- Drop-in coil replacements are custom-built to match the original coil’s size, layout, and performance — making installation faster and avoiding system modifications.
- Retrofit replacements involve adjusting or modifying ductwork, piping, or mounting hardware to fit a non-matching coil — often increasing labour and long-term risk.
- Drop-in coils typically cost more upfront in fabrication, but save significantly on installation, system efficiency, and future maintenance.
- Retrofitting may be appropriate when system specs are no longer available or when major upgrades are planned — but requires careful engineering.
- KCL specializes in drop-in coil replacements that are measured on-site, built to match, and designed to install without cutting, welding, or guessing.
You’re staring down a failed coil. Your system’s limping along. And the big question hits:
Do we retrofit a replacement — or build a drop-in coil that matches the original?
It’s one of the most important decisions building managers, HVAC contractors, and maintenance teams have to make. Get it right, and your system hums along for years. Get it wrong, and you’re chasing leaks, airflow issues, or even structural headaches.
Let’s break down the difference between retrofit and drop-in coil replacements — and why one is usually the safer, smarter, and more cost-effective choice.
What Is a Drop-In Coil Replacement?
A drop-in replacement coil is fabricated to match the original coil exactly — in size, layout, connections, material, and thermal performance.
It’s built to:
- Slide into the existing housing
- Align with current piping and airflow
- Avoid any modification to mounting, ductwork, or supports
At KCL, we create drop-in coils using:
- On-site measurement
- CAD-based fabrication drawings
- OEM spec matching or reverse-engineering
- Custom fabrication by top-tier North American coil manufacturers
What Is a Retrofit Coil Replacement?
A retrofit means using a coil that doesn’t match the original — and modifying the system to make it fit.
That could mean:
- Re-routing refrigerant piping
- Altering duct openings
- Fabricating adapters or mounting brackets
- Making electrical or control adjustments
In some cases, retrofitting is the only option (e.g., a major system redesign), but in most scenarios — it’s a workaround, not a long-term solution.
Comparison: Drop-In vs Retrofit
| Feature | Drop-In Coil Replacement | Retrofit Coil Replacement |
|---|
| Fit | Matches original exactly | Requires on-site modifications |
| Installation Time | Minimal (hours) | Longer (1–2+ days depending on scope) |
| Labour Cost | Lower | Higher due to extra work |
| System Integrity | Maintained | Risk of imbalance, airflow, or vibration issues |
| Performance | Matches original | May require system recalibration |
| Long-Term Reliability | High | Depends on retrofit quality |
| Upfront Coil Cost | Slightly higher | Lower (if using stock part) |
| Best For | Most replacements | Full upgrades or unavailable specs |
Why Drop-In Replacements Usually Win
If your goal is restoring original performance quickly and reliably, drop-in replacements are the gold standard.
They:
- Maintain system balance
- Prevent leaks or stress on piping
- Install faster and with fewer surprises
- Support long-term system health
At KCL, drop-in doesn’t mean slow. We measure, spec, and coordinate manufacturing fast — and deliver coils that fit perfectly the first time.
When a Retrofit Might Make Sense
There are situations where retrofitting is valid — and even necessary.
Consider retrofitting when:
- The original coil spec is unavailable, and reverse-engineering isn’t possible
- The entire HVAC system is being upgraded or redesigned
- The application calls for a performance upgrade with new controls or airflow paths
- The building is under major renovation, and layout is changing
In these cases, KCL can collaborate with engineers or contractors to provide a custom-fabricated coil that aligns with the new design.
Real-World Example: Drop-In vs Retrofit in a Toronto Commercial Building
A 15-year-old office tower had a leaking evaporator coil in a rooftop unit. The contractor had a generic coil in stock — but it required new pipe routing and ductwork fabrication.
KCL was called in to assess. We measured the failed coil, matched the original footprint, and delivered a drop-in coil in 3 weeks.
Result:
- 1-day install with no modifications
- Better performance than the stock retrofit would’ve provided
- Total project savings after install: over $2,000
The True Cost of Retrofitting
While retrofit coils may cost less upfront, they often result in:
- Increased install hours
- Higher risk of future leaks or airflow imbalance
- Code compliance issues if modifications are not properly documented
Many contractors and facility managers we work with say the same thing:
“We tried the retrofit route once. Never again.”
How KCL Makes Drop-In Easy
- We measure onsite to ensure precision
- We engineer coils to match your system — not guess or estimate
- We work with top coil fabricators in North America for speed and quality
- We coordinate directly with contractors and maintenance teams to support installation
Our drop-in coils are built to save time, reduce stress, and deliver results.
Frequently Asked Questions
Isn’t a drop-in coil more expensive?
Only slightly in terms of fabrication — but it typically saves much more in installation time, labour, and future reliability.
How fast can I get a custom drop-in coil from KCL?
Typical turnaround is 2–4 weeks, with expedited options available. We can start measuring within days of your request.
What if I’ve already retrofitted before?
No problem — we can measure your current system and create a custom coil that matches your updated layout exactly.
Can KCL help me evaluate whether retrofit or drop-in is better?
Yes — we’ll walk through your system, your timeline, and your budget to recommend the best fit.
If you’re facing a failed coil and weighing your options, don’t guess. Choose the solution that installs faster, lasts longer, and costs less over time.
Contact KCL to schedule a coil assessment or request a drop-in replacement quote today.