To keep up optimal functioning, cooling towers need regular maintenance and cleaning. However, over time, replacement and repair of many of the damaged parts need to be undertaken. To ensure the thermal efficiency of a plant, repairing and rebuilding industrial cooling towers becomes important. Repairing and replacing will initially help with regular maintenance to prolong the life of the cooling tower. Eventually, it will have to be rebuilt to maintain the structural capacity with which it can cool more efficiently.

Here are some tips on rebuilding and repairing cooling towers for increased cooling efficiency:

1. Start with the Suitability


The suitability of the reconstruction needs to be determined before the process can begin in earnest. Rebuilding and reconstruction then happen in several different ways. There is a possibility that the owner may decide to rebuild only certain parts of the cooling tower rather than change the entire structural design.

In such cases, the reconstruction of the cooling tower depends on the suitability of the application. Since the repair and rebuilding are minor, the efficiency will not be significantly impacted. Other times, the structural capacity of the cooling tower is severely compromised and demands immediate action, which is not limited to repair. In times like those, the cooling tower rebuilding is essential for proper functioning and improved cooling efficiency.

It is best to employ experts who have experience with complete structure reworks. A cooling tower rebuilding project needs precision and detailed reports every step of the way so that all the quality standards and expectations of the plant owner are met. While engaging with a cooling tower installation process, set your goals and make them clear to everyone involved, so that margin of error is minimized every step of the way.

2. Do Adequate Preparation Before Beginning


Preparation before rebuilding work is about to begin will include inspection of the site and performing a safety analysis based on the findings. Professionals need to be appointed for the same. Everyone working in the repair and reconstruction should be aware of the safety hazards. There are high voltage points that can prove harmful if not managed properly. Each person involved should be protected with adequate gear so that injuries can be prevented and work can be completed more efficiently.

The inspection and the assessment report before the reconstruction will involve looking at the following details:

  • Possible clogging and corrosion of parts
  • Damaged and deteriorating parts
  • Parts that need replacement or are missing
  • Drift Eliminators, nozzles, pipes, louver need to be inspected

It is only after looking at the inspection report that the expert in charge of reconstruction can determine the details to which the preparation needs to be made.

3. Reconstruction Experts should be Reliable


It would be a waste of time and money to employ a reconstruction company to have the inspection done. The assessment of the site will help determine the scope of the repair and reconstruction needed so you can hold off on hiring a company until the inspection report arrives. While considering the company which would prove suitable for your rebuilding project, you need to consider the following factors:

  1. Their experience in the field and whether their vision aligns with your vision
  2. Consider the price and compare it with the services being provided
  3. Compare the efficiency and customer testimonials whenever possible.
  4. Safety certification matters and ensures quality service
  5. Whether or not the scope of the service includes providing an alternative cooling method as the rebuilding process goes on
  6. Know the company they contract to buy the parts of the cooling tower. The parts should be durable and of good quality.
  7. A warranty for their work and the products used
  8. Check references and reviews online and offline.
  9. Their plan should be efficient and fall within budget.

If you want to do your own research to understand the reconstruction process better, you should try asking some questions to potential candidates. This will help you get a clearer idea of their business practices and approach to repairing and rebuilding. For instance, you can tell a lot about a company by its choice of material. In case the reconstruction is significant, there will be an expansive replacement of parts.

A company working with minimal vision will replace the parts with the same model. A more professional service provider would try to upgrade the parts wherever possible. For example, fiberglass plastic instead of wood and stainless steel instead of carbon steel for various cooling tower parts is one way for the company to show interest in the project.

4. Do a Perfunctory Test


You have done the inspection and have hired a company which has devised a plan for the reconstruction of the cooling tower. One final test before the reconstruction truly begins is to do a test on the current efficiency of the cooling tower.

As a plant operator, it is important to do a pretest. It will allow the assessment of the damage which has occurred so far and set parameters on how improvement should be achieved and to what extent. The performance of the pretest will help determine the effectiveness of the rebuild plan as well.

The pretest cannot be done by the staff, and professionals need to be contacted to assess different levels of performance. They will check the temperature, the rate of flow of water, and the rate of flow of air. This test will serve as the threshold you will need to improve upon. You can show the test results to the reconstruction company so that they can plan accordingly and make the required changes.


If the repairing and rebuilding of the cooling tower are done correctly, it can lead to significant improvement in the overall cooling of the plant system. One of the benefits of repairing and successful rebuilding will be prolonging the life of the cooling tower. As a plant owner, choose only the best practices and procedures for the repairs to maintain the structural integrity of the cooling tower.