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sales@altabreed.com HVAC Refurbishment & Custom Condenser Coil Replacement for Villas in Al Ain
Project Overview
Al Tabreed Industries completed a comprehensive HVAC repair and rectification project across eight residential villas in Al Ain, including the manufacture, supply and installation of 21 custom replacement condenser coils for existing LENNOX HVAC units.
The scope went beyond replacing individual HVAC components. The project involved identifying and rectifying multiple issues affecting the reliability of the installed air-conditioning systems, including damaged refrigerant components, deteriorated condenser coils, electrical protection, refrigerant pipe insulation and drainage arrangements.
A major part of the project was the manufacture, supply and installation of 21 replacement condenser coils, custom-made according to the original coil samples and existing equipment requirements.
The objective was to restore the existing HVAC systems to safe, leak-free and reliable operating condition while retaining the installed equipment wherever practical.
The HVAC Challenge
The existing HVAC systems required rectification across several areas rather than a single component replacement.
Some of the condenser coils showed significant deterioration and required complete replacement, while other areas of the systems required attention to refrigerant piping, liquid line valves, electrical wiring protection, insulation and drainage.
For the condenser coil replacement, dimensional accuracy was particularly important because the new coils had to integrate with existing LENNOX outdoor units in different capacities and coil configurations.
Rather than using a one-size-fits-all replacement, each new coil had to be manufactured according to the original sample and existing unit configuration.
Custom Condenser Coil Manufacturing
Al Tabreed manufactured 21 replacement condenser coils for the existing LENNOX HVAC units.
The project included three different coil requirements:
- 5 standard condenser coils for LENNOX HS29-4112T, 3.5 TR units
- 10 G-type condenser coils for LENNOX HS653-2M, 5 TR units
- 6 G-type condenser coils for LENNOX HS17-953-6M, 8 TR units
The existing coils were used as the reference for manufacturing the replacements, helping ensure compatibility with the installed HVAC equipment.
This approach allowed the existing units to be retained while replacing the deteriorated heat-transfer components with newly manufactured coils.
HVAC Rectification Scope
In addition to condenser coil replacement, the project included several supporting HVAC and electrical rectification works.
Refrigerant System Repairs
Damaged liquid line valves and copper refrigerant piping were replaced where required.
The refrigerant circuit work included:
- Copper pipe replacement
- Refrigerant pipe brazing
- Nitrogen pressure testing
- Vacuuming
- Leak testing
- Testing and commissioning
Condenser Coil Replacement
The existing condenser coils were removed and replaced with the newly manufactured coils.
The replacement process included:
- Removal of existing coils
- Installation of new condenser coils
- Refrigerant piping connection and brazing
- Nitrogen pressure testing
- Vacuuming of the refrigeration circuit
- Leak checking
- Testing and commissioning
- Final performance verification
Electrical Protection
The project also addressed damaged electrical wiring exposed to conditions that could contribute to rainwater-related tripping.
PVC conduit protection was installed together with the required fittings, supports and accessories.
In addition, 40 IP66 waterproof PVC isolators were supplied and installed across the project.
Refrigerant Pipe Insulation
Damaged refrigerant pipe insulation for the supply and return lines was replaced across the roof areas of the eight villas.
Closed-cell insulation with antifungal protection was used, with proper finishing applied to the completed pipework.
Drainage Modification
A new 14-metre UPVC drain connection was installed from the garden roof to the ground floor, including the necessary fittings, supports and testing.
Testing & Commissioning
Following completion of the repair and replacement work, the HVAC systems underwent a structured testing and commissioning process.
This included:
- Nitrogen pressure testing
- Refrigeration circuit vacuuming
- Leak detection
- Functional testing
- Performance verification
- Final commissioning
These checks were carried out to verify the integrity of the refrigerant systems and confirm that the completed HVAC installations were ready for operation.
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Project Outcome
The project resulted in a comprehensive refurbishment of the existing villa HVAC systems rather than isolated component replacement.
The completed works included:
- 21 newly manufactured condenser coils installed
- New liquid line valves
- Repaired and replaced refrigerant piping
- Roof-level refrigerant pipe insulation replacement
- Installation of waterproof electrical isolators
- Electrical conduit protection
- New UPVC drainage connection
- Testing and commissioning of the HVAC systems
By combining custom coil manufacturing with on-site HVAC rectification, Al Tabreed was able to address both the heat-transfer components and the supporting systems required for reliable operation.
Extending the Service Life of Existing HVAC Systems
When the main HVAC equipment remains serviceable, deterioration of condenser coils and supporting refrigerant components does not always require complete equipment replacement.
Custom replacement coils can be manufactured around the dimensions and configuration of existing units, allowing critical heat-transfer components to be renewed while retaining the installed HVAC equipment.
For this residential project in Al Ain, Al Tabreed combined custom condenser coil manufacturing, refrigerant-system rectification, electrical protection, insulation, drainage modifications and commissioning as part of one coordinated HVAC refurbishment scope.
This approach helped return the systems to safe, leak-free and operational condition while extending the usable life of the existing equipment.
Need a Replacement Coil for an Existing HVAC Unit?
Al Tabreed Industries manufactures custom condenser coils for replacement applications based on existing samples, dimensions and equipment requirements.
From coil manufacturing to site installation, refrigerant piping, testing and commissioning, our team can support HVAC replacement and refurbishment requirements across the UAE.
Contact Al Tabreed Industries to discuss your condenser coil or HVAC refurbishment requirement.
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