The Benefits of Refurbishing an Older Cooling Tower Instead of Replacing It
When an industrial cooling tower system starts showing signs of age, most facility managers face the same dilemma: replace it entirely or invest in refurbishment. For many industrial plants, refineries, and commercial sites across sub-Saharan Africa, refurbishment often proves to be the smarter, more cost-effective choice.
At Lekwa Cooling Tower Services, we’ve seen first-hand how refurbishment can extend the life of a system, reduce operating costs, and ensure reliable cooling without the heavy financial burden of a brand-new installation.
We have extensive work experience on the following cooling tower types:
Cooling Tower Nozzles
Cooling Tower Sprayers
Cooling Tower Impellers
Drift Eliminators
Distribution Pipes
PVC Fill Blocks
PVC Drift Eliminators
Fill Grids
Cooling Tower Splash Fill
Cooling Tower Pumps
Cooling Tower Gearbox
Cooling Tower FRP Walkways
Cooling Tower Sumps
Cooling Tower Drive Shafts
Cooling Tower Hub Assembly
Cooling Tower Couplings
Cooling Tower Louvers
Dark Room Louvers
Honeycomb Drift Eliminator
Trickle Pack Fill
Cooling Tower Vibration Switches
Refurbished Parts
Why Cooling Tower Refurbishment Makes Sense
Extending the Life of Your Existing System
An older tower doesn’t necessarily mean a failing one. With the right cooling tower refurbishment plan, you can restore performance levels close to those of a new unit. We’ve refurbished towers in power stations, chemical plants, and food processing facilities where downtime was simply not an option. After replacing worn parts and upgrading fill material, efficiency was boosted without the need for a full rebuild.
For a deeper look at refurbishment, visit our page on cooling tower refurbishment.
Cost Savings Compared to Replacement
A new industrial cooling tower system can be a major capital investment. Refurbishment costs, on the other hand, are a fraction of full replacement. Clients often tell us they’d rather allocate their budgets to core production upgrades while keeping their cooling towers operating reliably with well-planned refurbishment.
Our work as a cooling tower maintenance contractor across mining and industrial sectors has shown that refurbishment can deliver excellent ROI without the financial strain of a complete rebuild.
Reduced Downtime and Operational Disruption
Replacing a tower means construction, installation, and testing – often stretching into weeks. Refurbishment, however, can be scheduled around operations, with work carried out in phases to keep production running. We’ve completed refurb projects for clients in the steel and sugar industries where downtime would have cost millions in lost production.
Common Refurbishment Work That Delivers Big Results
Structural Reinforcement and Component Replacement
Cooling towers face harsh operating conditions: high humidity, chemical exposure, and continuous thermal stress. Over time, steelwork may corrode, wooden structures can rot, and fibreglass can deteriorate. Instead of starting over, our team strengthens existing structures and replaces compromised parts.
If your facility runs a GRP cooling tower, refurbishment might include replacing panels, nozzles, or fan stacks while preserving the main structure. Learn more about GRP cooling towers and why they’re often worth refurbishing.
Cooling Tower Spares and Fill Upgrades
The most common wear point is the fill – the heart of the tower’s heat transfer system. Aged fill loses efficiency, becomes clogged, and increases energy use. Replacing it with modern fill materials can immediately restore cooling performance.
We stock a range of cooling tower spares to ensure refurbishment is never held back by long waits for parts. Whether it’s drift eliminators, gearboxes, or fan blades, we keep critical components ready for fast turnaround.
Mechanical Overhauls
Fans, motors, gear drives, and distribution systems are all subject to heavy use. A refurbishment often includes upgrading or overhauling these mechanical systems to restore reliability. Instead of installing a new tower, replacing a gearbox or fan stack can extend your current system’s life by another decade.
Preventative Maintenance and Long-Term Reliability
Avoiding the Trap of Reactive Repairs
Too many facilities only act when a tower fails. By then, the damage has spread, costs escalate, and downtime is unavoidable. A proper cooling tower preventative maintenance plan combined with scheduled refurbishments avoids emergencies and extends operational life.
As specialists in field erected cooling tower systems, we often step in to carry out inspections, refurbishments, and structural upgrades that prevent catastrophic breakdowns. See how our team operates on large-scale projects here: field erected cooling tower specialist.
Safety and Compliance Benefits
Neglected cooling towers aren’t just inefficient – they’re a safety hazard. From collapsing structural sections to legionella growth in poorly maintained fill, risks are real. Refurbishment brings the system back in line with safety standards, protecting both your workforce and compliance obligations.
When Refurbishment Isn’t Enough
There are cases where refurbishment just isn’t viable. Severe structural collapse, complete corrosion, or towers undersized for current loads may call for replacement. In those situations, we design and supply new cooling towers built for modern industrial demands.
But here’s the reality: in most cases we inspect, refurbishment remains the more cost-effective cooling tower solution. That’s why our clients trust us to give an honest evaluation before committing to major expenditure.
Before and After
Here are some before and after photo’s of projects that we have worked on
Choosing a Trusted Cooling Tower Partner
Decades of Regional Experience
Operating across sub-Saharan Africa, we understand the unique challenges industrial cooling towers face in this climate. From high dust loads in mining regions to high humidity along the coast, we’ve developed refurbishment strategies tailored to each environment.
Reliable Service and Spares Support
Our clients rely on us not just for maintenance, but for long-term partnership. With access to leading cooling tower manufacturers in South Africa, and a strong supply of spares, we keep refurbishment projects running on time and on budget.
Why Refurbish Instead of Replace?
Refurbishment of an older cooling tower often delivers:
- Extended lifespan without massive capital spend
- Restored efficiency and performance
- Reduced downtime compared to replacement
- Improved safety and compliance
- A reliable, cost-effective solution for industrial operations
If your facility runs an ageing cooling tower, talk to our team before making the expensive decision to replace it. You may be surprised how refurbishment can bring it back to near-new performance.
Call us today or email our team to schedule an inspection and find out whether refurbishment is the right solution for your cooling tower.
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Frequently Asked Questions (FAQs) – Cooling Towers by Lekwa Cooling Tower Services
Cooling tower maintenance is crucial to ensure the efficient and reliable operation of the cooling system. It helps prevent issues such as scaling, corrosion, and biological growth, which can compromise performance and lead to costly repairs.
The frequency of cooling tower maintenance depends on factors such as the type of cooling tower, environmental conditions, and usage. However, as a general guideline, regular preventative maintenance should be performed at least twice a year.
Cleaning involves the removal of debris, scale, and biological growth from various components such as water distribution piping, sprayers, drift eliminators, air inlet louvres, and fill. This ensures optimal heat exchange and prevents blockages.
Mechanical services may include the refurbishment or replacement of impellers, electric motors, gearboxes, shafts, and v-belts. These components are critical for the mechanical functioning of the cooling tower.
Many cooling towers have components made of glass reinforced plastic (GRP). Repairing and maintaining these components are essential to preserving the structural integrity of the cooling tower and preventing issues like leaks.
Signs of potential issues include reduced heat exchange efficiency, unusual noises, visible corrosion, or increased water consumption. If any of these signs are observed, it is advisable to schedule maintenance promptly.
Yes, Lekwa Cooling Tower Services understands the urgency of cooling tower issues. We offer emergency repair services to minimise downtime and prevent further damage to your cooling system.
Absolutely. Lekwa Cooling Tower Services tailors maintenance plans to the specific needs of each client. We consider factors such as the type of cooling tower, operational conditions, and budgetary constraints to create a personalised maintenance schedule.
We prioritise swift responses to service requests. Our goal is to address maintenance needs promptly, minimising disruptions to your industrial processes. Contact us, and our experienced team will assist you as quickly as possible.
Yes, we offer training programmes to educate your staff on basic cooling tower maintenance practices. This empowers your team to perform routine checks and identify potential issues, contributing to the overall longevity and efficiency of your cooling towers.
For more information or to discuss your specific cooling tower maintenance requirements, please contact Lekwa Cooling Tower Services at 016 931 2061. We are here to provide expert guidance and support for all your cooling tower needs.
Frequently Asked Questions about Cooling Towers
- What is a cooling tower?
- How does a cooling tower work?
- What are the types of cooling towers?
- What are the main components of a cooling tower?
- What are the benefits of using cooling towers?
- What are the common applications of cooling towers?
- how-do-you-maintain-a-cooling-tower”>How do you maintain a cooling tower?
- What is the role of fill media in a cooling tower?
- How do you prevent Legionella growth in cooling towers?
- What is the purpose of drift eliminators?
- What factors affect the efficiency of a cooling tower?
- How do you size a cooling tower for a specific application?
- What is the difference between open and closed circuit cooling towers?
- How do you control the water level in a cooling tower?
- What are some energy-saving strategies for cooling towers?
- What is the lifespan of a cooling tower?
- Can cooling towers operate in cold climates?
- How do you troubleshoot common problems in cooling towers?
- Are there environmental concerns associated with cooling towers?
- What are some alternatives to cooling towers?
- What types of new cooling towers do you offer, and how do they differ from refurbished units?
- Can you provide details on the spare parts available for cooling towers?
- What maintenance services do you offer for cooling towers, and how often should they be performed?
- Do you offer customised maintenance plans tailored to specific cooling tower systems and customer needs?
- How do you ensure the quality and reliability of your maintenance services for cooling towers?
- Can you provide references or case studies demonstrating your successful maintenance services for cooling towers?
- What measures do you take to ensure compliance with relevant regulations and standards during maintenance activities for cooling towers?
- Do you offer emergency repair services for cooling towers, and how quickly can you respond to urgent situations?
- What is your approach to optimising cooling tower performance and energy efficiency through maintenance and upgrades?
- How do you stay updated on the latest advancements and best practices in cooling tower maintenance and services?
