Large-Scale Air Tempering Automotive Retrofit

Sylvan successfully executed the piping and sheet metal scope for a major air tempering retrofit at a large-scale automotive manufacturing facility. The project modernized the plant’s air conditioning and environmental control systems, significantly improving working conditions and overall operational performance.

This complex retrofit required the integration of new mechanical systems into an active production environment, with careful coordination to ensure uninterrupted manufacturing operations. The scope included installation of over 35,000 linear feet of polypropylene piping across the facility roof to support a new chilled water distribution system, as well as the retrofit of more than 30 existing air handling units with chilled water coils, drain pans, and high-efficiency fan arrays. The project also included installation of new rooftop units with heating and cooling coils, full integration into a new central utility plant for chilled water distribution and future scalability, and the coordination, fabrication, and installation of all associated piping supports, penetrations, and sheet metal systems. The work required precise engineering, installation, and system commissioning to meet strict performance requirements for airflow, temperature control, and system balance.

The project was successfully completed within an active manufacturing environment with zero disruption to plant operations. Advanced coordination and engineered support systems were utilized to ensure proper load distribution and long-term system reliability, while comprehensive testing and commissioning—including pressure testing and air and water balancing—validated full system performance.

The project achieved zero lost-time incidents, was delivered under budget, and was completed on schedule, meeting all critical milestones. The facility-wide air tempering upgrade significantly improved workforce comfort and supported long-term operational efficiency, representing a meaningful modernization of legacy automotive manufacturing infrastructure through enhanced chilled water and air handling capabilities.