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sales@altabreed.com Custom YORK Condenser Coil Manufacturing & Replacement for an HVAC System in Dubai
Project Overview
Al Tabreed Industries was engaged by an electromechanical contractor in Dubai to manufacture, supply and install replacement condenser coils for an existing YORK HVAC unit in Al Qusais.Â
Rather than replacing the complete equipment, the requirement was to reproduce the existing condenser coils according to the original dimensions and site conditions, allowing the YORK system to continue operating with newly manufactured heat-transfer components.
The project involved both custom coil manufacturing and complete on-site replacement work, from removal of the existing coils through refrigerant piping connection, pressure testing, vacuuming and refrigerant charging.
The Challenge:
Existing HVAC equipment often remains mechanically serviceable even when the condenser coils have reached the stage where replacement becomes necessary.
For this project, the replacement coils needed to fit within the existing YORK unit without requiring major modifications to the equipment.
This meant that dimensional accuracy was particularly important. The new coils had to be manufactured according to the existing coil/sample dimensions while maintaining the required tube and fin construction for the application.
The project also required careful coordination during installation to ensure that the existing refrigerant circuit could be properly reconnected and tested after the coil replacement.
Al Tabreed's Engineering Solution
The existing condenser coil was used as the reference for manufacturing the replacement units.
Al Tabreed manufactured new condenser coils using 3/8-inch copper tubes with aluminium fins, matching the dimensional and installation requirements of the existing YORK system.
By manufacturing the coils specifically for the existing equipment, the replacement solution allowed the customer to retain the YORK unit while renewing one of its most important heat-transfer components.
The work extended beyond manufacturing. Al Tabreed’s team also carried out the removal of the existing coils and installation of the newly manufactured replacements at the Dubai site.
Scope of Work
The project included:
- Manufacturing and supplying custom condenser coils suitable for the existing YORK Unit-1.
- Constructing the coils using 3/8" copper tubes and aluminium fins.
- Replicating the existing coil dimensions according to the original sample and site requirements.
- Dismantling and removing the existing condenser coils.
- Installing the newly manufactured coils within the existing YORK equipment.
- Reconnecting the refrigerant piping.
- Carrying out the required brazing and refrigerant-line joints.
- Performing nitrogen pressure testing and leak checking.
- Vacuuming the refrigeration circuit.
- Refrigerant charging as required before recommissioning.
On-Site Installation
Once manufacturing was completed, the replacement coils were transported to the project site in Al Qusais.
The installation team carefully positioned the new coils within the existing YORK equipment and completed the necessary refrigerant piping connections.
The photographs you have are useful here because they show something that many manufacturers cannot demonstrate: Al Tabreed is not simply supplying a coil from a catalogue—the team is physically replacing and integrating the custom-manufactured coil into existing equipment at site.
That is an important capability to communicate.
Testing & Commissioning
After installation and refrigerant piping connections were completed, the system underwent the required checks before returning to operation.
This included nitrogen pressure testing and leak inspection to verify the integrity of the refrigerant circuit, followed by vacuuming and refrigerant charging as required.
These procedures helped ensure that the newly installed condenser coils were properly integrated into the existing YORK system before commissioning.
Project Outcome
The project provided the customer with newly manufactured condenser coils designed around the dimensions and requirements of the existing YORK equipment.
Instead of replacing the complete HVAC unit, the condenser section could be renewed using custom replacement coils manufactured specifically for the existing system.
The completed project delivered:
- Replacement of deteriorated/old condenser coils
- Accurate fit within the existing YORK equipment
- New copper-tube and aluminium-fin heat-transfer surfaces
- Complete installation and refrigerant piping integration
- Pressure-tested and leak-checked refrigerant connections
- Continued utilization of the existing HVAC equipment
- Reduced requirement for complete equipment replacement
- Reduced requirement for complete equipment replacement
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Extending the Life of Existing HVAC Equipment
Replacement coils can provide a practical solution when the main HVAC equipment remains serviceable but its heat exchangers have deteriorated or require replacement.
At Al Tabreed Industries, condenser coils can be manufactured based on existing samples, drawings, dimensions and site requirements, making it possible to support replacement requirements for installed HVAC equipment where an exact standard replacement may not be readily available.
From coil manufacturing through installation and testing, this Dubai project demonstrates how a custom replacement approach can help restore existing HVAC equipment while minimizing the need for complete system replacement.
Need a Similar Solution?
If your facility is facing reduced cooling efficiency, coil corrosion, or system reliability issues, our team can help with custom-built solutions designed for long-term performance.
📞 Contact us today to schedule an inspection or consultation.
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