Every aging building maintenance unit reaches a moment where the question shifts from routine repair to something bigger. Owners of buildings 20 to 40 years old often ask whether it makes more sense to refurbish the existing BMU or replace it outright. The answer is rarely obvious, and cost, downtime, code compliance, and parts availability all weigh differently on each side.<\/p>\n
This guide breaks down how an OEM assesses that decision. It draws on the experience of Jonathan Lin, RRR Sales Manager for North America at the facade access group, who has spent 17 years working with building maintenance units. The framework is simple. Refurb first. Retrofit next. Replace only when neither can meet the building’s needs.<\/p>\n
<\/div><\/code><\/em><\/code>Understanding the Refurb, Retrofit, Replace Framework<\/h2>\nThe industry often collapses BMU work into two categories: fix it or replace it. That framing misses the middle ground where most decisions actually live.<\/p>\n
“As a service provider, the priority is to maintain equipment and have it last as long as possible. A proper maintenance program<\/a> with smartly timed retrofits can extend the life of a BMU for a decade or more. Which is why our group is so aptly named \u2014 Refurb, Retrofit, and Replace, in that order.” <\/em>\u2014 Jonathan Lin, RRR Sales Manager for North America<\/strong><\/em><\/p><\/blockquote>\nEach tier serves a different purpose:<\/p>\n
\n- Refurb<\/strong> covers general upkeep and preventative maintenance. The goal is to keep the equipment safe, reliable, and running as intended. This is where most BMU maintenance work sits, and it delivers the strongest return on invested effort.<\/li>\n
- Retrofit<\/strong> is the next service level. Parts and subassemblies are modernized or upgraded so the BMU can continue to receive general upkeep. Retrofits also improve performance and quality of life for operators. Common scopes include modern control systems, updated winch mechanisms, and safety upgrades to meet current standards. FAS offers dedicated retrofit services<\/a> for both CoxGomyl and Manntech equipment.<\/li>\n<\/ul>\n
Replace<\/strong> is the last option. It is reserved for cases where refurb and retrofit can no longer keep the BMU compliant, safe, or fit for purpose.<\/p>\n<\/div><\/code><\/em><\/code>What Makes a Building Maintenance Unit a Candidate for Refurbishment<\/h2>\nBefore recommending any path, the OEM runs a structured assessment. Two questions drive the process. What is the root cause of the current issues preventing the BMU from working as intended? And where is the unit in its lifecycle?<\/p>\n
“When assessing a system, we are mainly looking for two things: the root cause of any issues that are preventing the BMU from working as intended and where a BMU is in its lifecycle. To do so we need to review documentation that shows equipment info, such as Operating and Maintenance manuals as well as assembly and electrical drawings, to understand design and operational intent as well as operational history, such as usage logs and previous inspection reports, to understand the true health and age of the BMU.” <\/em>\u2014 Jonathan Lin<\/strong><\/em><\/p><\/blockquote>\nA thorough BMU refurbishment assessment pulls together several data sources. Original O&M manuals establish design intent, drawings reveal how components were meant to work together, and usage logs show how hard the equipment has been worked. Previous inspection and safety compliance<\/a> reports flag issues that may have gone unaddressed.<\/p>\nThe final piece is logistics. Scheduling, budget cycles, and other planned work at the property all shape which path is viable. Even when replacement is the best long-term option, a refurbishment or targeted retrofit may serve as a stopgap while funding and planning fall into place.<\/p>\n
<\/div><\/code><\/em><\/code>When Building Maintenance Unit Replacement Becomes Unavoidable<\/h2>\nSome scenarios remove the option to refurb or retrofit. Recognizing them early saves owners from spending capital on work that will not solve the underlying problem.<\/p>\n
Structural issues top the list. When corrosion has compromised the steel structure of the BMU, no electrical or mechanical upgrade addresses the root problem.<\/p>\n
“We have an account in Miami where the BMU was from an era where only the outside of the steel was being galvanized and due to exposure to the salty air, continued corrosion was unavoidable and replacement was required.” <\/em>\u2014 Jonathan Lin<\/strong><\/em><\/p><\/blockquote>\nMissing information is another trigger. Without documentation showing how a BMU was built and how it has performed, no reliable diagnosis is possible. Unavailable parts push the same direction, since sourcing spares becomes unpredictable and expensive when the OEM no longer supports a legacy platform.<\/p>\n
Code and building changes finish the list. If a facade has been re-clad, extended, or fitted with new architectural features, the original BMU may no longer reach every elevation. Local code updates can also render an older machine non-compliant even if it still runs. In these situations, a full building maintenance unit replacement is the only path that meets the building’s actual requirements.<\/p>\n
<\/div><\/code><\/em><\/code>Cost, Downtime, and Scheduling Realities of BMU Refurbishment vs. Full Replacement<\/h2>\nThe practical differences between refurbishment and replacement come down to time on site, cost exposure, and how each option fits within the building’s operational calendar.<\/p>\n
“Refurbs typically take months while a replacement will take over a year to complete. If timed correctly, most refurbs can be completed during the offseason to minimize or eliminate downtime.” <\/em>\u2014 Jonathan Lin<\/strong><\/em><\/p><\/blockquote>\nThe timeline difference matters more than raw cost in many cases. A refurb scheduled around the building’s offseason often produces no visible impact on tenants or operations. A replacement requires roof access for demolition, structural verification, delivery of new components, installation, and commissioning. That process runs quarters, not weeks.<\/p>\n
Cost varies by scope, but a well-designed refurb or retrofit typically lands at a fraction of a full BMU replacement<\/a>. Phasing the work also helps facility teams secure funding across multiple budget cycles rather than fighting for one large capital approval.<\/p>\n“We recently took over a service account in San Francisco where a competitor could not keep a Mannesmann that was installed in 1985 running and told the customer it was at the end of its life and had to be replaced. The customer reached back out to us and as the OEM we were able to propose a refurb as well as suggest some preventative maintenance items that the competitor did not consider. By presenting our suggestions in a phased manner, the customer was able to secure funding for all of this work.” <\/em>\u2014 Jonathan Lin<\/strong><\/em><\/p><\/blockquote>\n<\/div><\/code><\/em><\/code>How Spare Parts and System Age Shape the Decision<\/h2>\nAge is a significant factor. The more operating hours a BMU accumulates, the more attention it needs. Lifecycle management can preplan major refurbishments and BMU upgrades in phases, but only up to the point where parts and subassemblies remain available.<\/p>\n
Downtime is a major concern for owners, and North America has seen a strong push for facilities to maintain a spare parts cache. Holding critical components on site helps minimize disruption and buys time to plan a modernization strategy when older parts become harder to source. The FAS OEM spare parts<\/a> program supports this approach with genuine components engineered to the original specification.<\/p>\n“Age is a major factor as the hours add up on equipment. The more TLC a BMU will require. We can work with a client on lifecycle management and preplan major refurbs and retrofits in phases, but at some point that is no longer an option as parts and subassemblies become obsolete.” <\/em>\u2014 Jonathan Lin<\/strong><\/em><\/p><\/blockquote>\n<\/div><\/code><\/em><\/code>What Owners Overlook When They Assume Replacement Is the Only Option<\/h2>\nMany owners arrive at the replacement conversation because a service provider has told them the current unit has reached the end of its life. That diagnosis is often correct, but it is also frequently wrong when the provider lacks OEM access to drawings, historical data, and engineering support.<\/p>\n
“As the industry leading OEM and service provider, we have the resources and experience that others do not to be able to properly diagnose root problems and provide a modernization or upgrade solution that is a fraction of the cost of a replacement and can prolong the life of a BMU for another decade or more.” <\/em>\u2014 Jonathan Lin<\/strong><\/em><\/p><\/blockquote>\nThis is where the value of asset management<\/a> from the original manufacturer becomes clear. Access to engineering records, retained knowledge of design intent, and a supply chain of certified parts change what is possible on an aging BMU.<\/p>\n