Controlled Air is currently tackling this exact challenge at the historic Capitol Theatre, transforming its cooling infrastructure to meet modern standards.

The Challenge: Replacing a Century-Old hvac Concept

Every historic building has a story, and the Capitol Theatre is no exception. The venue’s original cooling system dated back to the 1920s. In those days, state-of-the-art climate control meant placing massive blocks of ice in front of large industrial fans to push cool air through the auditorium.

While that primitive system was a marvel a century ago, today’s packed houses require precise, reliable, and energy-efficient cooling. To protect the venue’s reputation and ensure patron comfort, the ownership team partnered with Controlled Air to replace the aging infrastructure with a high-performance modern chiller plant.

The Solution: A Two-Phase Modernized hvac system

With the purchase order authorized, our team transitioned from planning straight into the active installation phase. The scope of work focuses purely on a complete HVAC chiller plant upgrade, designed to deliver 44°F supply chilled water with a 10°F temperature differential.

To minimize disruption and maintain project clarity, the workflow was structured into two distinct phases:

• Phase 1 (Design & Coordination): This initial phase involved site verification, equipment selection confirmation, and creating detailed HVAC design drawings to clear the way for local permitting.
• Phase 2 (Construction & Installation): With permits cleared, we are actively executing the physical installation, which includes cutting and capping the old 4-inch piping, rigging the new equipment onto the roof, and integrating the system controls.

High-Performance HVAC Equipment Lineup

To deliver the reliability and quiet operation an active theater environment demands, we selected a 115.9-ton YORK air-cooled scroll chiller utilizing eco-friendly R-454B refrigerant and low-sound variable speed drive (VSD) condenser fans. Circulating the water are two Grundfos inline chilled water pumps with built-in variable frequency drives, installed discreetly inside the attic space next to the existing 5-foot by 8-foot chilled water coil. The entire system is supported by heavy-duty infrastructure, including a Bell & Gossett air and dirt separator, Wessels and Amtrol ASME-rated tanks, and an Axiom glycol feeder system to ensure reliable fluid management and freeze protection.

The new chiller modules will be securely mounted on specialized 12-foot structural equipment support rails on the roof adjacent to the old unit, keeping the rooftop organized and secure.

Streamlining Complexity: Serving as the Owner’s Representative

Large-scale mechanical upgrades in historic properties are rarely simple HVAC jobs. They require careful choreography between multiple trades. To alleviate the logistical burden on the theater’s executive team, Controlled Air is stepping into an expanded role, representing the ownership team as the primary Owner’s Representative.

In this role, we are directly coordinating and engaging all specialized contractors on-site, including:

• General Contracting
• Asbestos Abatement
• Structural Steel Fabrication
• Electrical Infrastructure
• HVAC Installation and Controls

By serving as the central point of contact, we ensure that the structural, electrical, and architectural modifications handled by external New York licensed professionals align perfectly with our mechanical timeline. This turnkey approach keeps the project moving smoothly toward completion without draining the theater’s internal management resources.

Looking Ahead

This project stands as a prime example of Controlled Air’s full project management capabilities. We don’t just drop equipment on a roof. We engineer, design, price, and manage complex mechanical overhauls from conception to final commissioning.

We will share more updates and photos as the Capitol Theatre project progresses toward its final startup and testing phases. Stay tuned to see how we blend 21st-century comfort with 20th-century charm.

BEFORE PHOTOS: AFTERS COMING SOON!

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The Long Wharf Theatre project almost didn’t happen. The original engineer’s design was at a cost of $1 mil. Controlled Air, Inc. redesigned the project and brought the cost down to $500,000. We also helped the customer receive $25,000 in incentives from CL&P for being more efficient then required by code. Controlled Air, Inc. provided them with economical savings through custom design.

We installed 7 roof top units: Three AAON single VAV variable speed units and four efficient Johnson Controls units. The RTU’s were connected to a CO2 detection system that allows them to limit the outside air intake to only what is necessary, saving money and energy. Noise was also a concern for our customer and as such, we worked directly with acoustical engineers to ensure that the equipment ran with the lowest level of noise possible.

The Long Wharf Theater Main Stage project was later recognized for an “Excellence In Construction Award” by Associated Builders and Contractors, Inc.

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