AHU Replacement at Laboratory Testing Facility
Client: Classified
Sector: Healthcare
Project Focus: Air handling unit (AHU) replacement
Location: Classified, West Midlands
Service & technical partners
The brief
The laboratory required a reliable, energy-efficient replacement for its ageing air handling unit (AHU), which was critical to maintaining precise environmental conditions for continuous scientific procedures. The existing unit was over 20 years old, prone to failure, and used high GWP refrigerant gas.
The solution
SK Heating & Cooling worked alongside Weatherite Group to design and install a bespoke AHU system with low GWP refrigerant gas and energy-saving features, ensuring long-term reliability and sustainability for the facility.
The benefits
This project eliminated the risk of system failure, improved energy efficiency, reduced environmental impact, and provided a future-proofed, compliant solution. All work was completed on time with minimal disruption to laboratory operations.
The business challenge
The laboratory’s existing air handling unit had long exceeded its intended service life by a significant margin. Mechanical failures were becoming increasingly common and replacement compressors were often required to maintain functionality.
Moreover, sourcing spare parts had become a serious challenge. The use of high Global Warming Potential (GWP) refrigerant gas posed a significant operational and environmental risk. If a leak had occurred, the facility would have faced serious downtime with no viable repair option.
Given the laboratory’s 24/7 need for tightly controlled air and temperature conditions, a fast, reliable, and environmentally conscious solution was business critical.
Our solution
SK Heating & Cooling were tasked with redesigning the AHU system to meet the client’s needs for efficiency, reliability, and reduced environmental impact.
Working with Weatherite Group, SK proposed a bespoke, modern equivalent AHU featuring low GWP refrigerant gas and energy-saving turndown functionality.
Once the design was finalised and approved, we initiated a carefully planned programme of works in January 2025. To begin with, the team safely isolated, disconnected, and removed the old AHU and ductwork using a lift-and-shift operation.
We then transported and installed the new custom-built AHU, along with new external ductwork complete with thermal insulation and a stucco aluminium protective finish. In addition, we installed a new power supply and integrated the system with updated Building Management System (BMS) controls, ensuring seamless operation.
As a result, all works were completed within the scheduled timeframe and with minimal disruption to the laboratory’s ongoing testing programme.
Installation photos
The outcome
Operational improvements
The installation of the new AHU guarantees uninterrupted operation of the laboratory’s critical testing functions. The modern, highly reliable system has replaced the outdated and failure-prone unit, securing long-term operational stability.
Energy and cost savings
The new AHU offers significantly improved energy performance. Thanks to the energy-saving turndown features, the laboratory benefits from reduced energy usage and lower running costs over the long term.
Compliance and environmental improvements
By using a low GWP refrigerant gas, the new system meets current and future environmental standards. In doing so, it significantly reduces the laboratory’s environmental footprint.
Staff and process confidence
The laboratory team can now operate with confidence, knowing the environmental conditions required for testing procedures are securely maintained 24/7, without risk of equipment failure.
Future-proofed system
The upgraded system is built for long-term performance. With SK Heating & Cooling providing ongoing service and maintenance, the continued smooth operation and reliability of the equipment are assured, protecting the laboratory’s vital operations well into the future.
The benefits
- Full replacement of outdated, high-risk AHU
- Enhanced system reliability and operational security
- Improved energy efficiency and reduced running costs
- Significant environmental improvement with low GWP refrigerant gas
- Seamless integration with building systems and new BMS connection
- Delivered on time with no disruption to laboratory operations
Technical specification
Equipment installed
Custom-built Weatherite AHU with low GWP refrigerant gas, new external ductwork with thermal insulation and stucco aluminium protection.
Location
West Midlands laboratory testing facility.
Project timeline
Project initiated and completed within the agreed programme, with works completed in January 2025.
Scope of works
Isolation and removal of existing AHU and ductwork, lift-and-shift operation, transportation and installation of new AHU, installation of new ductwork and insulation, new power supply and BMS integration, commissioning and handover.
Controls/monitoring
New BMS connection and system regulation for continuous environmental control.
Compliance standards
F-Gas environmental compliance; Health & Safety regulations for lifting and installation operations.
Service & technical partners
Next steps
Need to upgrade critical ventilation or cooling systems with minimal disruption?
Contact the SK Heating & Cooling Team to discuss how we can support your facilities with future-proofed, compliant solutions.
Call: 01452 410500
Email: sales@skheatingandcooling.co.uk / service@skheatingandcooling.co.uk
Address: SK Heating and Cooling Ltd, 229 Bristol Road, Gloucester, GL1 5TL
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