- Air conditioning
- Collection systems
- Conveying systems
- Enclosure systems
- Exhaust systems
- Fire protection systems
- Make-up air systems
- Metal fabrication
- Oven systems
- Pollution control systems
- Process piping
- Structural systems
- Sustainable design engineering
Job Name: Zero Zone
Scope of Work: Electrical, Controls, Industrial HVAC
Location: North Prairie, Wisconsin
Project Description: Zero Zone was having difficulty with air balancing in their case paint booth. TOTAL Mechanical’s Electrical, Industrial and Controls Divisions were able to design and install a solution to a complex make-up air issue that had stumped our competition. TOTAL’s solution also significantly reduced the noise in the booth and cut energy costs by a third. In addition, the project was completed under budget and ahead of schedule. The project was expected to require two shut-downs to complete, but our crew was able to accomplish it in one, which allowed Zero Zone to resume production much sooner than expected. Zero Zone sent a note of thanks stating, “your thoroughness, efficiency, knowledge and follow-up made this project flawless… we truly appreciate all your efforts.”
This project provides a perfect example of how good things can happen when we make our customers’ problems our own, working as a team to solve them. It also illustrates the value TOTAL Mechanical brings as a full-service mechanical contractor, with the ability to work across trades to solve complex problems.
Cambridge Major Laboratories
Job Name: Cambridge Major Laboratories
Scope of Work: Complete Plumbing, Fire Protection, HVAC and Process Mechanical Systems
Location: Germantown, Wisconsin
General Contractor: Skyline Development
Project Hours: 79,635
The following is a summary of HVAC equipment installed at this facility:
- Multiple Process and HVAC Chillers and heaters
- Cooling Towers
- Process and HVAC Pumps for Therminol, and Water
- Chemical Reactors and Condensers
- HVAC Air Handlers and Make-Up Air Units
- Process and Laboratory Exhaust and Pressurization Control Fans
- Chemical Supply Pumps
- Waste Handling Pumps
- Waste Storage Tank
- Compressors and Vacuum Pumps
CML is an Active Pharmaceutical Ingredient (API) manufacturer, providing advanced chemistry services to leading pharmaceutical and biotechnology companies around the world.
CML hired TOTAL Mechanical to design and build the HVAC mechanical systems, laboratory ventilation and pressure control systems, plumbing, and fire protection for a new large-scale production and R&D laboratory. TOTAL Mechanical’s engineering and design staff created detailed CAD construction drawings for the facility and developed the process and instrumentation drawings in conjunction with CML’s facility engineering staff. We also assisted in the design and installation of solvent and chemical distribution piping to deliver contaminate-free chemicals from a twelve-station tank farm.
TOTAL Mechanical provided a full-time licensed professional engineer as an on-site project manager with an assistant project manager for 15 months to efficiently coordinate the project with the General Contractor, Owner, and other trades.
The completed system serves five production laboratories, each with two to three reactors and condenser systems capable of controlling chemical reactions from -90°C to +250°C with pressures up to 300 psi.
U.S. Gypsum Mineral Wool Production Facility
Job Name: United States Gypsum Mineral Wool Production Facility
Scope of Work: Dust Collection Installation
Location: Red Wing, Minnesota
General 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
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!
Robert J. Lex – Executive Vice President
Harwood Engineering Consultants