**Site Bite: Measuring OEM Coils for Replacement at the Defense Finance & Accounting Service**
Join Jack Kessler, our standout intern, as he travels to Limestone, Maine, to assist in measuring large air handler coils for a critical replacement project at the Defense Finance & Accounting Service (DFAS).
As an intern, stepping out of state to measure over 25 coils can be both exciting and challenging. But I’ve been fortunate to work under James Filauro, our experienced Account Manager from the New York tri-state area. His guidance has been invaluable, helping me build the skills and confidence needed to take on this important task.
The goal of today’s visit was to measure and replicate aging OEM coils inside large air handling units (AHUs) at DFAS. These coils were originally manufactured in 1991 and featured cast iron headers — a design that, after 30 years of operation, had started showing signs of wear. Rust, corrosion, and potential leaks were concerns, which could lead to serious issues like coil failure and water damage.
In addition to these risks, the old steel headers also caused reduced water flow, increasing the chance of sediment buildup in the chilled water system. To address this, we planned to replace the steel headers with high-quality copper ones during the replacement process.
Copper headers offer superior efficiency, durability, and resistance to corrosion, especially in chilled water systems. They’re easier to repair using brazing rods, unlike steel, which is often difficult or even impossible to fix once damaged. Plus, copper helps prevent mold and mildew growth, improving indoor air quality and reducing odors.
During the site visit, I followed best practices such as measuring header-to-header center distances, connection center-to-center dimensions, and carefully recording all measurements in my workbook. After a few units, I noticed patterns in fin heights and lengths, allowing me to match duplicate coils more efficiently and only verify dimensions when necessary.
After measuring over 25 coils, I packed up my tools and returned to the office to finalize the coil designs and create detailed CAD drawings. This experience was a major milestone in my career, and I’m proud to have played a key role in such an important project.
Nationwide Coils maintains one of the largest and most comprehensive coil drawing databases in the industry. We can replicate any commercial HVAC coil, regardless of make or model. If you need assistance, feel free to email us anytime for a quote.
**Written by: Jack Kessler**
**Intern, Nationwide Coils**
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