Precision Chiller Dismantling & Mechanical Retrofit Case Study

A local New Jersey representative for a major chiller manufacturer recommended R. Baker & Son for a demanding chiller change-out project. The scope: remove two 1,200-ton chillers and their associated multi-cell cooling tower, then clear the way for two new high-efficiency heat pump chillers and fluid coolers to take their place.

Fast, Efficient Cooling Tower Demolition

Speed and precision were critical from the start. The large three-cell cooling tower was drained, cleaned, dismantled, and disassembled with a 130-ton hydraulic boom crane fitted with an extended jib, reaching 75 feet in from the loading dock. Large lifting baskets made quick work of removing the plastic splash fill, electric pony motors, fan blades, sump piping, and other components.

Solving the Real Challenge: Demolition Inside an Operating Central Utility Plant

The bigger challenge was removing the existing chillers and piping in a highly congested space while keeping the live central utility plant running without disruption. Hot work permits were obtained and the crew performing the work were all OSHA trained and certified.  Two obstacles stood out: managing smoke from oxy-acetylene cutting torches, and coordinating fire alarm test mode and fire watch procedures to keep the site safe throughout.

R. Baker & Son developed a site-specific safety plan that addressed both. The team reclaimed all refrigerant and prepped the chillers for removal, then used the existing refrigerant purge system fans to properly exhaust the mechanical room. This gave the space the air changes and cross-ventilation needed to cut safely without smoke buildup. The team also worked with the client to place air handler duct smoke detectors in test mode during the cutting schedule. Paired with active fire watch, this let crews disassemble the old chillers and piping quickly, with zero business interruption.

Ahead of Schedule, Ready for the Next Phase

Both chillers, along with their associated piping, were fully cut and disassembled in just two days, a full day ahead of schedule. That head start let R. Baker & Son move directly into supporting the next phase: bringing in the new heat pump chillers, rigging plate frame heat exchangers, and setting the new fluid coolers in place for the mechanical contractor.

A Model for Safe, Efficient Retrofit Work

The project delivered on every front: safety, demolition execution, and rigging support. The client was especially impressed with the refrigerant purge system solution for ventilating the mechanical space during cutting, noting that it kept the project moving without delays or setbacks.

Ready to tackle your next chiller change-out or mechanical retrofit? R. Baker & Son brings decades of demolition and rigging expertise to even the most complex, occupied-building projects. [Contact us] to see how our team can keep your project safe, on schedule, and running without interruption.

Founded in 1935, R. Baker & Son All Industrial Services is a certified Minority and Women-Owned Business Enterprise (M/WBE) - recognized as the oldest and largest M/WBE-certified demolition contractor in North America. We are your trusted partner for complex industrial and construction projects, specializing in heavy rigging, machinery moving, plant relocation, and expert crane erection, dismantling, and support services across the United States, Canada, and Puerto Rico.

With significant bonding capacity and an unmatched safety record backed by extensive involvement in OSHA VPP Star projects, we deliver precision and reliability to every job site. Our comprehensive services include heavy rigging, complex machinery installation and removal, plant relocation, industrial dismantling, and specialized support for high-reach and tower crane operations.

Discover why leading industrial and commercial clients rely on R. Baker & Son for safe, precise solutions to their most demanding heavy rigging and dismantling projects. Learn more about our expertise in dismantling.