- A custom coil isn’t just about unusual sizing — it’s about matching the original coil’s airflow, capacity, material, connection layout, and operating pressures.
- True custom fabrication ensures the new coil drops into place without modifying ductwork, piping, or mounting systems.
- Custom coils are critical in older or specialized systems where off-the-shelf solutions don’t exist or would create inefficiencies.
- KCL handles every aspect of custom coil production — from on-site measurement to CAD drawing coordination and direct-from-manufacturer delivery.
- With deep experience in Ontario’s commercial and institutional sectors, KCL delivers precision-engineered coils for everything from rooftop HVAC units to large-scale refrigeration systems.
You’ve probably heard the term “custom coil” before. But what exactly does that mean? And when is a custom coil actually necessary?
Spoiler alert: it’s more common — and more critical — than you think.
In commercial HVAC and refrigeration systems, coils aren’t always something you can pull off a shelf. Many systems, especially older or purpose-built ones, need coils that fit and perform exactly like the original.
Let’s look under the hood at what makes a coil truly custom — and how KCL ensures your replacement is done right.
What Defines a Custom Coil?
A custom coil is built to match very specific specifications — ones that differ from today’s off-the-shelf models or generic stock options.
This includes:
- Casing size and shape
- Tube layout and diameter
- Fin spacing and materials
- Number of rows and air pass configuration
- Connection location, size, and type
- Orientation for airflow direction (horizontal, vertical, etc.)
- Operating capacity and pressure requirements
In short, if your replacement coil can’t be pulled from a catalog, it’s custom — and needs to be engineered for your system’s exact layout and conditions.
Why Are So Many Coils Custom?
Because HVAC and refrigeration systems vary widely across:
- Building age
- System brand or model
- Environmental needs
- Load requirements
- Design constraints (mechanical room size, airflow, duct placement)
Most coils are originally engineered to fit into a unique air handler, chiller, or rooftop system. When that coil fails, an exact match is often the only way to restore performance without costly retrofits.
That’s where KCL comes in.
What Goes Into Custom Coil Fabrication?
Here’s what happens behind the scenes once you call KCL for a custom coil:
1. Site Assessment & Measurement
We send a rep to measure the failed coil in place, capturing:
- Casing dimensions
- Fin height and length
- Tube diameter and number of rows
- Connection types and distances
- Airflow direction and system orientation
2. Engineering Review
We work with trusted manufacturers to:
- Translate measurements into detailed drawings
- Cross-check thermal capacity and airflow specs
- Adjust for material upgrades (e.g., epoxy-coated fins)
3. CAD Drawings & Sign-Off
You receive a detailed CAD drawing of the proposed coil for approval. Nothing moves forward until everyone is aligned — avoiding mistakes or surprises.
4. Precision Fabrication
The coil is manufactured to spec, using the selected materials and layout. Each bend, weld, and connection is crafted to match your system exactly.
5. Delivery & Support
KCL coordinates direct delivery to your site, so the coil arrives ready to install. We stay in touch with contractors and service teams during the install to ensure success.
Real-World Examples of Custom Coil Needs
🏢 Office Tower Rooftop Unit (Toronto)
A 25-year-old system needed a new condenser coil — but the OEM had been discontinued. We measured the old coil, replicated the casing and connections, and supplied a new one with upgraded fin coating for urban pollution exposure.
🚆 Subway Platform Air Handler (GTA)
High humidity and vibration had caused repeated coil failures. We built a heavy-duty evaporator coil with copper fins and vibration-resistant casing to fit the existing housing perfectly.
🏫 School Chiller System (Ottawa)
The air handler’s coil had an unusual slant-mount configuration. KCL worked with the client’s engineer to reproduce the angle, bracket, and airflow path — no duct changes required.
Why Custom Doesn’t Mean Complicated (With KCL)
The word “custom” can make some building managers nervous — thinking it means delays or higher cost. But with KCL, custom is our standard.
✅ We streamline the process
From measurement to manufacturing, we manage the entire lifecycle. You’re not stuck coordinating between techs, engineers, and vendors.
✅ We reduce errors
Because we measure in the field and review every drawing, our custom coils are right the first time — saving time and install headaches.
✅ We avoid retrofits
Our coils are designed to fit exactly into your system — no welding, patching, or redesign required.
Custom Doesn’t Always Mean “Unique” — Sometimes It Just Means “Not Off-the-Shelf”
Even small deviations — like a different fin spacing or connection thread — are enough to make a stock coil incompatible. That’s why so many coil replacements are, by definition, “custom.”
And that’s exactly what KCL is built to handle.
Frequently Asked Questions
How long does it take to get a custom coil?
Standard lead time is 2–4 weeks, depending on complexity and material availability. Expedited options are often available for urgent projects.
What if I don’t have any specs or drawings?
No problem. We can visit your site, measure the failed coil, and reverse-engineer a match based on performance needs and layout.
Do custom coils cost significantly more?
Not necessarily. While they may cost more than a basic stock coil, KCL’s direct-from-manufacturer pricing keeps costs competitive — and saves you money on labour and retrofit work.
Can you match coils from discontinued equipment brands?
Yes. We regularly replace coils from legacy or discontinued systems — building new ones to match size, capacity, and layout.
If your building needs a coil that doesn’t exist on a shelf, don’t settle for a workaround.
Contact KCL Systems to get a precision-engineered, made-to-measure coil that installs easily and performs exactly as it should.