For more than 75 years, Jarrell Mechanical Contractors has brought comfort and precision to complex mechanical projects across the U.S. From massive distribution centers to postal facilities and high-tech manufacturing sites, the third-generation, St. Louis–based company has built its reputation on quality workmanship, adaptability and a large bench of over 300 employees and 125 service vehicles.
So, Jarrell Mechanical Contractors was the natural choice when one of St. Louis’s most iconic venues, The Fabulous Fox Theatre, required a careful replacement of its split DX HVAC systems. The project posed a distinct set of challenges. The Fabulous Fox Theatre is a historic building with confined service areas and a strict no-flame policy in critical zones.
“Most of our work these days is outside of St. Louis, but this one hit close to home,” said Bryan Vaughn, project manager and quality control manager at Jarrell Mechanical Contractors. “It was a direct replacement, but the space constraints and piping access inside the Fox meant we had to think differently.”
Originally opened in 1929 and restored in the early 1980s, The Fabulous Fox is a living piece of art. As such, maintaining its structural and visual integrity was non-negotiable for Jarrell Mechanical Contractors. This meant replacing the aging rooftop condensing units and the evaporator/blower section on the floor without open flame, particularly where tight quarters left little margin for error.
“In one section, the line set wasn’t the right size for the new equipment. We knew immediately we weren’t comfortable using a torch in that confined space,” Vaughn explained.
While the team used traditional brazing methods for some of their refrigeration and HVAC piping, this situation required a different approach. It would be the team’s first time using press fittings. They chose to use the Rapid Locking System (RLS) XL line, which is ideal for the 1-5/8″ standard application needed.
The project involved several riser and lateral connections, with about eight couplings and six to eight elbows to navigate the tight pipe runs from the rooftop unit down to the evaporator section. What made the job stand out wasn’t just the fittings but how well the team adapted to them.
“Our guys had never used press before. We gave them hands-on training and let them run with it,” said Vaughn. “They felt good using it. The installation went smoothly, and the leak check passed with no issues. They were extremely happy with RLS.”
Beyond the successful first experience, Vaughn said the decision to use press was about more than space; it was also about safety, speed and cost efficiency. Unlike brazing, press fittings don’t require nitrogen purging or flame protection, which creates real savings on materials and time.
“In sensitive areas like a historic theater, or a server room, which we worked in for another job in Dallas, you can’t afford to have a flame. And when you braze in data centers, you’re shutting down fire detection systems, pulling permits and jumping through hoops,” Vaughn said. “With press, none of that’s needed.”
Jarrell’s team used Milwaukee M18 tools to complete the press installs, appreciating how intuitive the process became once underway.
“Honestly, this made a hard job easier,” Vaughn said. “It’s a labor-saver and a good fit for tight areas and high-profile spaces.”
With thousands of fittings used across their jobs each year, Jarrell Mechanical Contractors plans to add press to their arsenal of pipe fitting solutions. The Fabulous Fox install helped redefined what’s possible when the right tool meets the right application. The experience gave the contractor team confidence in this new solution as it was safer, while also saving time and money, which are all critical in this business.