Restoring Aging HVAC Systems Without Replacement

How The Right Restoration Approach Can Extend System Life Without Full Replacement

As HVAC ductwork ages, moisture intrusion, corrosion, and leaks can compromise system performance and lead to damage within the building. Left unaddressed, trapped moisture can also contribute to microbial growth, unpleasant odors, and indoor air quality concerns that affect occupant comfort and health.

With the right restoration approach, however, full system replacement is often unnecessary. Certified HVAC duct cleaning specialists such as True Cleaning Solutions (TCS) and Midwest Duct Cleaning (MWDC) routinely restore aging systems in place, reducing disruption and extending service life. Their services span industrial, commercial, and residential applications and include air duct cleaning and sealing, mechanical system restoration, coil cleaning, and air filtration.

Experience Inspires Practical Solutions

Brooks M. Ingrassia, ASCS/CVI/VSMR, a Managing Partner at TCS and MWDC, has more than a decade of experience cleaning and restoring HVAC systems throughout the Midwest and Rocky Mountain regions. Over the years, Brooks has seen firsthand how corrosion-related drainage issues lead to odors, leaks, and declining system efficiency. Addressing those problems early, through very thorough cleaning and targeted repairs, helps HVAC systems operate as intended while avoiding costly replacements.

To support this specialized work, Brooks relies on Carlisle HVAC restoration products, which allow his teams to clean, seal, and rehabilitate ductwork and drain pans efficiently.

Preventing Costly Drain Pan Replacement

Replacing a corroded drain pan in a large commercial air handling unit can be expensive and disruptive. According to Brooks, replacement costs can range from $15,000 to $20,000 per unit, depending on system configuration. Accessing the pan often requires removing coils or other components and taking the unit offline for extended periods.

By contrast, restoration offers a more economical alternative.

“At MWDC, we charged $12,000 to maintain an HVAC unit at a medical facility in Kansas City,” Brooks said. “That work included removing rust and corrosion, sealing seams, and reinforcing components using Hardcast® Pan-Grip. The product allowed us to stop the corrosion, restore the drain pan, and prevent future damage without replacing the unit.”

Why Pan-Grip Is Central to HVAC Restoration

Pan-Grip creates a corrosion-resistant surface designed to restore drain pans, air handling units, and cooling towers. It seals leaks and protects horizontal surfaces without rusting, even in challenging conditions.

Key features include:

• Strong mechanical grip and adhesion
• Seamless membrane that stops leaks immediately
• Efficient installation with minimal equipment
• VOC-free formulation suitable for occupied or sensitive environments
• Ability to cure in standing water without a primer

These properties allow restoration work to move quickly while minimizing impact on building operations.

Spotlight: After-Hours Restoration in Denver

In Denver, the TCS team is restoring a large HVAC system during overnight hours to avoid disrupting daily operations. Each night, the system is shut down temporarily, restored, and returned to service before employees arrive.

The restoration process includes:

• Inspecting drain pans and HVAC components for corrosion, pooling, and leaks
• Cleaning and preparing surfaces to promote adhesion
• Applying Pan-Grip to create a durable, long-lasting seal
• Reinforcing seams and transitions with Hardcast Foil-Grip® 1402 tape as needed

The system stays available during the day because restoration happens overnight.

Labor and Cost Savings Through Restoration

By restoring drain pans in place, TCS avoids the labor, coordination, and operational disruption associated with replacement. Pan-Grip enables crews to work during off-hours without dismantling equipment or halting building operations.

“A product like Pan-Grip stops the rust and prevents further decay,” Brooks explained. “It lets us clean the system and address uneven pans caused by corrosion, so water drains properly again. When you’re finished, you’re left with a smooth, restored surface.”

Replacement projects, on the other hand, often require removing walls, doors, or duct sections to access equipment. These projects can force HVAC shutdowns during business hours and require coordination among multiple trades, driving up labor and material costs.

A Cost-Effective Addition to Routine Maintenance

Because of its efficiency and ease of use, Pan-Grip has become part of Brooks’ routine HVAC cleaning and maintenance work.

“When I see rusted metal, I’ll suggest coating it with Pan-Grip and explain why,” Brooks said. “Very rarely do customers say no. The labor is minimal for us, and the customer gets a solution that’s effective without being expensive.”

The VOC-free formulation is also valued by both crews and facility owners, particularly when work is performed inside air ducts or occupied buildings.

“It’s a very safe product to use,” Brooks added. “When you’re working inside HVAC systems, using low-VOC products is important for everyone involved.”

A Trusted Industry Partnership

Brooks’ relationship with Carlisle HVAC began early in his career, when company representatives helped him learn the business and better understand restoration solutions. That collaboration continues today through product guidance, troubleshooting, and job-specific recommendations.

“When we’re trying to solve a problem, my first call is usually to my Carlisle HVAC reps,” Brooks said. “I send photos, we talk through the situation and figure out which products make the most sense.”