Project: HVAC Air Handling System Replacement
Client: Ross Laboratories
Date: 2026
Industry: Beauty
Services: HVAC design, installation & replacement
Scope: Removal of redundant mechanical plant and installation of new high-efficiency plug-fan AHUs with DX outdoor units

Scope of Works

  • HVAC site inspection and SWMS
  • Isolation and de-energisation of mechanical services
  • Removal and replacement of AHUs
  • Installation of DX HVAC systems
  • Ductwork reconfiguration
  • Insulated rooftop refrigerant pipework
  • Electrical wiring to HVAC equipment
  • BMS / controls integration
  • Roof platform fabrication
  • Lift logistics (crane and helicopter)
  • Multi-trade coordination
  • HVAC testing and commissioning
  • As-installed drawings and O&M manuals
  • 12-month warranty

After-hours labour was utilised to meet strict lift scheduling requirements.

CFM Solution

  • Early utility engagement and HVAC project planning
  • Engineered lift methodology tailored to constrained HVAC installations
  • Helicopter lifting to eliminate crane encroachment risks
  • Pre-assembly of HVAC equipment to reduce time on site
  • Staged installation and contingency planning (Plan B/C)
  • Consolidated approvals (SWMS, lift studies, rigging plans)
  • Dedicated lift director, certified spotters, and real-time coordination

Key Challenges

  • Live powerline “No-Go Zones” impacting HVAC plant installation and lifting methodology
  • Multi-authority coordination (DNSP, spotters, lift teams, airport operations)
  • Restricted crane access and helicopter lift risks (wind, rotor wash, load control)
  • Uncertain outage availability requiring contingency planning
  • Complex permits and compliance for HVAC installation near live services
  • Public and tenant access management
  • High standby cost risk for cranes, helicopters, and specialist HVAC crews

Outcome

The HVAC upgrade was completed safely within restricted lift windows despite flight-path and live powerline constraints.

This project demonstrates CFM’s expertise in delivering complex HVAC system replacements in highly constrained environments using alternative lifting methods and precise coordination.