As HVAC ductwork ages, it is subject to surface moisture, corrosion and leaks that not only reduce the HVAC system’s efficiency but often damage the building’s infrastructure and furnishings. In addition, accumulating moisture can cause microbial growth and contamination to spread, emitting foul odors and threatening occupant health.

Fortunately, with the right products, skilled and certified HVAC duct cleaners, like True Cleaning Solutions (TCS) and Midwest Duct Cleaning (MWDC), can restore aging HVAC systems without the disruption and expense of a replacement. TCS and MWDC provide comprehensive mechanical system cleaning for industrial, commercial, and residential HVAC systems, which include air duct cleaning and sealing, restoration, coil cleaning, and air filtration.

TCS / MWDC Managing Partner Brooks M. Ingrassia ASCS/CVI/VSMR started cleaning and restoring HVAC systems 12 years ago and relies on Carlisle HVAC products to clean, seal, and restore systems throughout the Midwest and Rocky Mountain regions. Therefore, Brooks understands how thorough duct cleaning and ongoing maintenance keeps HVAC systems running efficiently, pumping clean air by resolving problems like odors and leaks that occur when corrosion prevents water from draining properly. Thorough duct cleaning and repair also help avoid costly replacements.

Duct Cleaning and Restoration Prevents Costly Replacements

“It can cost $15,000 to $20,000 to replace one drain pain on a large commercial air handling unit because you have to remove the coil or other parts depending on how the system is built, not to mention the disruption caused by having to take down the system for an extended period of time,” Brooks explained.

At MWDC, we charged $12,000 for maintaining an HVAC unit for a medical facility in Kansas City,” said MWDC Managing Partner Brooks. “The job entailed removing rust and corrosion, taping up seams, and strengthening components by applying Hardcast® products from Carlisle HVAC, namely Pan-Grip. Using Pan-Grip can stop the rust, prevent further decay, and allow us to clean and restore ductwork, and prevent future damage elsewhere in the unit.”

How Pan-Grip Streamlines HVAC Restoration Projects

Pan-Grip creates a new, corrosion resistant, restored surface for drain pans, AHU restoration, and cooling tower restoration. Impervious to water, Pan-Grip is designed to seal and repair corroded and leaking drain pans and horizontal surfaces without rusting. It can even cure in standing water and be applied to clean surfaces without a primer. Pan-Grip Features:

• Strong mechanical grip and adhesion.
• Seamless membrane stops leaks immediately.
• Faster installation with minimal equipment needed.
• VOC-free ingredients make it safe to apply even in sensitive facilities.

Spotlight: Nightly Restoration Keeps a Large HVAC System Humming

In Denver, the TCS team is restoring a very large HVAC system at night to avoid disrupting operations. They switch the HVAC system off while they work and turn it back on before they leave so the facility is comfortable for employees when they arrive. The team’s process includes:

1. Inspecting HVAC units and drain pans for signs of corrosion, leakage, or pooling.
2. Cleaning and preparing surfaces to ensure proper adhesion.
3. Applying Pan-Grip to seal the pan with a durable, long-lasting coating.
4. Reinforcing transitions and seams using Hardcast Foil-Grip 1402 tape as needed.

How Pan-Grip Promotes Labor and Cost Savings

Pan-Grip allows the TCS team to restore drain pans and other deteriorating components without replacing them, avoiding the extensive costs, disruption, and coordination typically associated with replacement. With Pan-Grip, Brooks’ crew restores pans in place, during off-hours, without tearing down equipment or halting operations.

“A product like Pan-Grip can come in, stop that rust, prevent further decay. It allows you to clean the system and prevent future damage somewhere else in the unit. Pan-Grip also helps even out a pan that becomes uneven due to rust or degradation and starts holding water where we don’t want. When you use Pan-Grip, you end up with this nice smooth pan,” Brooks explained.

In contrast, replacing a drain pan in a large air handling unit often requires disassembling major portions of the HVAC system and removing doors, walls, or sections of duct just to access the equipment. The process can disrupt normal operations by shutting down the HVAC system during business hours—and sometimes even closing off areas affected by construction. Facility managers may need to coordinate with multiple contractors, causing labor and parts costs to soar.

“Pan-Grip is such a cost-effective solution, it’s one of the things we lean on. In our facility in Denver, using Pan-Grip doesn’t require a massive amount of labor,” Brooks says. “It can be part of the service we provide without the facility incurring this massive cost that makes a facility manager reconsider whether or not to pursue the project.”

In fact, TCS crew uses Pan-Grip as part of routine HVAC cleaning and maintenance project.

“When I see pieces of metal that look rusty, I’ll say to the customer, ‘Hey, let me provide you with an estimate to coat that with Pan-Grip, and here are its benefits and why we suggest it.’ Very seldom do I get told no, partly because of the simplicity of the product. It creates a very low labor cost on my end, and we’re providing a solution the customer is thrilled with—one that’s not an expensive fix for them.”

Customers and workers also appreciate the Pan-Grip’s VOC-free formula since it doesn’t emit noxious fumes or pose any risks to their health.

“It's a very safe product to use. I like that for my team and for facilities. When we're working inside the air ducts and HVAC units, you always want to use the lowest VOC products you can.”

Driving Innovation through Partnership

Shortly after entering the industry in 2013, Brooks met Carlisle HVAC representatives at an industry event, who “took him under their wing” and helped him learn the business and how to use restoration products effectively. That support has continued over the years through shared insights, troubleshooting, and product guidance.

“I trust and rely on Carlisle HVAC’s people and products. When we start thinking about using products to fix a problem—whether it’s a foil tape, a mastic tape, or some sort of restoration product—my first thought is to reach out to my Carlisle HVAC representatives for their thoughts. I send pictures and then we talk about a game plan and what products can help.”

About Carlisle HVAC

As an industry leader, Carlisle HVAC Brands produces industry-leading solutions that equip HVAC systems to perform at peak efficiency every day, all day, even in tough conditions. Our product brands include Hardcast® (Duct Sealants & Adhesives), DynAir (Duct Airflow Hardware & Accessories), and Gripnail® (Duct Insulation Fastening Equipment).Our energy-efficient products promote sustainability by forming airtight seals around ductwork and ensuring proper air exchange throughout the facility, which are critical for optimal HVAC performance, energy efficiency, occupant health, and indoor comfort. Carlisle HVAC Brands are trusted by professionals for their proven performance, award-winning industry recognition, and reliable warranty coverage. Learn more.