Replacing rooftop units (RTUs) is routine work for many HVAC contractors. But when crane access is limited, even a standard replacement can become a logistical headache. Modern HVAC/R encountered this challenge while replacing an RTU at a large commercial retail property in Ohio.
Modern HVAC/R primarily provides service and maintenance, so tackling a rooftop unit replacement under restrictive access conditions was a first. The crane on-site would not be able to set the unit close to its final location. The team needed a solution that would allow them to safely move and position the load across the roof, despite winter weather, rooftop obstacles, and varying surface textures.
Several factors set this project apart from a typical RTU replacement:
• Extremely limited crane access, requiring the unit to be set far from its final location.
• Winter conditions, including snow and approximately one inch of ice on the roof.
• Rooftop obstructions, such as gas lines and miscellaneous mechanical components.
• Variable roof textures, which made standard rolling solutions impractical.
Modern HVAC/R determined that a gantry system was required. However, selecting the right type, size, and configuration was a critical challenge. Traditional rigging options simply wouldn’t provide the mobility or safety needed for this environment.
Pneumatic casters made transportation across an icy rooftop possible.
After a local crane company referred them to LGH, Modern HVAC/R connected with LGH Rental Representative Jason Bugansky to evaluate the jobsite conditions and lifting requirements.
While the team had already identified that a gantry was necessary, they relied on LGH’s expertise to determine the correct gantry size and configuration. Based on the roof conditions and the weight of the RTU, LGH recommended a 2-ton aluminum gantry outfitted with 16-inch pneumatic casters. Use of these casters would prove to be a key decision for the project’s success.
Office Manager Gyllian Oakes noted,
“Ohio snow with a one-inch-thick layer of ice on the top of the roof was a challenge that we were pretty worried about! The gantry had no issue getting through this.”
Pneumatic casters allowed the gantry to roll smoothly across icy, uneven roof surfaces without damaging the roof or compromising stability. According to Modern HVAC/R, this recommendation made the difference between a manageable installation and what would have been a difficult day for their technicians.
Although there was a minor scheduling hiccup during delivery, LGH resolved it quickly and without disruption. Once the gantry arrived on-site, the installation proceeded smoothly.
With three technicians on the roof, Modern HVAC/R was able to:
Oakes commented,
“Our technicians appreciated that they didn’t have to break their backs due to how easily the gantry moved and it was even better that they didnt have to rush to set the unit and could just leave it suspended on the gantry while they worked on the electrical for the unit.”
Despite exceeding their original budget estimate, the team viewed the investment as well worth it. The gantry system reduced physical strain on the technicians. As a result, the gantry system improved safety and kept the project on schedule, even in challenging weather.
LGH chain hoists, beam trolleys, clamps, and an aluminum gantry crane made this RTU replacement possible.
Most importantly, the project served as a valuable learning experience. Modern HVAC/R now has firsthand knowledge of how effective a pneumatic caster gantry can be for rooftop installations with restricted access.
This RTU replacement demonstrated how the right rigging solution can turn a challenging rooftop environment into a successful installation. With limited crane access, winter weather, and rooftop obstacles working against them, Modern HVAC/R relied on LGH’s expertise and specialty equipment to get the job done safely. Oakes concluded,
“I reached out to probably six to seven different crane/rigging companies, and none of them even had a gantry. This was our first time using a gantry like this, and truthfully LGH was the only company that was willing and determined to help us complete this project. Jason worked with us and was very patient, as we had a lot of issues coordinating everything else on this project. Once we had an install date, he was on it!”
From equipment selection to on-site support, LGH provided the confidence and capability needed to complete the project without compromise.
Modern HVAC/R is an owner-operated business focused on providing transparency and customer-driven solutions. With a foundation based on service and communication, you can be confident that any choice you make regarding repair, maintenance, or replacement will be best suited to your needs. With passionate technicians and mechanical preparedness, we have the solutions for every HVAC/R situation.
LGH is North America’s largest organization dedicated exclusively to the rental of lifting and moving equipment. With one of the most comprehensive inventories of hoisting, rigging, jacking, pulling, material handling, and safety equipment available, LGH supports contractors with expert guidance and proven solutions for even the most complex jobsites. Learn more at RentLGH.com.
