Phased Replacement of Hospital Cooling Towers Adjacent to Helipad – 500-Ton Crane, Zero Downtime, Weekend Execution

The team executed a phased cooling-tower replacement while keeping the hospital’s chilled-water system online 24/7. Early work pushed through roof-level ice and snow in sub-freezing conditions, with demolition performed by hand—piece by piece—to minimize crane time and risk. An ultra-tight site constrained the 500-ton crane pad and trucking routes directly in front of the Emergency Department, requiring continuous public access and meticulous traffic control. With the towers beside the helipad, real-time coordination with flight and EMS crews ensured uninterrupted helicopter transport for patients. Operations ran around the clock: crane setup Friday night; all lifts completed through Saturday day and night ahead of an approaching rain/lightning front; and full disassembly/demobilization on Sunday. Materials and debris were routed via freight elevators and carefully sequenced through active corridors to avoid impacts to food services, cleaning, linens, and patient care. Through precision planning and choreography, the new towers were set, connected, and ready for commissioning within a narrow pre-cooling-season window.