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80 kW Mitsubishi Ducted HVAC System Installation
25-year-old constructed property
Project Overview
We were engaged to install a complete 80 kW Mitsubishi Electric Ducted Air Conditioning System in a 25-year-old building with no prior HVAC provisions. The project scope included full ducted HVAC installation covering airflow design, fresh air integration, piping, electrical systems, and commissioning. The building's age and heavy concrete construction presented significant challenges requiring innovative solutions and skilled workmanship.
Key Challenges
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Old building with no prior HVAC provisions or designated shafts for ducting
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Dining area had zero fresh air provision requiring complete ventilation redesign
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Thick reinforced concrete walls making openings for ducts and piping difficult
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Extended copper pipe runs between indoor and outdoor units with careful slope management needed
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Complex airflow design requiring accurate load calculations and balanced multi-zone distribution
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Long pipe runs increasing brazing joints with risk of leakage and pressure loss
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Complex routing for power cables and communication wiring with limited access routes
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Concrete cutting with risk of structural damage requiring precision and safety planning
Our Solution
How we delivered
1
Custom HVAC Design
Developed a tailored solution for the building's specific needs:
Developed a zone-wise airflow design
Performed detailed heat load calculations
Ensured optimal supply and return air balance across all zones
2
Fresh Air Integration
Addressed the complete lack of ventilation in the dining area:
Designed and installed a dedicated fresh air system
Ensured compliance with ventilation standards for the dining area
3
Core Drilling & Structural Coordination
Overcame the challenges of working with heavy concrete construction:
Used advanced core cutting machines for precision work
Coordinated with structural considerations to avoid damage to load-bearing elements
4
Optimized Copper Routing & Precision Brazing
Managed the complexity of long-distance piping:
Planned efficient routing to minimize bends and pressure losses
Maintained proper insulation and support throughout all pipe runs
Performed nitrogen purging during brazing for clean joints
Completed leak testing and pressure testing successfully
5
Drainage System Engineering
Engineered reliable condensate drainage across long runs:
Maintained proper slope across long distances
Installed traps and insulation to prevent condensation issues
6
Electrical System Execution
Delivered clean and reliable electrical infrastructure:
Installed control panel and communication wiring
Ensured proper cable management and labeling throughout
7
Professional Commissioning
Rigorous testing to ensure peak system performance:
System vacuuming and gas charging
Performance testing under load conditions
Verified airflow, temperature, and overall system efficiency
Results & Impact
Successfully installed and commissioned 80 kW Mitsubishi Electric ducted system
Improved indoor air quality with proper fresh air supply to all areas
Balanced airflow achieved across all zones
Reliable system performance despite significant structural challenges
Full client satisfaction achieved
Project Gallery
See the transformation
Conclusion
This project showcases our capability to deliver complex HVAC retrofit installations in challenging older buildings. Proper planning, innovative execution strategies, accurate airflow and ventilation design, and skilled workmanship in brazing, electrical, and commissioning were essential to overcoming the structural limitations and ensuring long-term system performance.
