Lee Mechanical was selected to complete a comprehensive boiler replacement project for Bay View Terrace, a 25-story condominium building located on Milwaukee’s lakefront.

The project involved phased demolition and replacement of the building’s aging boiler infrastructure while maintaining heat for residents during winter construction.

The total project value was $715,000 and required close coordination among multiple trades, vendors, and the building owner to ensure safety, continuity of service, and long-term system reliability.

Scope of Work:

Bay View Terrace is a 25-story high-rise condominium building situated directly on the lakefront. The boiler plant is located in a rooftop penthouse, creating significant access and material-handling challenges. The building’s height, active occupancy, and winter construction timeline required detailed planning and execution to minimize disruption to residents. Lee Mechanical performed HVAC, plumbing, and electrical work associated with the boiler replacement, including:

  • Demolition of eight existing boilers in two phases

  • Installation of five new 1,000 MBH boilers

  • Rework of the boiler primary system and integration with the existing secondary system

  • Prefabrication and installation of new 6-inch hot water mains

  • Temporary flue venting of existing boilers due to an owner-direct roofing project that removed the original exhaust system

  • Extensive coordination to restore building heat less than one week after contract award

Controls upgrades were completed by Masters, general trades by Beeler, and roofing by Langer.

Unique Challenges and Solutions

One of the primary challenges was material handling. The original plan required transporting equipment from ground level through elevators to the 25th floor and then up a stairwell to the penthouse. To improve efficiency and reduce labor, the Lee Mechanical team revised the approach and set a 275-ton crane.

The crane was used to:

  • Demolish four boilers during Phase 1

  • Lift all prefabricated 6-inch hot water mains

  • Hoist all five new boilers using custom rigging designed by Lee Mechanical to safely tilt the boilers for roof access

  • Lift additional equipment including air separators, expansion tanks, and primary pumps

Given the winter schedule, maintaining heat throughout construction was critical. Lee Mechanical implemented advanced control strategies and phased planning to keep the building operational while half of the boilers were removed. The team also adjusted sequencing to bring one new boiler online earlier than planned to address temperature concerns.

Hydro Flo representative Charlie Meier was present during the crane picks to ensure proper handling of the boilers, protect warranty requirements, and provide on-site support to the installation crew.

Through proactive planning, creative problem-solving, and close collaboration with all project partners, Lee Mechanical successfully executed a complex boiler replacement under challenging conditions. The project delivered a modern, efficient heating system while maintaining resident comfort and safety throughout construction.

“I’ve worked on numerous projects at Lee Mechanical, including Cargill Cocoa, Charter Wire, and many other locations, but most recently I was part of the team at Bay View Terrace. What I appreciate most about working with Lee is the true team mindset. I’ve yet to meet anyone here who isn’t willing to help a coworker. That culture starts in the office and with management, and it carries all the way into the field. Everyone genuinely wants to see each other succeed.”

– Sam O’Brien, Steamfitter Foreman,
Lee Mechanical