Our experience
Our experience
Tūai Hydro Power Station
Our upgrade of the Tūai Power Station delivered QA on schedule and to a high standard.
The scope of works was to remove all platforms and old ducting within gate one, and measure, fabricate and fit new platforms and stairs. The fragility of the 1929 building meant the project required careful logistical planning to keep everyone safe on site and prevent any damage to the existing infrastructure. Before going to the site, we successfully completed multiple trial assemblies and communicated details of these trials thoroughly with the client.
The outcome was a seamless delivery of quality platforms and stairs, within the timeframe.
“AEC were engaged to supply and install access platforms at Tuai, including removal of redundant ducting and damper doors. The project was challenging with multiple contractors working in the same area and a tight timeline. AEC worked well with all the stakeholders, finished their work ahead of schedule and had no safety incidents. Communication during the different project stages of design, fabrication and installation was always timely, clear and professional.”
Kobus K
Senior Mechanical Engineer
Genesis Energy
Piripāua Penstock Refurbishment Programme
The Piripāua Penstock Project has brought together AEC and CMS teams to carry out scheduled works
and attend to reactive works as required.
During penstock refurbishments, we were asked to tender on repair work and the installation of a new Rietmeyer
flow meter system. The work involved specialist stud welding within the penstocks with no margin for error, as well as the disassembly and assembly of the main inlet valves. A highly skilled team was required due to the age of penstocks.
The project is running well and Genesis is now able to confidently schedule a return to work for these penstocks.
“AEC was engaged to do all the mechanical work required to enable penstock internal lining application by others. The work included main inlet valve removal, penstock protection system removal and replacement, welding repairs, and penstock service water take-off stub replacement. Welding work posed several challenges due to known issues with penstock material, however, clear and timely communication between AEC and Genesis Energy meant issues were resolved, and the work was completed with a high degree of conformance to quality.”
Kobus K
Senior Mechanical Engineer
Genesis Energy
Karāpiro Gate Replacement
As part of Mercury’s ongoing Hydro Rehabilitation Project, we were engaged to install three new intake gates and a new hydraulic operating system at their Karāpiro site. We were approached to offer a turnkey solution that could accommodate 45t gates.
Led by AEC, the PropellWorks team successfully installed the first two gates, adhering to industry-leading tolerances. As of 2025, we are working to embed the third unit’s steelworks.
As an ongoing, multi-year project, a stable skilled site team with Hydro experience is proving invaluable. Our combination of resources provides a team that satisfies all Mercury’s needs.
”AEC have now fully installed the 1st and 2nd gate with excellent success as we had to adhere to industry-leading tolerances. Presently we are working on the 3rd unit’s embedded steelworks which is critical for the smooth operation of the gate.”
Bede G
Senior Project Manager
Mercury Energy
Terminal Expansion
CMS worked on the Terminal Expansion at the Stolthaven site at the Port of Tauranga from September 2019 through to its completion in August 2020. The chemical storage site is a hazardous facility, with flammable fumes in areas around the site.
Robust Health and Safety processes were essential. There were separate inductions, and extra permitting required to work in the hazardous areas, and these were strictly enforced.
CMS was contracted to fabricate, install and test all the chemical lines to B31.3 standard, install all free-issue mechanical equipment (pumps, valves etc), fabricate and install all service lines and fabricate and install pipe bridge, pipe supports and walkways to the appropriate standards. The period of the project included the height of the pandemic lockdowns in New Zealand. CMS adapted quickly to put the necessary processes in place to be able to work in a Level 3 COVID lockdown alongside other contractors.
A month was lost to the Level 4 lockdown, but once work was underway again, the project was accelerated to meet a specific deadline - a ship with chemicals that had to be unloaded to a timeframe. We met the deadline, finishing on time and on budget, excluding variations and acceleration costs, with zero LTI.
“Working with CMS has been a hassle-free and professional experience. Needing a well-trained and experienced contractor to work on an expansion project for a major hazard facility, CMS offered what we needed and finished on time and budget."
Sam C
Project Manager
Stolthaven Terminals
Project Basalt (Winstone Wallboards)
Project Basalt was completed in September 2023. The project involved a base build, contracted to Fletcher Building, and a plant and equipment install, that was contracted to a Canadian plasterboard equipment specialist, Gypsum Technologies.
CMS was the lead mechanical installer for Gypsum Technologies. We were responsible for the plant installation as well as the associated ducting, piping and accessways.
In addition to installing the main plant, we assembled and installed all flatpack items. We also fabricated cyclones, the kettle jacket and various other items of plant off-site and transported them from our workshop to the Tauriko site.
At the project’s peak, we had 64 employees on-site and we worked closely with the Fletcher Building team to deliver an exceptional safety record. Over a 22-month period, we supplied over 100,000 man-hours with a zero LTI and a TRIFR of 4.86 for the project.
"The Tauriko plant and equipment install was by no means a straightforward build. It involved massive amounts of collaboration, planning and interface with base build contractors, which CMS managed well.”
Karl T
Health and Safety Manager
Winstone Wallboards
Maintenance and Shutdown Services
We perform regular maintenance for Ballance Agri-Nutrients at their two Mt. Maunganui sites. Both sites are highly hazardous with the presence of dangerous chemicals.
When turnaround shutdown work has been scheduled we’ve delivered excellent results for Ballance. We take an agile and proactive approach to ensure we complete the work required in the specified timeframe. Experience has taught us that communication is key. We treat our customers as partners and our partnership with Ballance has allowed us to quickly and effectively deal with challenges such as emergent work. Together we plan for contingencies and access to resources when needed - the bonus: PropellWorks has one of the most critical resources available in-house - experienced and reliable labour that allows us to deliver consistently outstanding results.
In the past Ballance Agri-Nutrients have also engaged us to perform a scheduled turnaround shutdown at their Kapuni site in Taranaki.
“Contract Mechanical Services showed significant innovation, and a focus on ensuring Ballance Agri-Nutrients had a better product and a safer installation, through their early engagement with us.”
Neil T
Project Manager
Ballance Agri-Nutrients
Steel Rectification
Our SCS team is the preferred contractor of OceanaGold at their Waihi Gold Mine site for the rectification of steelwork at the Baxter Road water treatment plant. The plant requires a major refurbishment of aged equipment to elongate the lifespan of the site. SCS manage the onsite blasting and coating of equipment, loader discharge pipes and tanks. The team also provides ongoing maintenance works for the Baxter Road site.
The SCS team is responsible for:
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Project planning and management
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Site Safety
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Site management
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Blasting and coating
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Meeting shutdown timeframes
“SCS impresses with their attention to detail and professionalism. Random task observations are part of our compliance control legislation and the SCS team are well above standard. The team is industrious, punctual, and follows instructions well. I am happy to outline task requirements and leave them to it knowing the job will be completed in a timely manner and to a high standard.”
Shannon H
Maintenance Planning Specialist
OceanaGold
Transmission Line Work, Substation, and Maintenance Services
In 2020, at the start of the COVID lockdown, we played a critical role in repairing Transpower’s storm-damaged Direct Current link from the Haywards substation in Wellington to Lake Benmore in the South Island.
We have experience and expertise in building high voltage electrical switchgear. In the past, we have fabricated high voltage equipment stands for Transpower substations, as well as built transmission pylons, manufacturing the parts and equipment.
We researched and developed the construction of Parallel Body Extensions for Transpower towers. We now manufacture and supply these nationwide.
We also provide Transpower’s service providers (Omexom, Downer, Ventia, Northpower, and others) with fabricated items to comply with Transpower’s strict specifications.
"AEC is consistently driven to deliver a high quality, well-finished product within the timeframes provided. Their internal review and QA process with client checks means equipment meets specification parameters allowing for ease of install without delay. AEC have proven themselves, and excel as a go-to for short notice critical works with good outcomes under constrained circumstances.”
Robyn B
Grid Project Project Manager