Maintaining comfort and achieving maximum efficiency are the objectives of our services in heating, ventilation and air conditioning.

TOTAL Mechanical is southeast Wisconsin’s premiere commercial HVAC contractor, offering comprehensive services for virtually any building—commercial, industrial and institutional. Our focus on energy efficiency means that your HVAC mechanical systems will provide year-round comfort while lowering operating costs, providing you the greatest return on your investment on this mission-critical equipment.



Contact us to learn more about our services or to schedule a consultation.

Or, you can call or email your drawings and takeoff sheets to:
Andrew Boeck, PE, VP Commercial Division / 262-523-2500 /

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Our HVAC services include:

  • Operational assessments
  • Design / Build services
  • Planned maintenance
  • Emergency repair
  • Energy optimization

Case Studies

GE Fitness Center

GE Fitness Center

Job Name: GE Fitness Center – Solar Water Heater
Scope of Work: Design-Build
Location: Pewaukee, WI

The following is a summary of equipment installed at this facility:

  • 16 Solar Skies SS-40 panels with a total area of 637.22 ft2
  • 2 260-gal storage tanks
  • HTP drain-back tank
  • Solar controls made by IMC Instruments
Project Summary:GE Healthcare is one of the most environmentally conscious employers in southeast Wisconsin. Through the “ecomagination” initiative, GE is actively pursuing innovative and profitable solutions to environmental problems. Since 2004, the program has resulted in a greater than 22% decrease in greenhouse gas emissions, with the goal of a 25% decrease by 2015. GE has also reduced water usage by over 30% since 2006, surpassing the original goal of a 20% reduction by 2012.[1]

In order to reduce energy usage at their US headquarters in Waukesha, Wisconsin, GE Healthcare’s Global Facilities Manager, Mark Colannanni, initiated a program to augment the employee fitness center’s gas-fired water heaters with a solar hot water system. GE Healthcare’s Project Engineer, Chris Jurik, contracted with Jim Leuzinger of Pewaukee-based TOTAL Mechanical and Aaron Adler of Milwaukee-based Hot Water Products to design and install the system.

Engineers from TOTAL Mechanical designed the system and determined the best location for the solar panels, hot water piping, controls, and related equipment. Representatives from Hot Water Products assisted with the site evaluation, RetScreen software simulation, conceptual design, product procurement and delivery. Mike Westfahl, a Journeyman plumber from TOTAL Mechanical, then installed the system and filled it with Dowfrost, a propylene glycol-based heat transfer fluid that contains food-grade corrosion inhibitors. The system was leak-tested, insulated, valve-tagged, and labeled prior to bringing it on-line.

The system consists of 16 Solar Skies SS-40 panels with a total area of 637.22 ft2, two 260-gal storage tanks, an HTP drain-back tank, and solar controls made by IMC Instruments. It is capable of generating up to 39 kilowatts of energy, which is equal to 116,100 BTU – enough to provide hot water to as many as three homes.


Key opportunities/challenges:

It may seem that a solar water heater would not be as effective in Wisconsin as it would be in a warmer, sunnier climate. However, Wisconsin has as many sunny days as southern Texas, and the efficiency of a solar water heater is not significantly affected by the ambient air temperature. GE’s solar array faces south, at an angle of 43 degrees from horizontal. This maximizes the amount of direct sunlight captured during the winter, when the sun is at its lowest in the sky. In the summer, the energy lost to indirect sun exposure is made up for by the longer periods of daylight.


Benefit to GE Healthcare:

The system is expected to contribute between 20% and 100% of the fitness center’s hot water, with an annual average of 48%. By reducing GE’s dependence on non-renewable energy, the system also insulates GE against rising fossil fuel costs. With an anticipated lifespan of at least 30 years, the system will ultimately save GE nearly $180,000. Over that period, it will have reduced greenhouse gas emissions by 281 tons, which is the equivalent of 648 barrels of crude oil. In addition to the savings realized by reducing natural gas consumption, the solar hot water system also reduces the maintenance requirements of the existing natural gas water heaters. Since the solar system is able to reduce demand on the gas burners, the burners will require less frequent maintenance, and should last longer than if they were to continue as the only source of hot water for the facility.

St. Joseph Outpatient Center

St. Joseph Outpatient Center

Job Name: St. Joseph Outpatient Center
Scope of Work: Plan & Specification
Location: 201 N. Mayfair Rd., Wauwatosa, WI 53226
General Contractor: Hunzinger Construction Company
Project hours: Over 35,000 hours

The following is a summary of equipment installed at this facility:
  • Five (5) Mammoth Heating/Cooling Roof Top Units
  • One (1) York Air Handling Unit and Air Cooled Condensing Unit
  • Two (2) Leibert Equipment Room Cooling Units and Drycooler
  • Five (5) Patterson Kelley Process Hot Water Boilers
  • Three (3) Fulton Humidification and Sterilization Steam Boilers
  • 194 Price Variable Air Volume Boxes
  • 21 Power Roof Ventilators, Exhaust Fans & Ceiling Exhaust Fans
  • Rittling Convectors, Unit Heaters & Fin Tube
Project Summary:
St. Joseph’s Outpatient Center is a 210,000 square foot, state-of-the-art ambulatory care center.  The five-story building includes 60 office spaces for physicians along with a 5-story parking structure.  In addition, four acres of land have been purchased north of the building in anticipation of future expansion.
TOTAL Mechanical acted as the primary coordinator for the mechanical, electrical and plumbing throughout the entire duration of the project.  They successfully managed to stay on track with the challenging construction schedule.  The on-site project management staff coordinated all equipment and material deliveries to ensure that heating, ventilating and air conditioning systems were operating for the finishing trades.  TOTAL Mechanical also coordinated temperature control installation and had the entire building commissioned and owner training completed prior to owner occupancy.
TOTAL Mechanical installed 5.35 miles of piping, 700 valves, 3000 hangers, 20,000 pipe fittings and 170 tons of sheet metal ductwork.  The crew size peaked at 50 mechanics.  Cooperation among all involved resulted in the on-time completion for the ten month project.
The St. Joseph Outpatient Center is featured in the 2004 May issue of Wisconsin Builder as one of the Top 20 projects completed in Wisconsin for 2003.  Hunzinger Construction also received Midwest Construction Magazine’s Award for 2003 Project of the Year in the Health Care Category for this project!
U.S. Gypsum Mineral Wool Production Facility

U.S. Gypsum Mineral Wool Production Facility

Job Name: United States Gypsum Mineral Wool Production Facility
Scope of Work
:  Dust Collection Installation
:  Red Wing, Minnesota 
 Contractor:  TOTAL Mechanical of Wisconsin, Inc.
Project Hours: Over 12,000 Man Hours; Over 3,500 Sheet Metal and Project Management Hours

The following is a summary of equipment installed at this facility:
  • (4) 60,000 CFM Drum Filters
  • 1/4 inch Abrasive Resistant 400 Ductwork
Project summary:
United States Gypsum Company was incorporated in 1901 to become the first gypsum company with a national scope.  They are a subsidiary of USG Corporation which has numerous locations worldwide.  United States Gypsum Company partnered with TOTAL Mechanical of Wisconsin, Inc. to upgrade their equipment to conform with DNR standards and regulations.
Although TOTAL Mechanical and USG had a previous working relationship in Wisconsin, this Minnesota Mineral Wool Production Facility was the first out-of-state project for the two companies.  Projections called for a three week shutdown, but TOTAL Mechanical was able to pool its resources and propose a plan to complete the project in only eleven days.  This careful planning saved the company ten days of material storage and kept downtime at the plant to a minimum.
Safety was the number one priority of the project and a full time Safety Director was on site during all working hours.  Daily safety meetings were held to ensure proper lifting procedures and to review many additional safety issues for that days’ activities.
The project began with the demolition of USG’s existing four-story dust collection building.  Crews worked around the clock with over twenty-four people per shift.  The next phase of the project included 40, 100 and 265 ton cranes which were brought in on semis and took several days to assemble.  Over 12,000 manhours were spent on the project from start to finish including project management, sheet metal hours, set-up and clean-up.
TOTAL Mechanical overcame the challenge of time and saved money for USG in storage costs and plant shutdown time.  The USG Mineral Wool Production Facility Project was completed on schedule and TOTAL Mechanical hopes to complete many USG projects throughout the country in the future!
Food Processing Facility

Food Processing Facility

Job Name:  Food Processing Facility
Scope of Work
:  Pipe Fitting
:  Milwaukee Suburb
 Contractor:  Working directly for Corporation
 Hours:  TOTAL Mechanical has spent roughly 120 hours per week at the project site since work began on August 25, 2003.  (Time and Material)
The following is a summary of equipment installed at this facility:
  • Stainless Steel Sanitary Piping – Food Grade
  • Boiler Piping
  • Cooling Tower/Chilled Water Piping
  • Steam Piping
  • Food Processing Equipment
Project Summary:
The Corporation has evolved into a thriving food processing plant.  Their ability to adapt with changing technology has enabled them to find success with products such as weight loss shakes and iced coffee drinks.  They pride themselves on their fresh products and sterile packaging.

The Corporation looks to TOTAL Mechanical to help them maintain their respected reputation as they move toward product expansion.  As new product lines are developed, TOTAL Mechanical assists to ensure all food process piping equipment is operating effectively.

The work environment at the processing plant presents a challenging circumstance.  Due to product safety specifications, steam is used to heat/pasteurize various products.  TOTAL Mechanical employees demonstrate their ability to work under demanding conditions as they accept a hot and humid work environment.
As the Corporation continues to grow, TOTAL Mechanical demonstrates its pipe fitting expertise and allows the Corporation to maintain their reputation as a fresh and sterile food processing plant.