Fifth Third Bank Headquarters Chiller Replacement

At Fifth Third Bank’s 32-story corporate headquarters in downtown Cincinnati, replacing aging cooling infrastructure presented a challenge far beyond selecting new equipment. Eight chillers and six cooling towers served multiple chilled water systems across three buildings, and the existing chiller plant was built into the upper levels of the tower. A conventional replacement approach would have required extensive demolition of the penthouse and portions of the top floor, along with costly helicopter lifts to remove equipment.

Motz Engineering worked with Fifth Third Bank to develop a more practical solution: establish a new chiller plant in the basement rather than reconstruct the existing rooftop-area plant. This strategy allowed the new equipment to be installed while the original chillers remained in operation, preserving chilled water service until the building complex could be transferred to the replacement system.

The engineering process began with a Program of Requirements and Basis of Design covering the project’s MEP scope and evaluating multiple chiller options. During schematic design, Motz developed a building energy model to verify equipment sizing, then performed a life cycle cost analysis to compare alternatives. Together, these steps helped the owner evaluate the investment in terms of system requirements and long-term operating considerations, not simply initial equipment cost.

Construction sequencing was equally important. Once the cooling load had been transferred to the new plant, contractors coordinated with Motz to dismantle the former chiller installation. Because the old equipment could not be removed intact, components were cut into carefully sized sections and transported through the tower’s service elevator. The approach avoided the extensive penthouse demolition and repeated helicopter lifts associated with removing the original plant from above.

Motz also provided testing, adjusting, and balancing (TAB) and commissioning services during construction to verify system performance and support efficient operation. The combination of engineering analysis, phased installation, and performance verification addressed both the immediate replacement need and the practical realities of working within an occupied high-rise campus.

For owners of large, continuously operating facilities, major central plant replacements are as much about access and sequencing as they are about equipment. Evaluating alternate plant locations, confirming loads through energy modeling, comparing life cycle costs, and planning the transition before demolition begins can help reduce disruption and avoid expensive construction constraints.

The Fifth Third Bank Headquarters Chiller Replacement demonstrates how thoughtful MEP engineering and commissioning can turn a difficult infrastructure replacement into a coordinated, operations-focused modernization.