How long does cooling tower replacement take?

Timeline depends on tower size, access constraints, and whether piping modifications are needed. Typical projects take 2-4 weeks from old tower removal to new tower commissioning. We schedule work during shoulder seasons when possible to minimize cooling impact.

What are the benefits of a new cooling tower?

Modern cooling towers offer better efficiency, quieter operation, improved drift eliminators for water conservation, and superior corrosion resistance. They also integrate better with building automation for optimized performance and reduced water treatment chemical usage.

Cooling Tower Replacement: Efficient Heat Rejection

Cooling towers are the critical link between your chillers and the atmosphere. When towers deteriorate, chiller efficiency suffers, water consumption increases, and the risk of Legionella contamination rises.

We manage complete cooling tower replacement projects from equipment selection through commissioning. Whether you need a simple like-for-like replacement or an upgrade to more efficient, quieter technology, our team ensures minimal downtime and optimal integration with your existing systems.

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Cooling tower replacement project Toronto

Improved efficiency

Modern towers with high-efficiency fills and VFD fans reduce condenser water temperatures, allowing chillers to operate more efficiently and consume less electricity.

Water conservation

Advanced drift eliminators reduce water loss to less than 0.001% of circulation rate. Better water treatment compatibility means fewer blowdown cycles and lower water consumption.

Health & safety

New towers with proper drift eliminators and designs that support effective water treatment significantly reduce Legionella risk and support regulatory compliance.

Types of cooling towers

Different buildings have different requirements based on capacity, space, noise sensitivity, and existing infrastructure. We work with all common tower configurations.

Induced Draft

Fans on top pull air through the fill. Most common type for condo buildings. Efficient and relatively quiet.

Forced Draft

Fans push air into the tower from below. Good for retrofit situations with height restrictions.

Crossflow

Air flows horizontally through falling water. Lower pump head requirement, easier maintenance access.

Counterflow

Air flows upward against falling water. More thermally efficient, smaller footprint.

Closed Circuit

Water in closed coils, no direct contact with air. Used where water quality is critical.

Hybrid/Adiabatic

Dry coolers with evaporative assist. Reduced water use, good for water-restricted sites.

Deteriorating cooling tower requiring replacement

Why proactive tower replacement?

Cooling towers operate in harsh conditions—constant water exposure, summer heat, winter freeze cycles, and airborne contaminants. Deterioration is inevitable, and the consequences of failure are severe.

Chiller efficiency: Degraded towers deliver warmer condenser water, forcing chillers to work harder. Every 1°F increase in condenser water temperature costs 2-3% in chiller efficiency.
Legionella risk: Old towers with deteriorated drift eliminators, dead legs, and areas difficult to treat create Legionella risk. Modern towers are designed for effective water treatment.
Structural safety: Corroded basins and supports can fail catastrophically. The weight of a full cooling tower on a compromised structure is a serious safety hazard.
Noise complaints: Worn bearings, unbalanced fans, and deteriorated components increase noise levels, often leading to resident complaints and municipal noise bylaw issues.

Our replacement process

Cooling tower replacement requires careful coordination of crane operations, piping modifications, and water treatment integration. Our process ensures a smooth transition.

Assessment

Existing equipment evaluation
Capacity verification
Structural assessment
Crane access evaluation
Noise study (if needed)

Engineering

Equipment selection
Piping design
Structural engineering
Controls integration
Permit applications

Procurement

Equipment ordering
Lead time management
Crane booking
Traffic permits
Material staging

Demolition

System isolation
Water drainage
Piping disconnection
Old tower removal
Basin preparation

Installation

Tower placement
Piping connections
Electrical hookup
VFD installation
Controls wiring

Commissioning

System startup
Water treatment setup
Performance testing
BAS integration
Documentation

Cooling tower manufacturers we install

We work with leading cooling tower manufacturers and can recommend the best fit for your building's requirements, noise constraints, and budget.

BAC

Industry leader

Marley

SPX Cooling

Evapco

Evaporative cooling

Tower Tech

Factory assembled

Amcot

FRP construction

Delta

Cooling towers

Reymsa

Fiberglass towers

Mesan

Modular design

Material options: We install towers in galvanized steel, stainless steel, and fiberglass (FRP) construction depending on your water quality, environment, and longevity requirements. FRP towers offer superior corrosion resistance and longer life in challenging environments.

Compliance & safety

Cooling tower replacement involves significant regulatory and safety requirements. We handle all compliance aspects so you can focus on building operations.

Legionella Compliance

New towers designed for effective water treatment. Proper drift eliminators, accessible components, and integration with water treatment programs to meet Ontario regulations.

Noise Bylaws

Equipment selected and installed to meet municipal noise requirements. Sound attenuators and VFDs specified where needed to minimize impact on neighbors and residents.

Crane & Rooftop Safety

Full fall protection compliance for rooftop work. Crane operations coordinated with proper permits and traffic control. WSIB coverage for all workers.

For property managers & boards

Cooling tower replacement is a significant capital project that affects building cooling capacity and resident comfort. We understand the importance of proper planning and transparent communication.

Board presentations: We present options clearly, explaining trade-offs between equipment types, materials, efficiency levels, and total costs.
Reserve fund alignment: Projects can be timed to match funding availability, with documentation supporting reserve fund study updates.
Water treatment coordination: We work with your water treatment provider to ensure proper setup and ongoing compliance for the new equipment.
Minimal disruption: We schedule crane work and major activities to minimize impact on residents and coordinate with other building activities.

Cooling Tower Projects Across Toronto

We've completed cooling tower replacements in buildings across the GTA—from single-tower mid-rises to multi-cell high-rise installations. See our project portfolio for examples.

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FAQs

Equipment lead times currently range from 10-20 weeks depending on manufacturer, size, and material (galvanized vs. stainless vs. FRP). Once equipment arrives, on-site work typically takes 2-4 weeks from old tower removal to new tower commissioning. We coordinate crane operations, often completing the swap in a single day to minimize cooling system downtime.

Cooling towers reject heat from the chiller condenser. Degraded towers deliver warmer water to the chiller, forcing it to work harder. Modern towers with efficient fills and proper airflow deliver cooler condenser water—every 1°F improvement translates to 2-3% better chiller efficiency. For a building spending $50,000/year on cooling, this can mean $5,000-15,000 in annual savings.

Legionella is a serious concern for cooling towers. New towers are designed with proper drift eliminators (reducing aerosol release), accessible basins and components (enabling effective cleaning), and configurations that support proper water treatment. We coordinate with water treatment providers to ensure the new system is properly set up and that your ongoing treatment program is effective.

For buildings with multiple cooling towers, we can stage replacement to maintain partial capacity. For single-tower buildings, we typically schedule during spring or fall when cooling demand is minimal. The actual tower swap often takes only 1-2 days. If summer replacement is unavoidable, temporary cooling solutions can be arranged.

Fiberglass reinforced plastic (FRP) towers offer superior corrosion resistance and typically last 25-30+ years with minimal maintenance. Galvanized towers cost less initially but are susceptible to corrosion and typically last 15-20 years. Stainless steel falls in between. For most Toronto condos, FRP offers the best long-term value despite higher initial cost.

Costs depend on tower capacity, material (galvanized, stainless, FRP), crane requirements, and piping modifications needed. Typical projects range from $75,000 for smaller towers to $300,000+ for large multi-cell installations. FRP construction adds 20-40% to equipment cost but offers significantly longer life. We provide detailed proposals after site assessment.

Ready to upgrade your heat rejection system?

Request a site assessment and detailed proposal. We'll help you understand your options, timeline, and budget requirements for a successful cooling tower replacement.

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