Replacing a CRAH Unit: Checklist for Live Data Center Operation

By Tobias Schott  · Reading time approx. 22 minutes · Last updated: October 2026

Supervisor and rigger working in coordination on the unit
Replacing a CRAH unit means moving a tall, heavy unit through narrow aisles without touching the neighbouring units.

A CRAH unit can be replaced in a live data center if redundancy, load path, protective measures and the sequence of trades are fixed before the first move – the lifting equipment is then the smallest part of the task.

You need to replace a CRAH unit: the heat exchanger is damaged, the fan has reached the end of its life, or the unit no longer fits the cooling concept of the data center. The data hall – the white space on international sites – keeps running in a live environment. The neighbouring units carry the load, and the maintenance window for the replacement is tight. Every step has to be right: a mistake does not affect the air conditioning of an office, but the cooling of live servers.

As project manager you stand between the operator, the cooling contractor, the electrical contractor and the installation contractor. Who isolates what and when, who carries the load and when, who documents what? And how does a tall, heavy unit get through the narrow CRAH gallery without touching the neighbouring units or the raised floor? If these questions are still open on the day of the work, you lose hours of your maintenance window.

This article is the in-depth follow-up to our foundation guide “Data Center Installation: What's Different for Subcontractors”. It takes you through the replacement phase by phase: assessment, preparation, isolation, removal, moving in, positioning, handover. It adds the protective measures, the floor load check and the acceptance – and ends with the checklist you can use to walk through the replacement with everyone involved.

Key points at a glance

What is a CRAH unit?

A CRAH unit (Computer Room Air Handler) is a recirculating air cooling unit that cools the warm exhaust air from the servers via a chilled-water heat exchanger and returns it to the data hall as cold air. A CRAC unit (Computer Room Air Conditioner), by contrast, has its own refrigeration circuit with a compressor.

CRAH units stand either directly in the data hall at the boundary between cold aisle and hot aisle, or in a plant corridor next to it. This corridor is usually called the CRAH gallery and counts as grey space. The units essentially consist of a housing, a heat exchanger with fin pack and copper tubing, a fan section, filters, control valves and the controls. The units are tall, heavy and firmly connected to the building through water connections, condensate drain and power supply; the chilled water is supplied by the chiller via the plant areas.

Replacing a Computer Room Air Handler does not mean carrying out a device. It means dealing with a piece of plant that is isolated, disconnected, dismantled, moved, repositioned and reconnected – in a room that keeps running. The basics of working in a data center, from access and dust control to the raised floor, are on our page on data center construction.

When does a CRAH unit need to be replaced?

A CRAH unit is replaced when a repair is no longer technically possible or economically sensible. Other triggers are the end of its service life and a changed cooling concept for the hall. Whether you repair or replace the CRAH unit depends on the damage pattern, spare parts availability and the moving-in route.

Typical triggers

Repair or replace?

The decision is made by the operator together with the cooling contractor, not by the installation contractor – based on the assessment, damage pattern and spare parts availability. Behind it lies the question of whether the unit is obsolete and parts would only be available as remanufactured items. What we contribute from our maintenance and servicing practice is the mechanical assessment: can the faulty module be removed without moving the whole unit? Is there a moving-in route at all to get the unit out in one piece? And what does the replacement cost in time and effort compared with a repair – qualitatively, not in figures.

How does the replacement of a CRAH unit work?

Explanatory graphic: replacing a CRAH unit in six phases with responsibilities of operator, specialist trades and installation contractor
Six phases, three trades, one sequence – who takes over when is fixed before the first move. Graphic: Omega Mounting

The replacement of a CRAH unit runs in six phases: assessment and decision, preparation, isolation by the specialist trades. These are followed by removal of the old unit, moving in and positioning of the new unit, handover and commissioning.

PhaseWhat happensWho is responsible
1. AssessmentIdentify the damage, decide on repair or replacement, check redundancy.Operator, cooling contractor.
2. PreparationSite survey, load path, lift plan, risk assessment/RAMS, change request, access list, protective material, maintenance window.Installation contractor, project management.
3. IsolationIsolate electrically and lock out against reconnection. Shut off and drain the water side, disconnect condensate.Electrical and cooling contractors.
4. RemovalRelease the old unit, dismantle if necessary, move it out of position, transport it away.Installation contractor.
5. Moving in and positioningMove in the new unit, position, level, fix in place.Installation contractor.
6. Handover and commissioningHand over documentation package, connection, filling, test run, punch list.Installation contractor, then specialist trades and operator.

Phase 1: Assessment and decision

It starts with the question of whether the hall will keep running safely without this unit. Redundancy is the prerequisite for any replacement during live operation. This means sufficient reserve cooling capacity from the remaining units, designed in the industry as N+1 (one unit more than needed) or 2N (fully duplicated). The operator confirms this, usually via a change request, through which every intervention in live plant is registered and approved. Only then is the date set.

Phase 2: Preparation

Preparation is the longest part. During a site visit we measure the old unit and the load path. We check door clearances, headroom, turning radii, lift capacity and floor loads. Then we prepare the lift plan and the risk assessment, or rather the RAMS – the method statement that in data centers combines risk assessment and work instruction in one document. We register personnel for the access list and machines for approval, and agree the maintenance window with all trades. How access, induction and machine approval generally work in a data center is explained in the foundation guide.

Phase 3: Isolation

Before the installation contractor touches the unit, the electrical and cooling contractors have isolated it. That means: absence of voltage confirmed and locked out against reconnection (lockout/tagout, LOTO – lock and tag on the switching device), water side shut off and drained, condensate drain disconnected. This isolation is documented and handed over to us with the permit to work – the written authorisation to work in a defined area for a defined period. Without this written handover we do not start.

Phases 4 to 6

Removal, moving in and handover are covered in detail in the following sections.

What protection do the floor and neighbouring units need?

The floor and the neighbouring units are fully protected before the first lift. All walkways and travel routes are covered with protective fleece and taped down cleanly. Neighbouring units, cable trays and pipework are covered or shielded, and the machines are checked for suitable, non-marking tyres.

Floor protection

Protective fleece along the entire load path, taped at transitions and joints so that nothing slips and no edge becomes a trip hazard. For high point loads, additional load spreading plates or hardboard; on the raised floor always along the pedestal lines. The fleece stays in place until the following trade has taken over and the area has been cleaned.

Often overlooked in planning: the CRAH gallery is also the escape route for everyone working there. The BG BAU/BAuA information sheet “Site set-up – traffic areas, transport routes, storage and parking areas” specifies a clear width of at least one metre for escape routes used by up to 20 people, in line with ASR A2.3. For you this means: temporarily parked modules, packaging and protective material must never narrow the aisle so much that nobody can get past the unit. That is why the lift plan states where things may be set down and where not.

Protecting the neighbouring units

The neighbouring units run during the replacement and carry the cooling load. They are protected against contact by lifting devices and loads – by spacers, covers and a load path defined in the lift plan with safety clearances. Overhead cable trays and pipework in the travel route are marked and, where necessary, mechanically protected. Dust control here also means: no drilling, sawing or grinding in the CRAH gallery without extraction and approval. The BG BAU/BAuA information sheet “Site set-up – low-dust working” sets the direction: extract dust at the point of origin, partition off the work area, clean only with a dust extractor. Dry sweeping or blowing off with compressed air is not permitted. In a data center this is not a formality, because particles in the air filters of the neighbouring units are exactly the damage the replacement is meant to avoid.

Machines and supervision

Every machine movement takes place under the direction of the lifting supervisor, the appointed person for lifting operations; no lifting device passes through a pinch point without a banksman. The load area is cordoned off, nobody stands under or beside the suspended load. Before each use, machines and lifting accessories are checked again and the check is documented. The day begins with a toolbox talk in which the sequence, hazards and stop authority are repeated for everyone involved.

What you as the client should expect to see: the German technical rule TRBS 1201 (inspection and testing of work equipment) requires a periodic inspection of lifting accessories and lifting attachments at least once a year. In addition, there is a check on every working day. Ask to see the test certificates before the work starts. A test sticker only proves that an inspection took place – not that the item is free of defects today. That is why the daily check belongs in the work sequence, not just in the inspection log.

The reason for the replacement: damaged heat exchanger of the faulty CRAH unit
Protective fleece on every walkway and travel route, transitions taped down cleanly – before the first wheel turns.

Which floor loads and transport routes need to be checked?

Overview: load path and floor loads when replacing a CRAH unit – checkpoints for each section from the truck to the installation position
The load path is measured and calculated in advance – every pinch point and every point load is in the lift plan. Graphic: Omega Mounting

The entire load path from the truck to the installation position must be checked: unloading area, access doors, lifts, corridors, CRAH gallery. At every point along this route, the permissible distributed and point load of the floor counts.

The load path

CRAH units are rarely on the ground floor directly behind the gate. The typical moving-in route runs via an unloading area, a heavy-duty or goods lift, corridors with fire doors and finally the CRAH gallery with its narrow aisles between the units. Every pinch point is measured: door clearance, headroom, turning radius and swept path, thresholds, gradients. The dimensions of the new unit – packed and unpacked – are checked against them. If centimetres are missing, we plan how the unit can be tilted, turned or dismantled.

Floor loads

For each section of the load path we obtain the load assumptions: live load and point load of the raised floor, slab load of the structural floor, lift capacity. Then we calculate the actual load from unit plus lifting device plus wheels against these values – what matters is the floor pressure under each individual wheel, not the total weight. Two compact lifting devices carrying a unit synchronously distribute the weight differently from a single set of machine skates; that has to be in the lift plan. If the point load exceeds the permissible value, load spreading plates or an alternative route come into play; in case of doubt, the operator's structural engineer confirms the values.

Behind this is an obligation that makes your selection easier. Under the German technical rule TRBS 2111 Part 1 (mobile work equipment), the suitability of a lifting device must be reassessed for each individual place of use – especially when the places of use change. A CRAH gallery with a raised floor is a different place of use from a factory hall. So do not ask whether the contractor “has a lifting device”, but whether the lift plan demonstrates why this device with this floor pressure may work in this aisle.

Lift

The lift is often the bottleneck: lift capacity, car dimensions, door clearance and the question of whether the unit fits in upright or lying down. If the lift is not sufficient, the remaining route is via an installation opening or an installation shaft by crane – and that is a different project with a different lead time.

How is the old CRAH unit removed?

After documented isolation, the old CRAH unit is released from its fixings under control and moved out of its position step by step. It leaves the CRAH gallery either in one piece or dismantled into modules.

Releasing and securing

First, the bolted connections at the base, connection flanges and cable and pipe penetrations are released – only the mechanical ones; the specialist trade has already disconnected the water and power connections. The unit is secured against tipping before the last fixing is removed. Tall, narrow units have a high centre of gravity; this determines lifting points, lifting accessories and lifting equipment. Before the actual lift, this is checked with a trial lift: raise a few centimetres, check the position, set down.

Moving

Out of position, the unit moves on lifting devices, machine skates or hydraulic machine skates, always under direction, always with an eye on the neighbouring units. In narrow aisles, heavy modules such as the fan section are secured separately on hydraulic machine skates and moved individually – this reduces weight and height per transport movement and spares the floor.

Dismantle or move in one piece?

Whether the unit is dismantled depends on the load path and its condition. If the housing can be separated without damage, this is often the gentlest option. If the unit is scrap anyway, it may also be cut – but not in the CRAH gallery with flying sparks and swarf. Cutting work takes place outside, or under extraction and with a fire watch, under a hot work permit. This is the separate permit for work involving flame, sparks or hot surfaces. In a data center it additionally governs the isolation of the fire alarm system in the affected section.

Transport away

The old unit or its modules are packed, loaded onto the truck and sent for disposal or returned to the manufacturer. Refrigerant – if the unit has its own refrigeration circuit – may only be recovered by qualified personnel in accordance with the German Chemicals Climate Protection Ordinance. That is the job of the cooling contractor, not the installation team.

Slinging at height – with full PPE against falls
Heavy modules such as the fan section are secured on hydraulic machine skates and moved through the aisles.

How is the new CRAH unit moved in and aligned?

The new CRAH unit is moved in along the checked load path and unpacked near the installation position. Using lifting devices, it is positioned to the millimetre at the existing connection points, aligned and fixed to the plinth.

Moving in

From the truck across the unloading area to the CRAH gallery, the unit follows the lift plan: unload, transfer to lifting device or machine skates, through doors and lift, under direction through every pinch point. Add to this the escort – in a data center, external companies must be accompanied by the operator. Packaging is only removed where no particles can reach the data hall – not in the white space.

Positioning

In the CRAH gallery, installation comes down to centimetres. Two synchronously guided compact lifting devices allow a tall unit to be raised evenly and moved along the narrow aisle without tipping or touching the neighbouring units. The target position is defined by the existing connections – water, condensate, power, air routing; the unit is set out to them, and in long rows aligned with the neighbouring units by laser measurement.

Aligning and fixing

After setting down, the unit is levelled so that condensate drains and doors close. It is then bolted to the plinth or support frame. Tightening torques are recorded in the torque record where required. Then we check whether all connection flanges are in the position the specialist trade needs – a centimetre of offset on the water side means rework that nobody wants inside the maintenance window.

What belongs to acceptance and handover?

Explanatory graphic: replacing a CRAH unit – acceptance and handover in three steps: documentation package from the installation contractor, connection by the specialist trades, test run and normal operation by the operator
The mechanical installation is handed over when every document is countersigned – the replacement is complete when redundancy is restored. Graphic: Omega Mounting

Acceptance includes the documented handover of the mechanically installed unit to the specialist trades: position, alignment, fixing, condition of the surroundings, photos, test certificates and defect-free completion notice. Open items go on the punch list, which is worked off before acceptance.

Handover by the installation contractor

Connection and commissioning

The cooling and electrical contractors then take over: connect the water side, fill, vent, check for leaks. Then the electrical connection, controls, integration into the building management system. The operator carries out the test run – for new plant as a site acceptance test (SAT) as part of commissioning. Then the unit goes into normal operation. Only then is redundancy restored, the change request closed – and only then is the replacement complete.

Spider crane retrieval from the basement of a data center in Raunheim
This spider crane installed CRAH units in the basement of a data center in Raunheim – and then had to get out again itself.

How we do it in practice

Two jobs from our project diary show the replacement and its context in the Rhine-Main region.

CRAH unit replaced in Frankfurt during live operation

In a data center in Frankfurt we replaced a CRAH unit during live operation. Finding: a damaged heat exchanger, the fin pack torn open down to the copper tubing – no repair possible on site. One supervisor and three experienced lift-&-shift riggers needed two working days. The new unit was unloaded from the truck and transported up to the second floor. In the narrow aisles of the CRAH gallery, two synchronously guided compact lifting devices were used to position the tall unit to the millimetre. The faulty unit was picked up under control, moved out of its position step by step and transported out of the CRAH gallery. Heavy modules such as the fan section travelled through the aisles secured on hydraulic machine skates. All walkways and travel routes were covered with protective fleece and taped down. Access ran through several secured areas with security gates and interlocked doors. RAMS and detailed lift plans were in place before the start – with load weights, lifting points, lifting equipment, machine positions, load paths and safety clearances.

The spider crane that installed CRAH units

In a data center in Raunheim, a spider crane stood in the basement. It had been brought in during the shell construction and installed CRAH units until the very end – by then the building had been completed around it. Getting it out was a lift-&-shift project in its own right. The only route led through a shaft occupied by a construction hoist that could not be dismantled. In the upright passage, two centimetres were missing. Four fitters retrieved the spider crane from the basement in a single day. The steps involved:

For CRAH replacement this shows two things: which lifting equipment can work in the CRAH gallery at all depends on the building. And whatever goes in has to come out again.

Is a comparable replacement coming up for you – in Frankfurt, Offenbach, Hanau or elsewhere in the Rhine-Main region? Then get in touch with us. A site visit in the CRAH gallery usually clarifies within an hour whether the unit fits through in one piece, which lifting devices are suitable and how long the maintenance window realistically needs to be.

What this means for your role

For buyers: Tender the replacement with a scope of works whose line items list lift plan, RAMS, protective measures and documentation package as separate items. Otherwise you will be comparing quotations that contain different things. Define in an interface list what is provided by the client (isolation, proof of redundancy, access, lift) and what the cooling and electrical contractors deliver. Include waiting times at security gates or postponed maintenance windows as a provisional item so that they do not come back as a change order. Evidence of suitability includes references for replacement work during live operation, the qualification of the appointed person for lifting operations and the test certificates for the lifting equipment.

For designers: Every CRAH unit you place today will be replaced at some point. Door clearances, headroom in the CRAH gallery, lift capacity and car dimensions, point and distributed load of the raised floor and reserve space for manoeuvring are the design parameters. Later they decide between two days and two weeks. Record the moving-in route and load assumptions in the installation planning. Plan for the replaceability of chiller, CRAH and standby power system from the outset – our guide on replacement in the live data center shows how.

For project managers and site managers: Fix the sequence of trades in the construction schedule and make documented isolation with a permit to work the prerequisite for the lift release. Have the lift plan and RAMS submitted before delivery and walk the load path together in a joint site visit. As site manager you brief on site, coordinate preceding and following trades in the CRAH gallery, release each phase and receive the completion notice. Plan security gate and check times as working time within the cycle, not as a buffer. Everything in the foundation guide on data center installation applies here even more strictly: the CRAH gallery is narrow, the neighbouring units are running.

For maintenance managers: You provide the assessment and damage pattern that trigger the replacement, and you take the new unit into your maintenance schedule and inspection intervals after handover. Have the fault history, maintenance records and measured values of the old unit ready so that the replacement does not begin with a root cause analysis. At acceptance, check that access for filter changes, valves and controls is retained. Clarify spare parts stocking for the new type and add the unit to your asset file with commissioning data and inspection log.

For safety officers and HSE coordinators: Replacement in a live CRAH gallery combines lifting operations, electrical isolation and work on water- or refrigerant-carrying pipework in a confined space. Check whether the risk assessment under Section 5 of the German Occupational Safety Act (ArbSchG), or the installation contractor's RAMS, covers the running neighbouring units, the escape routes in the aisle, the load area and the interfaces with the specialist trades. Also check whether the permit to work properly references the isolation with LOTO. Require an induction and toolbox talk for everyone involved. Define in writing who has stop authority – anyone involved may stop the lift, the lifting supervisor releases it again.

For facility managers and operators: You take the replacement through your data center's change process: change request, proof of cooling redundancy (N+1 or 2N during the work), maintenance window, access list and escort. Schedule the maintenance window so that your operations team is reachable, the monitoring processes the feedback and nothing falls into the shift handover. Have a fallback ready in case the window is not enough. At the end, demand a documentation package that you can present to your customers or to certification – from the load path to the handover record with the punch list worked off.

CRAH unit replacement checklist: template on request

The CRAH unit replacement checklist brings the six phases of the replacement together with their checkpoints on one page:

Each item has a responsibility column for installation contractor, cooling contractor, electrical contractor and operator. The checklist helps project managers to walk through the replacement with everyone involved beforehand. On the day of the work it serves as a shared tick list – so that the maintenance window holds and no trade waits for another. Request the checklist via our Contact form – reference “CRAH replacement checklist”.

Why Omega Mounting?

Omega Mounting is based in Rodgau near Frankfurt, a few kilometres from the data center sites in Frankfurt, Offenbach, Raunheim and Hanau. The linked CRAH replacement in Frankfurt and the spider crane retrieval in Raunheim show how we deliver lift & shift in finished buildings – with our own lifting equipment, lift plan and documentation. Our workshop in Rodgau manufactures transport frames, load spreading plates and adapters when the installation situation requires it. And because CRAH failures do not keep office hours, you can reach us via the 24-hour hotline even when a replacement has to go into the maintenance window at short notice. With us you get a single point of contact for site survey, lift plan, lifting equipment and documentation. And short lines of communication if, on the day, things in the CRAH gallery turn out differently from the plan.

Conclusion

Replacing a CRAH unit is less a question of lifting equipment than of organisation. Redundancy confirmed, trades in sequence, load path measured, floor loads calculated, protection laid out, isolation documented. Then removal and moving in are two controlled working days instead of a week full of surprises. The checklist in this article helps you not to overlook any of it. If the replacement is coming up for you, send us the floor plan of the CRAH gallery, the type of unit and your preferred date – we will get back to you with an honest assessment of load path, lifting equipment and time required.

Planning maintenance, moving in or installation in the Rhine-Main region?

Tell us briefly what it is about – we will come back to you with an honest assessment.

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Tobias Schott, managing director of Omega Mounting GmbH, on a construction site in front of scaffolding

About the author

Tobias Schott

Managing director of Omega Mounting GmbH, Rodgau · more than 20 years of hands-on experience in installation and maintenance

A trained mechatronics technician, at home in maintenance, servicing and industrial installation since 2004 – first at his father's side, since 2012 with Omega Mounting: from the overhead conveyor in Frankfurt to the crane system in a new-build hall. Plans and leads lifting operations as appointed person in data centers and on industrial sites in the Rhine-Main region, is an instructor and examiner for cranes, mobile elevating work platforms and telehandlers, and a safety officer. On jobs abroad he is known as the “German Troubleshooter” – the one you call when things get stuck on site. He learned what quality means not from a manual but from his father: Made in Germany as a standard for his own work, not as a label. That is why it comes first at Omega Mounting – before speed and before price. He writes these guides from that practice: what works on our sites is in them – what only exists in the standard is not.

Frequently asked questions

Yes, if the remaining units carry the cooling load during the replacement – that is, if N+1 or 2N redundancy still holds with one unit fewer. The operator provides this proof in the change process before the maintenance window is scheduled. The replacement itself then takes place in the protected CRAH gallery under direction and escort, without touching the white space.

That depends on the load path, the amount of dismantling and the maintenance window. For the replacement in Frankfurt described in this article, one supervisor and three riggers needed two working days for removal and moving in. Preparation with site survey, lift plan and access registration ran beforehand. Connection and commissioning by the specialist trades are added to the construction schedule.

The electrical and cooling contractors: they establish absence of voltage, lock out against reconnection (LOTO), shut off the water side, drain it and disconnect the condensate drain. The isolation is documented and handed over to the installation contractor with the permit to work for the area, period and activity. Without this handover, the mechanical work does not start.

Not necessarily. Whether in one piece or in modules is decided by the load path: door clearances, headroom, lift and the narrow aisles in the CRAH gallery. Heavy modules such as the fan section are often moved separately on machine skates to reduce weight and height per transport movement. Cutting work with flying sparks requires a hot work permit and takes place outside the CRAH gallery.

The permissible distributed and point load of each section along the load path: raised floor, structural slab, lift capacity. The installation contractor calculates the actual load from CRAH unit, lifting device and wheels against these. What matters is the floor pressure under each individual wheel. If values are missing, the structural engineer confirms them; if they are exceeded, the installation contractor lays out load spreading plates or chooses a different route.

Risk assessment under Section 5 and briefing under Section 12 of the German Occupational Safety Act (ArbSchG), inspection and safe use of work equipment under the Industrial Safety Ordinance (BetrSichV), and DGUV Rule 100-500 for lifting accessories and lifting operations. In data centers this is usually combined in the RAMS (method statement, i.e. risk assessment plus work instruction) together with the lift plan. The permit to work, the induction and the operator's site rules complement it.

In advance: lift plan, RAMS, test and qualification certificates. During the work: the daily machine and lifting accessory checks, protective measures, deviations and near misses. At handover: installation record with position, alignment and tightening torques, photo documentation, punch list and defect-free completion notice. These documents are your evidence towards the operator and belong in the as-built records.

In principle yes, the six phases and the sequence of trades are the same. Chillers and standby power systems are heavier and usually stand in the grey space or on the roof, so mobile cranes, machine skates or installation openings come into play. The logic stays the same, also outside data centers in production or logistics.

Because a replacement during live operation depends on site visits, short-notice coordination and fast response. From Rodgau, the data centers in Frankfurt, Offenbach and Raunheim are a short drive away. That applies to the site survey beforehand just as much as to the installation in a night-time maintenance window or the on-call service when a unit fails at short notice.

Through a short enquiry with three pieces of information: floor plan or photos of the CRAH gallery with the route from the lift to the installation position. Type and dimensions of the old and new units. And the intended maintenance window. We arrange a site visit, walk the load path with you and send you a written assessment of lifting equipment, protective measures and time required. Your contact is Tobias Schott – reachable via our Contact form.

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