Custom Ductwork, Zero Downtime

When a local poultry manufacturer needed to replace an aging rooftop air unit, Southern Thermal managed the full insulation scope, including all ductwork fabrication, pipe insulation, and coordination with the mechanical contractor. The duct work was prefabricated on the ground which allowed installation for this project to completed over a single weekend to keep production on schedule.

This is what it looks like when prefabrication, precision scheduling, and field expertise come together on a commercial HVAC project.

Why Weekend Installation Matters in Food Processing

Food processing facilities cannot afford downtime. Every hour a production line is offline costs the operation money, product, and schedule.

By coordinating the crane lift and full system tie-in over the weekend, our crew ensured the plant returned to full operation by Monday morning. Ground-level prefabrication of ductwork and piping assemblies shortened on-site installation time and reduced disruption to the facility's daily workflow.

This approach is standard for our team: plan thoroughly, prefabricate off-site when possible, and execute within the client's operational window.

Custom Ductwork and Piping Fabrication for Commercial HVAC Systems

Every duct and pipe assembly on this project was designed to integrate with the facility's existing structural routes. That means efficient airflow, consistent temperature control, and minimal rework.

Our in-house mechanical insulation and fabrication capabilities allow us to handle projects like this from design through installation — without relying on third-party fabricators. The result is tighter tolerances, faster turnaround, and a system built to perform from day one.

What We Delivered

Full rooftop air unit replacement for a commercial poultry processing plant
Custom ductwork and piping fabrication to match existing structural routes
Weekend crane lift and installation to avoid production downtime
Ground-level prefabrication for faster, safer on-site assembly
Coordination with the mechanical contractor for seamless system tie-in

Built for Long-Term Performance

The new rooftop system delivers improved airflow, greater reliability, and consistent temperature control across the facility's processing area. Every component was installed with attention to fit, function, and long-term durability, because in a food processing environment, the system has to perform every day without exception.

A Relationship Built on Trust

This project reflects the kind of partnership we build with every client. As a repeat customer, this manufacturer trusts our team to deliver solutions that meet their exact needs — on time, on budget, and without disrupting their operation.

That trust is earned one project at a time. And it is the foundation of everything we do at Southern Thermal Solutions.

Explore our mechanical and fabrication capabilities to see how we help clients move forward with confidence, no matter the challenge.

Frequently Asked Questions

Yes. With proper planning, prefabrication, and weekend scheduling, rooftop HVAC units can be replaced without interrupting weekday production. Our team coordinates crane lifts and system tie-ins within tight operational windows to keep facilities running.
On-site ductwork fabrication is the process of cutting, shaping, and assembling metal duct components directly at the project location. This allows the installation team to make real-time adjustments for existing structural obstacles, tighter tolerances, and faster project completion.
Yes. We regularly coordinate with mechanical contractors on commercial and industrial HVAC projects. Our team handles ductwork fabrication, piping, and insulation while integrating with the contractor's scope to deliver a complete, turnkey system.
Southern Thermal Solutions is headquartered in Mt. Crawford, Virginia, with a second office in Chesapeake, VA. We serve commercial and industrial clients across the East Coast and Southeast United States.