- Most coil failures are caused by corrosion, vibration, dirt buildup, improper materials, or poor maintenance — and often a combination of these factors.
- Coils installed in humid, dusty, or chemically aggressive environments are far more likely to fail early, especially without protective coatings or airflow filtration.
- Common failure signs include refrigerant leaks, ice formation, poor airflow, and visible fin or tube damage.
- Many coil failures can be prevented with regular cleaning, upgraded materials, and precision-matched replacements that don’t stress surrounding components.
- KCL supplies custom coils across Ontario that are built to resist the most common failure points — and provides expert measurement and material selection guidance to help extend service life.
When a coil fails in an HVAC or refrigeration system, it’s rarely random. These components work hard, and they’re exposed to a range of environmental and mechanical stressors.
Whether you’re dealing with a sudden leak, low performance, or a series of frustrating service calls, understanding why coils fail — and how to prevent it — can save you time, energy, and money.
Here’s a breakdown of the most common failure points we see in Ontario buildings — and how KCL helps customers stay ahead of them.
1. Corrosion
The #1 Coil Killer
Corrosion eats away at coil tubing and fins, weakening structure and creating leaks.
Common causes:
- High humidity levels
- Airborne contaminants (e.g. cleaning chemicals, kitchen exhaust)
- Galvanic reaction between dissimilar metals
- Salt spray in coastal or industrial areas
What it looks like:
- Pitting on tubes
- Rust or green/black discoloration
- Tiny refrigerant leaks that reappear even after repair
How to prevent it:
- Use epoxy-coated or phenolic-coated fins in corrosive environments
- Upgrade to all-copper coils for better resistance
- Keep equipment away from direct exposure to cleaning agents or moisture sources
2. Vibration and Mechanical Stress
Even a perfectly sized coil can fail early if the system vibrates excessively or if mounting is poor.
Common causes:
- Rooftop equipment exposed to wind
- Subway or train station HVAC near constant vibration
- Poorly secured or unsupported coil brackets
What it looks like:
- Stress fractures at headers or u-bends
- Repeated leaks near fittings
- Rattling or clanking noises
How to prevent it:
- Use vibration-isolated mounting brackets
- Choose heavier-duty construction for coils in high-vibration zones
- Match the coil’s frame and support points exactly to the original
3. Dirt, Debris & Blockage
Dirty coils don’t just reduce efficiency — they lead to premature failure by trapping moisture, blocking airflow, and straining compressors.
Common causes:
- Poor air filtration
- Dirty work environments (warehouses, transit stations, mechanical rooms)
- Lack of routine coil cleaning
What it looks like:
- Dust-caked fins
- Uneven temperature control
- Icing on evaporator coils
How to prevent it:
- Install or upgrade filters
- Schedule seasonal cleanings
- Choose coils with wider fin spacing in dirty environments (fewer clogs)
4. Improper Coil Selection or Replacement
You’d be surprised how many failures come from installing a coil that’s “close” but not quite right.
Common issues:
- Wrong refrigerant compatibility
- Inaccurate dimensions causing pressure issues
- Mismatched fin or tube configuration
- Poor airflow alignment
What it leads to:
- Poor system performance
- High static pressure
- Early coil fatigue
How to prevent it:
- Always match or improve OEM specs
- Work with suppliers who measure on-site
- Avoid generic coils not designed for your system’s load and environment
5. Chemical Exposure
In food-service, lab, or public areas, airborne chemicals can break down fin and tube coatings — especially if the coil isn’t protected.
Common sources:
- Disinfectants
- Cleaning sprays
- Cooking grease vapors
- Chlorine from pool areas
What it causes:
- Formicary corrosion (tiny pinhole leaks)
- Fin deterioration
- Discoloration and pitting
How to prevent it:
- Specify protective coatings during coil replacement
- Use indoor-rated coils for environments with chemical exposure
- Keep units clear of chemical storage areas
6. Freeze Damage
Freeze-ups don’t just reduce performance — they can burst tubes and destroy coils completely.
Causes:
- Poor airflow
- Low refrigerant charge
- Cold outdoor air entering an unheated space
- Thermostat or defrost cycle failure
Signs:
- Ice on the coil or surrounding casing
- Sluggish airflow
- Cracked or bulging tubes
Prevention:
- Ensure proper refrigerant levels
- Use temperature sensors and freeze stats
- Replace failing coils with ones that match thermal load exactly
What To Do When a Coil Fails
Before you order a replacement, be sure to:
- Identify the root cause of the failure — not just the symptom
- Check environmental conditions and system specs
- Avoid shortcuts like generic coils or rushed installs
This is where KCL’s expertise makes a difference. We don’t just sell coils — we help you solve the problem permanently.
How KCL Helps You Avoid Repeat Failures
- On-site measuring to ensure an exact fit
- Custom fabrication based on your building, not guesswork
- Material and coating recommendations tailored to your application
- Coil upgrades available to extend service life (like all-copper or fin coatings)
- Support throughout Ontario for commercial, institutional, and industrial sites
Whether your current coil failed from corrosion, freezing, vibration, or design — we’ll help you replace it with a solution that lasts longer and works better.
Frequently Asked Questions
Can I repair a coil instead of replacing it?
If the damage is minor, yes — but if corrosion or pressure issues are involved, repairs are usually short-term. A properly matched replacement is more reliable and efficient.
How long should a well-maintained coil last?
With proper material selection and care, coils often last 10–20 years. In harsh environments, 5–10 years is more common without upgrades.
Can KCL help me choose better materials for my environment?
Absolutely. We’ll evaluate your application and suggest coatings, metals, and spacing that can extend the coil’s lifespan significantly.
If your coil has failed once — don’t let it happen again.
Contact KCL to get a coil built for your exact environment, system, and operating conditions.