**Site Bite: Ruptured U-Bends in a Frozen Water Coil**
Bundle up, as we head out with Jack Kessler to inspect a common but serious issue: a frozen water coil.
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**Main Image: Ruptured U-Bends**
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During the winter months, frozen water coils are one of the most frequent problems we encounter. Recently, we were called out to a luxury condo in New York City where a Dunham-Bush® unit suffered severe damage due to freezing. The water inside the unit turned to ice, causing the U-bends in the copper tubing to rupture.
The unit featured a 2-row hot water coil and a 4-row chilled water coil, both using 5/8" copper tubing. Because this unit was responsible for 100% outside air, it was the first to be exposed to extreme cold when the dampers were open. Normally, a freeze stat would activate and close the dampers when temperatures drop below 32°F. However, in this case, the freeze stat had failed, leaving the dampers open and allowing the system to freeze.
As water freezes, it expands by about 9%, which is enough to cause significant damage to the delicate copper tubing. In this instance, the expansion led to ruptured U-bends, making the unit inoperable.
**To Repair or Replace? That Is the Question**
When faced with a damaged coil, the decision to repair or replace often comes down to several key factors:
- **Accessibility**: If the damaged U-bends are on the back of the coil rather than the front, they may be easier to braze.
- **Urgency**: If the unit is critical to the building’s operations, a quick brazing repair can get things running again faster.
- **Age of the Unit**: Older coils might not be worth repairing if they’re nearing the end of their lifespan.
In this case, a full replacement was necessary. However, many times, a skilled technician can successfully repair a coil using brazing techniques. It all depends on the situation and the condition of the unit.
Whether you're dealing with a frozen water coil or another type of heat exchanger, we can help. At Nationwide Coils, we specialize in custom and OEM replacement coils for all makes and models. If your system has been damaged by freezing, don’t wait—contact us today for a free quote.
**Written by: Jack Kessler**
**Intern, Nationwide Coils**
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