Commercial rooftop units (RTUs) are workhorses that typically last 15-20 years with proper maintenance. But at some point, continuing to repair an aging unit costs more than replacing it. Here are five clear signs replacement makes more sense than another repair call.
The Unit Is Over 15 Years Old
Age alone isn't a reason to replace, but an RTU over 15 years old combined with any other issue on this list is a strong signal. Older units use outdated refrigerants (R-22, now phased out), have obsolete controls, and lack modern efficiency ratings. Replacement SEER ratings of 14-17 vs. an old unit's 8-10 can mean 40% lower operating costs.
Repair Costs Exceed the 50% Rule
If a single repair will cost more than 50% of the replacement cost of the unit, it's generally time to replace. A $4,000 compressor replacement on a unit worth $7,000 new doesn't make economic sense — especially if other components are at end of life.
Frequent Breakdowns (More Than 2 Per Year)
One emergency repair call per year is normal. Two or more per year on the same unit signals systemic failure. Each breakdown means downtime, tenant complaints, and emergency labour charges. The cumulative cost quickly exceeds replacement.
Refrigerant Is R-22
R-22 refrigerant was phased out under federal regulations. It is no longer manufactured in Canada and prices have increased dramatically. If your system needs refrigerant and it uses R-22, each recharge is expensive and temporary. A system leak on an R-22 unit is almost always a replacement trigger.
Uneven Temperatures or Poor Air Quality
If some zones are too hot and others too cold despite service, or if occupants are complaining about air quality, the unit may no longer have the capacity or the distribution capability to serve the space properly. This is especially common when a building has been renovated or expanded since the RTU was installed.
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