Boiler Replacement Without Compromise: Inside the Longwood Gardens Project
Looking for a boiler replacement company that can handle high-risk, high-precision projects? APEX Mechanical & Fabrication specializes in boiler replacement services that demand zero downtime, tight coordination, and seamless execution, even in the most sensitive environments.
Case in point: Longwood Gardens.
Let’s break it down.
In the heart of Pennsylvania’s Brandywine Valley lies a living masterpiece: Longwood Gardens. Visited by over a million people annually, it’s not just a garden. It’s a cultural landmark.
As part of its ambitious $250 million Longwood Reimagined expansion project, Longwood faced a major infrastructure challenge: replacing an aging boiler heating system tucked in a below-grade mechanical room without interrupting operations or affecting guests.
Zero downtime. Tight spaces. Fragile root systems. No room for error.
We were trusted to deliver, and we did.
👉 Want the full breakdown? Download the case study.
Tackling Pipe Replacement with Precision and Care
Along with numerous Longwood Reimagined updates, we were brought in to lead the boiler system replacement, which included:
- Removing and replacing two buried boilers
- Installing 500+ feet of underground piping
- Integrating seamlessly into the existing mechanical and control systems
All this had to happen without disruption to guests, no impact on greenhouse temperatures, and under the tight scrutiny of Longwood’s operations and project team.
Here’s how we did it:
- Phased installations kept heat flowing to critical greenhouse zones.
- In-house fabrication ensured every component fit within less than 1 inch of clearance, all while meeting full ASME compliance.
- A custom-engineered rigging plan allowed the flex-tube boiler system to be installed in an active, below-grade room without disturbing the surrounding environment.
Throughout the project, from submittals through install and start-up, Apex Mechanical was flexible and professional. As each challenge presented itself, they worked with the construction managers, engineers and boiler supplier to evaluate solutions, present options and complete installs on time meeting all specifications and requirements. Many of the piping designs had to be modified in the field based on space and access limitations. APEX coordinated all of the design changes and provided reasonable resolutions to all of the install issues that they encountered.
APEX Mechanical was a great partner and completed a first-class installation that met all of the final design and start up requirements for the project. Longwood Gardens appreciates [their] dedication and commitment to making this a successful installation.
Vice President, Longwood Reimagined Project
Longwood Gardens, Inc.
Steam Boiler Replacement Without Disruption or Delay
As with many post-pandemic projects, supply chain delays threw curveballs, especially on the boiler unit delivery, which was pushed from summer 2022 into spring 2023.
We didn’t flinch. In partnership with Bancroft Construction and Longwood Gardens, we:
- Developed temporary operational solutions to maintain heat with just two boilers
- Revised plans around shifting delivery windows
- Still met the critical deadline to complete the boiler replacement service before the summer shutdown
Tony Ingram, Senior Project Manager at Bancroft Construction, shared that the Bancroft team “enjoyed working with our partners at APEX” and specifically praised their “problem-solving approach” throughout the project’s many logistical challenges.
Results That Speak Volumes
The Longwood Gardens boiler replacement project was anything but routine. Despite every obstacle—space limitations, underground install paths, and pandemic-era lead times—we delivered:
- A fully integrated, energy-efficient boiler system
- Zero greenhouse downtime
- No guest disruption
- Completion ahead of a 16-week critical path window
- ABC Excellence Construction Award
- Praise and endorsements from both the client and construction partner
Grablewski acknowledged that the project “presented many challenges,” but highlighted that APEX “coordinated all of the design changes and provided reasonable resolutions to all the installation issues they encountered.”
Explore the Full Longwood Gardens Project Story
Every project is an opportunity, but this one meant more. From trenchless piping strategies to a complex steam boiler replacement, this job demanded precision, flexibility, and care.
We’re proud of what our team accomplished and deeply thankful to Longwood Gardens and Bancroft Construction for trusting APEX to get it done right.
Why APEX for Boiler Replacement Services?
APEX Mechanical & Fabrication delivers boiler replacement services built for performance, safety, and speed. Our team is trusted by facilities across the Mid-Atlantic for work that meets the highest standards, whether it’s a planned replacement or an emergency response.
What sets us apart?
- Expertise across boiler types: From high-pressure steam to hot water and flex-tube systems, we install, repair, and replace all major boiler configurations.
- ASME-certified welders: All work is completed to ASME Section I & IV standards, ensuring long-term safety, compliance, and reliability.
- Zero-downtime execution: Our team plans and phases installations to avoid operational disruption—even in critical environments like greenhouses, hospitals, and universities.
- Full lifecycle service: We don’t just replace—we integrate, test, and support your systems for peak efficiency.
- 24/7 availability: When boilers fail, you don’t have time to wait. APEX is ready around the clock with fast-response service and dependable crews.
📞 Need a partner for your next boiler replacement project? Contact us.