Bancroft was contracted to replace four 1,000-ton single cell cooling towers, consisting of aging ceramic and BAC systems, along with two double cell steel cooling towers that served Buildings 1 and 6. The project scope extended far beyond simple equipment replacement. It called for a complete overhaul of all associated piping, pumps, chemical systems, controls, and supporting accessories to ensure long-term performance and reliability.
To ensure uninterrupted cooling and facilitate future maintenance, Bancroft designed the system in an N plus 1 configuration. This meant that even with one unit offline, the system could continue running 24 hours a day, supporting the continuous operations of the medical center.
Demolition was a carefully planned effort. Bancroft’s approach included the removal of steel support structures, including the dunnage platform for the cooling towers. Steel columns that penetrated the roof were cut down to just three feet above the structure, all while preserving the roof’s integrity and supporting a safe construction environment.
To power the new system, Bancroft designed upgraded electrical systems, including a new distribution panel that fed the cooling towers and all related equipment. Piping systems were reconfigured to maximize performance and efficiency, forming a fully controlled cooling tower loop working in tandem with four chillers in the facility’s central plant.
As part of the design effort, Bancroft conducted a comprehensive cooling load analysis to confirm that the system’s 4,000-ton capacity would meet the demands of both Building 1 and Building 6. The design process ensured precise coordination between the new cooling towers and the existing chillers, minimizing risk and maximizing reliability. A full direct digital control system was also designed, installed, and integrated into the Building Automation System for seamless monitoring and control.
Client
Department of Veteran Affairs Margaret Cochran Corbin VA Campus
Location
New York, NY
Size
3,200 SF
Cost
$6,151,982
Dates
Design - 2020
Construction - 2025
Bancroft Services
Architecture, MEP Engineering, Cost Estimating, Construction Admin
Consultants
Johnson Wilbur & Adams - Structural Engineering
Contractor
Cornerstone Contracting, Inc.