by providing custom coil solutions designed to meet these new refrigerant requirements while maintaining system performance and reliability. We are able to do this by running performance on the spec’d coil in order to ensure that it meets the requirements of the system regardless of what refrigerant is being used.

To learn more about the EPA SNAP program, please visit the following website: Significant New Alternatives Policy (SNAP) Program | US EPA

Works Cited

“What Is R-410A Being Replaced With? R-454B and R-32 Explained.” Science Insights, Science Insights, https://scienceinsights.org/what-is-r-410a-being-replaced-with-r-454b-r-32/ . Accessed 8 June 2026.

“Important Changes Coming to Air Conditioning Refrigerants.” Air Flow Designs, Air Flow Designs, https://www.airflowdesigns.com/blog/important-changes-coming-air-conditioning-refrigerants/ . Accessed 8 June 2026.

How AI is Reshaping the Future of HVAC

Fri, 05 Jun 2026 14:25:37 GMT

Increasing demand for AI, high performance computing, along with hyperscale data center expansion are creating a massive new market for HVAC. The shift is in cooling, as data center cooling is moving beyond incremental airflow optimization, and towards liquid cooling in order to support AI and its specific cooling needs. Because of this, the data center liquid cooling market is projected to expand from 6.6 billion dollars to 38.4 billion dollars by 2033. North America is the current hotspot for this investment as it hosts the largest concentration of AI training clusters globally.

Historically, data centers have relied on air-based systems for their cooling, which includes CRAHs, chilled water systems, and precision cooling equipment. Because AI servers are now generating higher heat loads than previously (Modern AI racks can exceed 100 kW per rack compared to the traditional 5-15 kW loads of the past), facilities need heavier duty cooling, sparking the transition to liquid cooling solutions.

This transition to liquid cooling is not removing HVAC systems and instead restructures their role within AI facilities. Removing building heat, maintaining environmental conditions, and supporting chilled water distribution systems are all issues that HVAC remains a critical solution to. As a result of this, specialized coils, such as the ones HeatEX produces are growing in demand along with cooling towers, heat exchangers, and other thermal regulation components necessary for dealing with high heat rejection requirements.

This trend to support AI with Liquid cooling brings new challenges with infrastructure and compatibility for projects, as operators prioritize power usage effectiveness reduction and carbon footprint optimization. Ensuring coolant compatibility with diverse server architectures, leak prevention, and aligning cooling with rapidly advancing cycles are a few of these challenges. Operators are looking for companies that can specialize towards their plants and customize them to their need.

This emerging market puts HeatEX Technologies in a great position to assist these operating facilities. As custom cooling systems become more specialized, standard equipment may not always meet the same requirements for performance. Custom coil solutions, such as the ones HeatEX provides, can be engineered to meet these specifications and adds a key flexibility aspect to our product. Our precise and specialized coil technology positions HeatEX very well for the future of the HVAC industry.

In a market where air is no longer sufficient as the default for AI facilities, HeatEX is well positioned for this industry change.

Works Cited

“Data Center Cooling Trends 2026: From Air to Liquid.” Global InduVista, Thermal Logic, 2026, https://www.globalinduvista.com/news/Industrial_HVAC/Thermal_Logic/Data_Center_Cooling_Trends_2026_From_Air_to_Liquid.html . Accessed 2 June 2026.

“Data Center Liquid Cooling Market to Witness 28.7% CAGR Driven by AI Adoption, Investments and Sustainability Targets.” GlobeNewswire, 17 Feb. 2026, https://www.globenewswire.com/news-release/2026/02/17/3239044/0/en/data-center-liquid-cooling-market-to-witness-28-7-cagr-driven-by-ai-adoption-investments-and-sustainability-targets.html . Accessed 2 June 2026.

Murray, Lance. “Skilled Trades Workers Can Command Six-Figure Salaries as Data Center Boom Drives Demand.” Fortune, 20 Mar. 2026, https://fortune.com/2026/03/20/skilled-trade-demand-randstand-report-electricans-technicans-construction-workers-six-figure-salaries-data-center-boom/ . Accessed 2 June 2026.

Condenser Coil Replacement Project

Tue, 02 Jun 2026 16:03:21 GMT

Renaissance Hotel @ Ft. Lauderdale

Project Overview

At the Renaissance Hotel in Fort Lauderdale, the facility experienced severe deterioration of the condenser coil on a Trane RTAC225 air-cooled chiller. The unit was equipped with four condenser coils that had suffered extensive corrosion from environmental exposure, ultimately leading to coil failures and loss of system reliability.

HeatEx was selected to provide direct replacement condenser coils engineered for a precise OEM fit while delivering enhanced corrosion protection.

The Challenge

The existing condenser coils showed advanced corrosion and material degradation, significantly impacting performance and threatening system downtime.

• Severe corrosion across coil surfaces

• Loss of structural integrity in fin and tube material

• Reduced heat transfer efficiency

• Increased risk of refrigerant leaks

• Potential for costly emergency shutdown

Our Solution

• Engineering and manufacturing four replacement condenser coils

• Precision fabrication to ensure perfect fitment

• Verification of coil dimensions prior to shipment

• Delivery ready for seamless installation

Precision Fit Matters

• Matched original dimensions precisely

• Installed without modification

• Maintained proper airflow and refrigerant performance

• Reduced installation time and labor costs

The Results

• Restored chiller performance and reliability

• Eliminated risk of continued refrigerant leaks

• Extended equipment lifespan

• Improved corrosion resistance with protective coating

• Achieved OEM-quality fit and performance

Parc Lofts Condominium

Tue, 19 May 2026 01:40:50 GMT

AAON RN025 Replacement

Our client was looking for a long-term solution to leaking microchannel condenser coils in two separate units serving the common areas of the Parc Loft Condominiums — an issue impacting many residents.

Our team responded quickly, visited the jobsite to verify all connection locations, and manufactured replacement coils designed to match the original manufacturer’s fit and performance specifications.

In this case, we were even able to exceed the original performance requirements through our commitment to high-quality, U.S.-manufactured products and continuous improvement in our manufacturing processes.

At HeatEX Technologies, we combine responsiveness with precision by utilizing internally developed measurement technology and industry-leading performance verification tools to ensure our replacement coils fit properly, perform as intended, and provide reliable long-term solutions for our clients and partners.

Split-Coil Case Study

Thu, 07 May 2026 21:09:35 GMT

Split Coil Solutions for Tight-Space Installations

Redefining How Replacement Coils Are Built and Installed

Replacing coils in older air handlers or equipment rooms with limited access often turns into a costly, labor-intensive challenge. Full-size coils may not fit through existing access doors, stairwells, or hallways—forcing contractors to cut walls, remove louvers, or rent cranes. These complications drive up project costs and downtime. Our split coil design solutions provide a smarter alternative that allows contractors to bring in the coil in sections, assemble it on-site, and restore system operation quickly—without compromising performance, integrity, or operating pressure.

Traditional Split Coil Design

Conventional split coils are typically divided by fin length and joined internally with divider plates and gaskets. While effective in maintaining fluid separation, this approach presents two main drawbacks: - Higher fabrication and field labor costs due to internal divider plates, gaskets, and hardware. - Operating pressure limitations since gasketed divisions restrict system pressure ratings.

Our Simplified Split Coil Options

We engineered two practical alternatives that eliminate the need for divider plates and simplify the field installation process—ideal for contractors working in tight mechanical rooms, basements, or rooftop units with restricted access.

Option 1: Split by Fin Height (Top and Bottom Coil)

A single coil is divided horizontally, creating a top and bottom section. How It Works: The coil’s supply and return headers are fabricated with precision couplings designed to align both sections during installation. Once the coils are set in position, the top and bottom headers are welded or brazed shut, completing the assembly and restoring a continuous circuit. Technical Considerations: Depending on the model or coil geometry, the main connection points may shift slightly between the original and split versions. Minor field repiping adjustments may be required to align the coil’s supply and return lines with existing piping. These adjustments are minimal and typically performed within standard installation practices.

Applications: Ideal for vertical units or air handlers with height restrictions. Perfect for installations where access is limited to door or hallway dimensions. Advantages: - No divider plates or gasket seals. - Maintains full operating pressure rating. - Reduces fabrication complexity and cost. - Simplified field assembly with welded couplings. - Minimizes installation footprint and handling weight.

Top/Bottom Coil Example:

Assembled Example Below:

Option 2: Split by Fin Length (Side-by-Side Coil)

A single coil is divided vertically, creating a header side and return bend side that can be piped together in sequence. How It Works: The Header Side coil is fabricated with four connections—two for the main system supply and return, and two that turn 90° toward the leaving air side. The Return Bend Side coil features its own headers with two connections, also turned 90° toward the leaving air side. Once both coils are positioned, the header side coil feeds the return bend side coil through short interconnecting piping runs, creating a single continuous circuit. Technical Considerations : In certain models, connection orientations or spacing may vary slightly from the original coil design. Installers should anticipate minor repiping or header alignment adjustments to ensure smooth field integration. These are standard adjustments that can be completed without specialized equipment or significant field rework.

For this configuration, additional brackets or center support may be required to stabilize the coils when set in place and to maintain alignment during operation. Applications: Ideal for horizontal units, tight mechanical rooms, or multi-section air handlers. Suitable for retrofits where coil depth or access is restricted. Advantages: - Modular installation for confined spaces. - Eliminates the need for divider plates and pressure restrictions. - Maintains system capacity and flow characteristics. - Simplifies transport and installation logistics.

Header Side Coil Example:

Bend Side Coil Example:

Coil Assembly Example (Side-by-Side Coil Combined)

Installation Advantages

Both split coil options provide significant installation benefits: - Avoid crane rentals: Split coils can be transported through standard service elevators or stairwells. - No wall cutting or structural modifications: Coil sections fit through existing access openings. - Reduced downtime: Assembly and sealing can be completed quickly once sections are in place. - Lower labor and equipment costs: No need for heavy rigging or demolition. - Preserves equipment and building integrity: No compromise to air handler casing or mechanical room walls.

Key Benefits for Contractors

- Simplified field installation in confined or difficult-to-access locations. - Maintains system performance and pressure rating. - Reduces total project cost by eliminating crane, wall, or louver removal expenses. - Shorter lead times and faster turnaround. - Custom-built to match your exact coil design, performance, and circuiting requirements.

Additional Project Requirements

All split coil projects require a site visit before fabrication to ensure accurate measurements and proper design alignment. This step allows us to provide a precise and dependable proposal tailored to your installation conditions.

We can also supply drain pans, either intermediate or main pans, as required by the application to ensure proper condensate management and long-term system reliability.

Comparative Performance Metrics

Coil Tag: As built - Single Piece

Coil Model Number: 4W-08-32.5-10-110.0-52

Hand:Right

Coil Tag: Side-by-Side Split

Coil Model Number: 4W-08-32.5-14-50.5-26

Hand: Right

By adjusting the FPI and circuitry, even though the total surface area decreases on the face of the coil, we are able to increase the overall performance of the unit with minimal effect to fluid and air pressure drops.

Notes:

Certified in accordance with the AHRI Forced-Circulation Air-Cooling and Air-Heating Coils Certification Program which is based

on AHRI Standard 410 within the Range of Standard Rating Conditions listed in Table 1 of the Standard. Certified units may be

found in the AHRI Directory at www.ahridirectory.org

Mechanical and Service Contractors Association of Eastern PA - Allied Member Showcase

Wed, 29 Apr 2026 02:29:52 GMT

HeatEX Technologies at MCAEPA Allied member showcase

Pictured (from left to right): Matt Lane, Nick Bozzi, and Sage Harkins at the Allied Member Showcase for MCAEPA on April 23, 2026

On Thursday, April 23th, 2026, the HeatEX team participated in the Allied Member Showcase for the Mechanical & Service Contractors Association of Eastern Pennsylvania, where they had the opportunity to meet with Mechanical Contractors to explain what sets them apart.

Sage, Nick, and Matt are all passionate golfers, so they brought a little fun to the event by setting up a putting green and raffling off two separate rounds of golf at Applebrook Golf Club to whoever dropped their business card in a basket on their table.

The Allied Member Showcase was held at 2910 DeKalb Pike, Norristown, PA. The event gave allied members the opportunity to set up an 'Allied Tabletop', where the members of the Mechanical Contractors Association (Steamfitters Local Union 420 & Plumbers Local Union 690), Service Contractors Association (Steamfitters Local Union 420: MESJ, MESS, apprentices, & maintenance operatives), National Certified Pipe Welding Bureau (Philadelphia Chapter (Chapter 9) of NCPWB), Mechanical Contractors Association of America, & Mechanical Service Contractors of America walkaround and learn about the allied members' services & products.

To learn about more events hosted by the MCAEPA - check the calendar on their website !

Be sure to connect with us on LinkedIn , as we will let you know what events we are going to ahead of time!

Direct Replacement Coil Restores Fresh Air Unit @ Hyatt House - Naples

Thu, 23 Apr 2026 14:11:10 GMT

Unit Model: Greenheck Model rve-35-36p

Project Overview:

The Hyatt House Hotel in Naples, FL experienced performance issues with a Greenheck Model RVE-35-36P fresh air unit due to a failing OEM coil. The original coil (pictured above) showed visible corrosion and was beginning to lose refrigerant, resulting in reduced efficiency and unreliable operation.

The Solution:

We supplied a direct replacement coil designed specifically to match the original Greenheck coil dimensions and performance requirements. Because this was truly a direct replacement, installation was straightforward and required no modifications to the fresh air unit.

This can be directly attributed to the HeatEX Technologies process. We came out to the job site to measure the coil and ensure connection locations on the replacement coil would fit correctly to the existing unit.

The Results:

With the new coil installed, the fresh air unit returned to proper operation, improving reliability and restoring system efficiency.

Eliminated refrigerant leakage issues
Restored system efficiency
Maintained original equipment performance
Reduced downtime during installation because of proper sizing
Extended the life of the fresh air unit

Why Direct Replacement Coils Matter

Replacing failed coils with direct OEM-fit replacements is one of the most effective ways to restore HVAC performance without replacing the entire unit. This approach minimizes downtime, reduces installation complexity, and ensures the system continues operating as designed.