Fabricate and Chill(er)

Ductwork made in C&S Cos.' Syracuse, New York, sheet metal shop. The industrial HVAC contractor added duct fabrication services in June 2023. 

From car washes and factories to playgrounds and airports, SMACNA member C&S Cos. has long been involved in commercial, civil, industrial and architectural projects — big and small — across the country. Its services range from construction planning to engineering and sustainability guidance. 

A recent addition (since June 2023) to that service list is sheet metal fabrication and installation. C&S Cos. has opened a sheet metal shop near its corporate headquarters in Syracuse, New York. One of its recent industrial sheet metal projects was at nearby Syracuse University. 

Syracuse University is a private research institution that dates back to 1870. Thirteen schools and colleges are part of its campuses and satellite locations. Famous alumni include U.S. President Joe Biden, New York state Gov. Kathy Hochul, “American Bandstand” host Dick Clark, “Columbo” actor Peter Falk, and sports broadcaster Bob Costas. 

As part of a multimillion-dollar, multiyear modernization effort, the university is replacing three chillers on its campus. C&S Cos. was awarded a $150,000 contract to fabricate the chillers’ exhaust system ductwork, as well as make and install the duct for two air handlers. One is a rooftop air handler that distributes air throughout the structure and another serves the building’s basement. 

C&S Cos. is working as a subcontractor under Riggs Disler, a 116-year-old New Jersey-based construction firm. Riggs Disler is one of the largest mechanical, electrical and utility contractors in the country. 

Besides the sheet metal work, C&S Cos.’ general construction division also secured a contract to perform some concrete foundation work as part of the project. 

Don Young, a Senior Project Estimator at C&S Cos., says the university sheet metal work requires careful coordination due to the size of some of the piping. 

“There’s some large chilled water piping on this job: 30-inch diameter,” Young says. “That’s going to be installed in the same space we’re installing the duct system.”

BIM was important
With many subcontractors on the project, Young says building information modeling (BIM) coordination was extensively used before any duct was made or installed. It was critical to avoiding clashes and slowdowns. 

The only real problem, Young says, involved penetration issues in the floors. And those “we worked through,” he adds. “Our piece of the project is fairly simple.” 

A major university client is nothing new for C&S Cos., which has 20 locations across the country and counts automotive, industrial and pharmaceutical companies, schools and even governments as among its clients. 

Eric Taylor, P.E., a Senior Project Manager who worked on the project, says C&S Cos. performs industrial work. 

“We do a lot of general construction work for private industrial clients,” Taylor says. “A large portion of our business is process piping and sheet metal for private industrial clients.” 

The Syracuse University project is using 25,000 to 30,000 pounds of 20-gauge sheet metal, Young says. Most of it was turned into rectangular duct, but some spiral was purchased from an outside contractor for the project. Fabrication was done at C&S Cos.’ 25,000-square-foot Syracuse sheet metal shop. The shop is equipped with a full coil line and two plasma tables. Four C&S Cos. employees — two on-site and two in the shop — worked on the job. 

Coordinating success 
When asked what was the most interesting thing about the project, Taylor and Young thought about it for a few moments. “Coordination with the chillers and the rooftop unit,” Young says. “The sequencing. Coordinating access and logistics was probably the most important part.” 

“And the physical size,” Taylor adds. “These are very large chillers.” 

Working with chillers that were 2,500 tons required in-depth planning by the C&S Cos. team. “So after the chillers were set (in place), then the rooftop units could be scheduled,” Young says. From there, C&S Cos. workers could start the process of installing the ductwork. “Just get our duct system installed and then through the building, exterior into the interior.” 

As of summer 2024, C&S Cos.’ part of the Syracuse University project is wrapping up. The whole project was set to be completed by the end of September, as 
of presstime.