How much does RTU replacement cost?

3-ton $8,500–$16,000; 5-ton $11,000–$20,000; 7.5-ton $15,000–$26,000; 10-ton $18,000–$32,000; 15-ton $25,000–$45,000; 20-ton+ $30,000–$70,000+. Add-ons include curb adapters ($1,500–$4,500), crane services ($1,200–$3,500/day), electrical upgrades, gas modifications, and permits.

How long does RTU replacement take?

Standard single-RTU replacement typically 1–2 days on-site. Multi-RTU replacement projects scheduled across multiple visits. Crane work typically completes in one day. Larger projects with extensive curb work or roofing coordination can take longer.

What's a curb adapter?

Sheet metal adapter that bridges between an existing roof curb and a replacement RTU when the new equipment doesn't match existing curb dimensions. The most common solution for RTU replacement when equipment changes brands or models. Cost $1,500–$4,500 depending on dimensions.

Will my roof need work during RTU replacement?

Sometimes. Existing curb work and crane operations can affect roof membrane around the equipment. Older roofs or roofs with marginal condition may require membrane repair during RTU replacement. We assess during site survey and coordinate with roofing contractors when needed.

How long do commercial RTUs last?

Typically 15–20 years for properly maintained equipment, less for neglected or harsh-environment equipment. Salt Lake's temperature extremes and weather exposure can shorten service life. Coastal or industrial environments cause faster deterioration than typical commercial Salt Lake locations.

Can I add zoning to my RTU?

Most single-zone RTUs aren't designed for retrofit zoning, though some larger units can accommodate it. Multi-zone RTUs with internal damper systems are available as new equipment. For most retrofit zoning in commercial buildings, dedicated zoned distribution downstream of the RTU is more practical.

Do you handle emergency RTU repairs?

Yes, with same-day response on confirmed commercial emergencies during business hours and after-hours response for true emergencies. Maintenance contract customers receive priority response and waived diagnostic fees. Restaurant and food service emergencies prioritized.

Commercial Rooftop Unit Service in Salt Lake County

Rooftop packaged units (RTUs) are the workhorses of light commercial HVAC. Walk past any strip mall, office building, restaurant, or retail establishment in Salt Lake County and you’ll see them — squat metal cabinets on the roof, working through Salt Lake’s temperature extremes year after year, often for 15–20 years before finally needing replacement. They’re the most common commercial HVAC configuration because they’re efficient to install (one piece of equipment containing everything needed for cooling, heating, and ventilation), they keep mechanical equipment out of valuable interior space, and they’re broadly available across major manufacturer lines with established service networks.

The trade-off for these advantages is that rooftop service is genuinely different from ground-level service work. Technicians work on roofs in all weather conditions. Equipment access requires roof ladders, hatch coordination, or roof access through occupied tenant spaces. Equipment replacement requires crane scheduling, curb compatibility verification (the structural opening in the roof where the RTU sits), and coordination with roofing contractors when curb work affects the roof membrane. Salt Lake’s weather extremes — winter inversion conditions, summer heat, occasional severe storms — affect both equipment service life and the conditions technicians work in. Quality RTU service requires expertise specific to this equipment type and the operational realities of rooftop work.

Below is what RTU service covers, common RTU configurations and what their service requirements look like, what replacement projects involve, and how we approach the operational considerations specific to rooftop commercial HVAC.

RTU Equipment and Capacity Ranges

Light Commercial RTUs (3–10 Tons)

The most common RTU range in Salt Lake County’s light commercial market. Single-zone equipment serving spaces from approximately 1,500 to 5,000 square feet depending on occupancy and loads. Common in:

Restaurants under approximately 4,000 square feet
Standalone retail and shopping center tenant spaces
Small office buildings and single-tenant office properties
Medical and dental offices
Small mixed-use commercial buildings

Single-zone RTU pricing for replacement typically $8,500–$32,000 installed depending on capacity, equipment tier, and installation complexity.

Mid-Range Commercial RTUs (10–20 Tons)

Larger single-zone or multi-zone RTUs serving spaces from approximately 5,000 to 12,000 square feet. Common in:

Larger restaurants and food service operations
Larger retail stores and big-box tenants
Multi-story office buildings
Medical office buildings with multiple tenants
Light industrial facilities and warehouses

Mid-range RTU pricing for replacement typically $18,000–$45,000 installed.

Large Commercial RTUs (20–30+ Tons)

High-capacity RTUs serving larger spaces, often as part of multi-unit installations covering 10,000+ square foot buildings. Common in:

Large retail and big-box stores
Office buildings over 15,000 square feet
Manufacturing and industrial facilities
Schools and educational facilities
Religious and community buildings with large meeting spaces

Large RTU pricing for replacement typically $30,000–$70,000+ per unit installed.

Specialty RTU Configurations

Several specialty configurations serve specific applications:

High-efficiency RTUs with two-stage or variable-capacity compressors, modulating gas valves, and ECM blowers — premium tier with higher efficiency ratings and better part-load performance
Heat pump RTUs for all-electric installations or applications where heat pump operating costs are favorable
Gas/electric RTUs with gas heating and electric cooling — the most common configuration in light commercial
Dehumidification RTUs with enhanced moisture removal for applications requiring tighter humidity control
Restaurant-specific RTUs with makeup air integration, kitchen exhaust coordination, and increased outdoor air capacity for restaurant occupancy ventilation requirements
Multi-zone RTUs with internal damper systems serving multiple zones from a single unit — less common but available from major manufacturers

RTU Service We Provide

RTU Installation and Replacement

Complete RTU installation projects including:

Site survey — roof condition assessment, structural verification for new equipment weight, curb dimension verification, electrical service evaluation, gas service assessment
Load calculation — Manual N commercial load calculation for proper capacity sizing
Equipment selection across efficiency tiers and feature options
Curb adapter fabrication when replacement equipment doesn’t match existing curb dimensions
Crane coordination — scheduling crane services for equipment placement, coordinating roof access
Existing equipment removal with proper refrigerant recovery
New equipment installation with curb compatibility verification
Refrigerant system work with proper procedures (nitrogen purge, vacuum to 500 microns, charge by weight)
Electrical connections with proper sizing and protection
Gas service connection when applicable
Ductwork connection to existing distribution
Controls integration with existing BAS or new controls installation
Commissioning with documented measurements
Roofing coordination when curb work affects roof membrane

RTU Repair Service

Component-level repair on all major RTU systems:

Cooling system repair — compressor service, refrigerant work, condenser fan motor replacement, capacitor and contactor service, expansion device problems
Heating system repair — gas valve service, igniter and flame sensor work, heat exchanger inspection and replacement, burner cleaning, draft inducer service
Blower system service — ECM motor replacement, PSC motor service, belt and pulley work on belt-drive equipment, blower wheel cleaning
Electrical repair — control board replacement, motor starters, contactor service, voltage and amperage troubleshooting
Controls and BAS — thermostat and sensor service, BAS integration troubleshooting, zone control work on multi-zone RTUs
Cabinet and structural — panel and gasket replacement, base rail repair, drain pan service

RTU Maintenance Programs

Scheduled maintenance specifically tailored to rooftop unit service:

Spring pre-cooling season RTU preparation
Fall pre-heating season RTU preparation
Quarterly maintenance for high-duty-cycle applications
Documented service records suitable for property management and warranty support
Priority emergency response for maintenance customers

See our commercial HVAC maintenance page for detailed information on maintenance program structures.

RTU Replacement Project Considerations

RTU replacement projects involve several considerations specific to rooftop work:

Curb Compatibility

The “curb” is the structural opening in the roof where the RTU sits. Curbs are sized for specific equipment dimensions, and replacement RTUs often have different footprints than the equipment being replaced. Three options when curb compatibility is an issue:

Curb adapter fabrication — sheet metal adapter sized to bridge between existing curb and new equipment. The most common solution for RTU replacement when equipment changes. Adapter costs $1,500–$4,500 depending on dimensions and complexity
New curb installation — replacing the existing curb with new curb sized for replacement equipment. Requires roofing coordination and roof membrane work. Higher cost but cleaner long-term result on extensive renovations
Matched-curb equipment selection — selecting replacement equipment that matches existing curb dimensions, eliminating adapter or curb work requirements. Limits equipment choices but reduces project cost when feasible

Crane Coordination

RTU replacement requires crane services for both removal of existing equipment and placement of new equipment. Considerations include:

Crane scheduling typically 1–2 weeks lead time during peak season, less during off-peak
Site access for crane positioning — building location, parking lot configuration, overhead obstructions
Crane size requirements based on equipment weight and reach distance
Crane day scheduling — coordinating equipment delivery, technician availability, and crane availability for single-day execution
Weather contingency — crane operations affected by wind conditions, requiring rescheduling capability

Crane services typically cost $1,200–$3,500 per crane day depending on crane size and duration.

Roofing Coordination

RTU replacement work sometimes affects the roof membrane around the equipment curb. Considerations:

Existing roof condition — roof age, membrane type (TPO, EPDM, modified bitumen), and condition affect whether membrane work is needed during RTU replacement
Curb modification — installing new curb adapter or replacing curb itself requires membrane flashing and sealing
Warranty implications — roof membrane warranties may require licensed roofing contractor work for warranty preservation
Coordination with roofing contractor when membrane work is needed

We coordinate with roofing contractors familiar with our RTU work when membrane work is required. Some customers prefer to coordinate roofing themselves; others prefer integrated project management with single-contractor accountability.

Electrical Service Verification

Newer high-efficiency RTUs sometimes draw different electrical loads than older equipment. Replacement projects include:

Verification of existing electrical service capacity for new equipment
Breaker sizing per new equipment specifications
Disconnect verification or replacement
Whip and conduit replacement if needed
Coordination with licensed electricians for service upgrades when required

Gas Service Considerations

Replacement of gas-fired RTUs may involve:

Gas line capacity verification for new equipment input rating
Gas pressure verification at the equipment
Gas line upsizing if existing line is undersized for new equipment
Gas valve and regulator installation per equipment specifications
Combustion analysis with altitude correction for Salt Lake’s 4,300-foot elevation

Travis Hollings handles gas line work under his Utah journeyman plumber endorsement.

Common RTU Repairs

Compressor Failures

Most expensive common RTU failure. Diagnosis includes verifying compressor failure mode (electrical, mechanical, refrigerant flooding, contamination), determining whether repair or replacement is appropriate, and checking warranty status for potential coverage. Commercial compressor replacement typically $2,500–$6,500 depending on capacity and equipment.

Refrigerant System Repairs

Leak detection and repair, refrigerant recharging after leak repair, evaporator and condenser coil work, expansion device problems. Commercial refrigerant work often involves larger refrigerant quantities (10–40 pounds typical vs. 4–8 pounds residential) with proportional cost implications.

Capacitor and Contactor Replacements

The most common RTU repair calls. Capacitors fail through age and heat stress; contactors fail through arcing and mechanical wear. Both typically resolve same-day with parts stocked on service trucks.

Capacitor replacement: $300–$650 commercial sizes
Contactor replacement: $350–$650

Motor Failures

Condenser fan motors and blower motors fail through bearing wear, winding failures, or electronic component failures on ECM motors.

Condenser fan motor: $700–$1,400
Blower motor: $800–$1,800 (commercial sizes)
ECM motor module-only replacement (when motor itself is good): $500–$900

Gas Heating Section Failures

On gas-fired RTUs, gas heating section components include gas valves, igniters, flame sensors, pressure switches, draft inducers, and heat exchangers.

Gas valve replacement: $600–$1,400
Igniter replacement: $400–$700
Flame sensor: $200–$400 (often just needs cleaning)
Pressure switch: $300–$500
Draft inducer: $700–$1,400
Heat exchanger replacement: $2,500–$5,500

Control Board Failures

RTU control boards manage equipment operation, communication with BAS systems, and safety controls. Failures produce a range of symptoms from intermittent operation to complete shutdown.

Control board replacement: $500–$1,200

Drain Pan and Drainage Issues

RTU drain pans collect condensate during cooling operation. Drain pan failures (corrosion, cracks, biological growth blockages) cause water leaks that can damage the roof, electrical components, or interior spaces below.

Drain pan replacement: $400–$900
Drain line clearance: $150–$300
Secondary drain pan or float switch: $200–$500

RTU Pricing Summary

Installation and Replacement

3-ton single-zone RTU replacement: $8,500–$16,000 installed
5-ton single-zone RTU replacement: $11,000–$20,000 installed
7.5-ton RTU replacement: $15,000–$26,000 installed
10-ton RTU replacement: $18,000–$32,000 installed
15-ton RTU replacement: $25,000–$45,000 installed
20-ton+ RTU replacement: $30,000–$70,000+ installed

Project Add-Ons

Curb adapter fabrication: $1,500–$4,500
New curb installation with roofing work: $3,500–$8,500
Crane services: $1,200–$3,500 per crane day
Electrical upgrades: $500–$3,000 depending on scope
Gas service modifications: $500–$2,500
Mechanical permits: $300–$1,500 depending on jurisdiction and capacity

Maintenance

Quarterly maintenance per RTU: $300–$650 per quarter per unit
Biannual maintenance per RTU: $400–$850 per visit per unit
Annual maintenance per RTU: $250–$500 per unit per year

Frequently Asked Questions

How much does RTU replacement cost?: 3-ton RTU $8,500–$16,000; 5-ton $11,000–$20,000; 7.5-ton $15,000–$26,000; 10-ton $18,000–$32,000; 15-ton $25,000–$45,000; 20-ton+ $30,000–$70,000+. Add-ons include curb adapters ($1,500–$4,500), crane services ($1,200–$3,500/day), electrical upgrades, gas service modifications, and permits.
How long does RTU replacement take?: Standard single-RTU replacement typically 1–2 days on-site. Multi-RTU replacement projects scheduled across multiple visits. Crane work typically completes in one day. Larger projects with extensive curb work or roofing coordination can take longer.
What’s a curb adapter?: Sheet metal adapter that bridges between an existing roof curb and a replacement RTU when the new equipment doesn’t match the existing curb dimensions. The most common solution for RTU replacement when equipment changes brands or models. Cost $1,500–$4,500 depending on dimensions and complexity. Alternative is installing a new curb with roofing coordination, which costs more but produces cleaner long-term results.
Will my roof need work during RTU replacement?: Sometimes. Existing curb work and crane operations can affect roof membrane around the equipment. Older roofs or roofs with marginal condition may require membrane repair during RTU replacement. We assess during site survey and coordinate with roofing contractors when membrane work is needed.
How long do commercial RTUs last?: Typically 15–20 years for properly maintained equipment, less for neglected or harsh-environment equipment. Salt Lake’s temperature extremes (winter inversions, summer heat) and weather exposure can shorten service life. Coastal or industrial environments cause faster deterioration than typical commercial Salt Lake locations.
Can I add zoning to my RTU?: Most single-zone RTUs aren’t designed for retrofit zoning, though some larger units can accommodate it. Multi-zone RTUs with internal damper systems are available from major manufacturers as new equipment if zoning is needed. For most retrofit zoning applications in commercial buildings, dedicated zoned distribution downstream of the RTU is more practical than internal RTU zoning.
Do you handle emergency RTU repairs?: Yes, with same-day response on confirmed commercial emergencies during business hours and after-hours response for true emergencies. Maintenance contract customers receive priority response and waived diagnostic fees. Restaurant and food service emergencies prioritized due to refrigeration and food safety implications.

Schedule RTU Consultation

Whether you need RTU replacement, repair on existing rooftop equipment, or maintenance for ongoing reliability, call (385) 250-0687 for site evaluation. RTU site surveys include roof condition assessment, curb dimension verification, structural and electrical verification, and complete project quoting with permits and equipment costs detailed separately.

Phone: (385) 250-0687
Email: info@aegisheatingandair.xyz
Address: 4454 Manhattan Ct, West Valley City, UT 84120