Our Projects Engineering excellence

Explore our case studies to see how we bring ambitious engineering visions to life across our capabilities.

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Contract Manufacturing

Blue Pacific Minerals, Tokoroa

To successfully launch its Tokoroa facility, Blue Pacific Minerals needed equipment that could support safer, faster, and higher-quality liquid fertiliser production. Contract Manufacturing | Mining

To successfully launch its Tokoroa facility, Blue Pacific Minerals needed equipment that could support safer, faster, and higher-quality liquid fertiliser production.

Having been crowned as the category winner in SCNZ Exellence in Steel Construction in 2024, the architecturally stunning 71m-long pedestrian and cycling bridge is a prominent gateway (waharoa) to the new Waikato River crossing. Projects | Civil Engineering

Projects

Pedestrian Cycle Bridge, Auckland

An award-winning project constructing the Canada Street Cycle Bridge. The 160m Cycle Bridge links Canada Street in the Auckland CBD to the old Nelson Street Offramp in the central motorway junction. Projects | Civil Engineering

An award-winning project constructing the Canada Street Cycle Bridge. The 160m Cycle Bridge links Canada Street in the Auckland CBD to the old Nelson Street Offramp in the central motorway junction.

Hawkins Infrastructure Ltd

Point Resolution Rail Bridge

Fabrication of the structural elements for the Point Resolution Bridge Project. The project was initiated by the principal, Auckland Council, due to the advanced state of corrosion and structural degradation to the existing footbridge. Projects | Civil Engineering

Downer – Kiwirail

Rotokauri Hub Pedestrian Rail Bridge

Bridge over rail lines with access ramps and stairs down to platforms. Walk through lattice truss structure with SHS members and aluminium panel balustrades. Projects | Civil Engineering

Bridge over rail lines with access ramps and stairs down to platforms. Walk through lattice truss structure with SHS members and aluminium panel balustrades.

Hamilton City Council

Hamilton Water Treatment Plant

PFS spooled all the piping while the civil works were being constructed, and then moved to site to install. Maintenance | Waste and Water

PFS spooled all the piping while the civil works were being constructed, and then moved to site to install.

OJI Fiber Solutions

Tasman Evaporator III

3 large pressure vessels were installed on seismic pedestals accessed by stairs and walkways to all levels with extensive Stainless and Carbon Pressure Piping. Maintenance | Pulp & Paper

3 large pressure vessels were installed on seismic pedestals accessed by stairs and walkways to all levels with extensive Stainless and Carbon Pressure Piping.

Fonterra

Fonterra Waitoa - D3 Dehumidification Ducting

Fabricate and install large diam ducts, during Covid Lockdown, for Waitoa Dairy factory upgrade of their Dehumidification Process Plant. Projects | Dairy

Fabricate and install large diam ducts, during Covid Lockdown, for Waitoa Dairy factory upgrade of their Dehumidification Process Plant.

MADE Market Spiral Staircase

The Made Market Spiral Stairway is a standout architectural element, seamlessly connecting the dining deck on level 3 with "The Sheds," a dynamic space housing art studios, a coffee roastery, and a boutique restaurant. The stairway’s aesthetic is both distinctive and impactful, characterized by its elegantly curved facade that tapers into the central column, evoking the appearance of fluted glass. This design not only adds a striking visual appeal but also harmonizes with the eclectic character of the surrounding environment, enhancing the overall experience for visitors. Projects | Civil Engineering

Fonterra

Fonterra Hautapu - Stainless Boiler Stack

PFS was engaged to deliver a turnkey solution for the complete replacement of the Steam Boilers 1 and 2 stack, based on the design provided by Dobbie Engineering. The project scope included the safe removal and disposal of the existing stack, followed by the full supply, fabrication, and installation of a new 27m stainless boiler stack system. Our team managed all aspects of the project from start to finish, ensuring compliance with engineering specifications and seamless integration with existing plant infrastructure. Projects | Dairy

Oji Kinleith

Oji Kinleith - SC01 Tank

PFS was engaged to provide a complete turnkey solution encompassing the design, fabrication, and installation of three stainless steel storage vessels. Projects | Pulp & Paper

PFS was engaged to provide a complete turnkey solution encompassing the design, fabrication, and installation of three stainless steel storage vessels.

Contact Energy

Te Mihi Steam Dump Manifold

Main steam dump for the Te Mihi Geothermal Power Station for Contact Energy. Contract Manufacturing | Power & Energy

Main steam dump for the Te Mihi Geothermal Power Station for Contact Energy.

Hawkins Infrastructure Ltd

Grafton Gully Bridge

Award-winning cycle bridge at Auckland University. This bridge was designed to be an aesthetically interesting centrepiece to the cycleway project through Grafton Gully. Spanning a 20m gully with a 4m North-South fall, the bridge was developed as an ‘S’ Bend design with a constant fall of 10 degrees. Projects | Civil Engineering

NZ Steel

NZ Steel KOBM Skirt Replacement

NZ Steel traditionally procured this sort of work from Europe. By getting us to do the work, the lead time was significantly reduced. Projects | Power & Energy

NZ Steel traditionally procured this sort of work from Europe. By getting us to do the work, the lead time was significantly reduced.

Golden Bay Cement

Golden Bay Cement Silos

Detailed design, fabrication and installation of new silos was completed as part of a comprehensive new unloading, storage and dispatch facility build for Golden Bay Cement in Auckland. Projects | Mining

Detailed design, fabrication and installation of new silos was completed as part of a comprehensive new unloading, storage and dispatch facility build for Golden Bay Cement in Auckland.

OJI Fibre Solutions

OJIFS CD2 Flash Cyclone

Install of a new Stainless-Steel Flash Cyclone and Piping spools during the annual shutdown in March 2019. Maintenance | Pulp & Paper

Install of a new Stainless-Steel Flash Cyclone and Piping spools during the annual shutdown in March 2019.

Link Alliance

CRL Normandy Temporary Services Bridge

A temporary walk-through truss bridge was constructed for the CRL project to carry services and provide access over the rail line under construction. Projects | Civil Engineering

A temporary walk-through truss bridge was constructed for the CRL project to carry services and provide access over the rail line under construction.

Balance Agri Nutrients

Ballance Te Awamutu Dispatch Plant

Projects | Mining

Genesis Energy

Huntly E3P Condenser

Condenser supply, manufacture and installation. The condenser comprised of 8 modules - Side A and B tube modules, A and B inlet/outlet water boxes, A and B return water boxes, steam inlet trunk and water outlet sump. Projects | Condensers

Miraka Milk Powder Plant

Miraka Pipe Bridge & Steam Piping

Shop fabricate and install the pipe bridge and steam piping. Projects | Dairy

Shop fabricate and install the pipe bridge and steam piping.

Ballance Agri-Nutrients

Ballance Condenser Retube

Tubes in existing condenser had thinned and had to be replaced. Maintenance | Power & Energy

Tubes in existing condenser had thinned and had to be replaced.

Origin Energy

KUPE LNG Plant - Pressure vessels

Projects | Power & Energy

OJI Fibre Solutions

Surface Condenser Replacement

Fabricated a condenser casing around the Lamella plate assembly so that the old unit could be removed and replaced during the Nov 2019 shut. Maintenance | Pulp & Paper

Fabricated a condenser casing around the Lamella plate assembly so that the old unit could be removed and replaced during the Nov 2019 shut.

Flovac

Flovac Vessel

Design and fabricate Vacuum Vessel for Flovac. Contract Manufacturing | Waste and Water

Design and fabricate Vacuum Vessel for Flovac.

Winstone Aggregates

Whitehall Quarry Primary Aggregate Bin

The fabrication and installation of a 25-tonne primary aggregate bin for Winstone at the Whitehall Quarry. Projects | Mining

The fabrication and installation of a 25-tonne primary aggregate bin for Winstone at the Whitehall Quarry.

Genesis Energy

Huntly Condensate Water Polishing Plant

Genesis Power condensate polishing plant for water treatment in condenser boiler loop. Capability | Waste and Water

Genesis Power condensate polishing plant for water treatment in condenser boiler loop.

Energy for Industry

Washdyke Energy Centre

Steam lines from a energy plant to a number of different industrial processing sites. Maintenance | Power & Energy

Steam lines from a energy plant to a number of different industrial processing sites.

Genesis Energy

Huntly Precipitation Plant Lids

Lids on top of precipitator on huntly power station had baddly corroded. Capability | Power & Energy

Lids on top of precipitator on huntly power station had baddly corroded.

Dealers for 20-50t Diggers

Bush Rigs Project

Design, fabrication, installation and 'readiness for forest' for brand new excavators going straight into forestry operation. Forestry | Forestry

Design, fabrication, installation and 'readiness for forest' for brand new excavators going straight into forestry operation.

Carter Holt Harvey

Carter Holt Harvey no.2 Recovery Boiler Upgrade

Manufacture and installation of the superheater and screen tubes for the No 2 recovery boiler upgrade for Carter Holt Harvey Pulp & Paper. Maintenance | Pulp & Paper

Manufacture and installation of the superheater and screen tubes for the No 2 recovery boiler upgrade for Carter Holt Harvey Pulp & Paper.

Veolia Water Solutions and Technologies

Pluto Onshore LNG Demin Water Plant

Supply, fabrication, assembly and testing of skid based Deminerlised Water Treatment Plant to the Onshore Pluto LNG site, Woodside Burrup PTY Ltd. Capability | Waste and Water

Supply, fabrication, assembly and testing of skid based Deminerlised Water Treatment Plant to the Onshore Pluto LNG site, Woodside Burrup PTY Ltd.

Veolia Water Solutions and Technologies

Worsley Multi-Fuel Cogen Project-Condensate Treatment Plant

This project included the supply, fabrication, assembly and testing of a skid-based Condensate Treatment plant for the Worsley Multi-Fuel Cogen Project in Collie, WA. Maintenance | Waste and Water

This project included the supply, fabrication, assembly and testing of a skid-based Condensate Treatment plant for the Worsley Multi-Fuel Cogen Project in Collie, WA.

Siemens Pty

Huntly Condenser Module Replacement

Siemens Energy Pty engaged PFS Engineering to design, develop, and implement a full skidding arrangement to remove and replace two 60t condenser modules for three Huntly Power Station generation units. Maintenance | Power & Energy

Carter Holt Harvey

Kinleith #8 Boiler

The generating bank repair required the cutting out and removal of tubes and replacement. Maintenance | Pulp & Paper

The generating bank repair required the cutting out and removal of tubes and replacement.

Orica

Orica Mixed Bed Skid

Water treatment skid for Oricas plant in Sydney. Project | Waste and Water

Water treatment skid for Oricas plant in Sydney.

Sunshine Electricity

Condong & Broadwater Condensers

Sunshine Electricity chose us to build them condensers for a Sugar mill biomass cogeneration water plant. Capability | Condensers

Sunshine Electricity chose us to build them condensers for a Sugar mill biomass cogeneration water plant.

CRS Industrial Water Treatment Systems

CRS Water Treatment Skids

Fabricated 18 Skids for CRS Industrial Water Treatment System's Gorgon LNG Plant on Barrow Island, Australia. Contract Manufacturing | Waste and Water

Fabricated 18 Skids for CRS Industrial Water Treatment System's Gorgon LNG Plant on Barrow Island, Australia.

Fonterra

Fonterra Boiler Auxiliary Installation

Fonterra's Heat Recovery Boiler in Te Awamutu failed which contributed to the plant having to shut down. We urgently manufactured and installed a temporary 20m stack for the relocated boilers. Contract Manufacturing | Industry

Fonterra's Heat Recovery Boiler in Te Awamutu failed which contributed to the plant having to shut down. We urgently manufactured and installed a temporary 20m stack for the relocated boilers.

Inghams

SS Conveyors for Poultry Plant

Designed and fabricated conveyors to fit into the existing Inghams Poultry Plant food processing line and Building. Contract Manufacturing | Food Processing

Designed and fabricated conveyors to fit into the existing Inghams Poultry Plant food processing line and Building.

Australian Paper

Australian Paper Economiser Refurbishment

Refurbishment work was carried out on the Economiser during a factory shut at Australian Paper. There have been several factory shuts where this work and other work has been completed for Australian Paper. Capability | Pulp & Paper

Australian Paper

Australian Paper Evaporater Gas Duct

Replaced the existing gas duct to the Evaporator during a factory shut at Australian Paper. Maintenance | Pulp & Paper

Replaced the existing gas duct to the Evaporator during a factory shut at Australian Paper.

Fletcher Construction

Cradle for Tunnel Boring Machine SH20

Fabrication of a purpose-designed cradle to support the TBM – ‘Alice’ before she commenced tunnel boring. Contract Manufacturing | Civil Engineering

Fabrication of a purpose-designed cradle to support the TBM – ‘Alice’ before she commenced tunnel boring.

Genesis Energy

Mangaio Mini Hydro

Fabricated in-house and installed onsite the mechanical components for the tunnel plug, penstock pipes, bifurcation and outfall transition during a planned outage to the Genesis Energy Mini Hydro Scheme in Mangaio. Maintenance | Power & Energy

SLN

SLN Ducting

Fabricated and shipped large heavy ducts for process upgrade to a nickel plant. Maintenance | Mining

Fabricated and shipped large heavy ducts for process upgrade to a nickel plant.

Electrix

Gas Piping

Gas piping and supports for the Gas Network , including gas lines over bridges. Maintenance | Power & Energy

Gas piping and supports for the Gas Network , including gas lines over bridges.

Veolia Water Solutions & Technologies Pty Ltd

McKee Water Treatment Plant

Installation of Reverse Osmosis and Demineralisation skids, potable water plant and associated PVC piping for Todd Energy’s McKee Peaker Plant. Capability | Waste and Water

Installation of Reverse Osmosis and Demineralisation skids, potable water plant and associated PVC piping for Todd Energy’s McKee Peaker Plant.

GEA Processing

Holding Tube Pipes

Manufacture of Holding Tubes & Framework for GEA's Processing Factory. Maintenance | Dairy

Manufacture of Holding Tubes & Framework for GEA's Processing Factory.

Contact Energy

Wairakei Bio Reactor

Fabrication and installation of pump tubes and delivery pipes to a Contact Energy Bio-Reactor which uses sulphur oxidising bacteria to remove up to 80 per cent of hydrogen sulphide. Maintenance | Power & Energy

Fabrication and installation of pump tubes and delivery pipes to a Contact Energy Bio-Reactor which uses sulphur oxidising bacteria to remove up to 80 per cent of hydrogen sulphide.

Yashili Dairy Factory

Yashili Pipe Bridge

Full fabrication set of drawings as well as assembly and installation were completed after design for the pipe bridge was handed over by Babbage. Projects | Dairy

Full fabrication set of drawings as well as assembly and installation were completed after design for the pipe bridge was handed over by Babbage.

Fonterra

Dairy Manifolds

Fabrication of manifolds that were installed on-site and connected to a specialist process plant. Maintenance | Dairy

Fabrication of manifolds that were installed on-site and connected to a specialist process plant.

Contact Energy

Wairakei Western Borefield

Main contractor to Contact Energy for the Western Borefield Project, in which two new geothermal production wells and one reinjection well were connected to Contact Energy steam lines. Projects | Power & Energy

Main contractor to Contact Energy for the Western Borefield Project, in which two new geothermal production wells and one reinjection well were connected to Contact Energy steam lines.

PFS Customised Cabinetry

As well as our range of electrical enclosures we build & design to customers' requirements to suit all food, dairy & industrial application. Contract Manufacturing | Industry

As well as our range of electrical enclosures we build & design to customers' requirements to suit all food, dairy & industrial application.

Inghams Enterprises

Whole Bird Injector Conveyors

Contract Manufacturing | Food Processing

OnGas for Vector

Springhill LPG Vessel

OnGas horizontal bullet vessel at Springhill prison was able to contain more gas than was consented. The vessel had to be reduced in size. Maintenance | Power & Energy

OnGas horizontal bullet vessel at Springhill prison was able to contain more gas than was consented. The vessel had to be reduced in size.

Custom Product for Dairy Food Processing

Dairy Processing

Design & Manufacture of Food Processing Equipment. Design | Dairy

Design & Manufacture of Food Processing Equipment.

Tetrapak

SS Platforms for Dairy and food processing

New platforms for Tetrapak for a Fonterra Diary Plant in South Island. Maintenance | Dairy

New platforms for Tetrapak for a Fonterra Diary Plant in South Island.

Contact Energy

Te Rapa Boiler

Maintenance works for Contact Energy's Energy Plant at Te Rapa Diary factory during annual shut. Maintenance | Dairy

Maintenance works for Contact Energy's Energy Plant at Te Rapa Diary factory during annual shut.

GEA

Fonterra Lichfield Steam and Condensate piping system

Worked with GEA to install a full high and low-pressure steam system into Fonterra Lichfield’s new dryer facility in South Waikato from October 2015 till June 2016. Projects | Dairy

Worked with GEA to install a full high and low-pressure steam system into Fonterra Lichfield’s new dryer facility in South Waikato from October 2015 till June 2016.

Fulton Hogan

Steel form – AMETI Bridge Pier

Steel form for AMETI bridge – unique shape with all surfaces curved in 3 dimensions. Projects | Civil Engineering

Steel form for AMETI bridge – unique shape with all surfaces curved in 3 dimensions.

Wairakei Powerstation

Non-Combustable Gas Upgrade

Wairakei Powerstation removed non-combustable gas from their condensers using a steam system. The project was to upgrade the system, thereby using the steam to generate more power. Maintenance | Power & Energy

Wairakei Powerstation removed non-combustable gas from their condensers using a steam system. The project was to upgrade the system, thereby using the steam to generate more power.

OJI Fibre Solutions

Kinleith September Shut 2016 - 1st and 4th Effect Replacement Evaporator 5

During the September shut in 2016 we were engaged by OJI to complete the 4th effect shell and 1B lamella replacement. We had a strict deadline of 11 days to complete the work. Maintenance| Pulp & Paper

During the September shut in 2016 we were engaged by OJI to complete the 4th effect shell and 1B lamella replacement. We had a strict deadline of 11 days to complete the work.

OJI Fibre Solutions

OJI Fibre Evaporators

During the September shut in 2016, we were engaged by OJI Fibre Solutions to complete the 4th effect shell and 1B lamella replacement. We had a strict deadline of 11 days to complete the work. Maintenance | Pulp & Paper

During the September shut in 2016, we were engaged by OJI Fibre Solutions to complete the 4th effect shell and 1B lamella replacement. We had a strict deadline of 11 days to complete the work.

Tatua Dairy Company

Tatua Waste Water holding tanks

Upgraded Tatua Dairy Plant's waste water system. Fabricated 2 # stainless steel Holding tanks. Maintenance | Waste and Water

Upgraded Tatua Dairy Plant's waste water system. Fabricated 2 # stainless steel Holding tanks.

Laminex

Laminex Board Plant - Resin Lines & Vessels

Relocated Laminex's resin lines and vessels into a new line at their Auckland Board plant. Maintenance | Pulp & Paper

Relocated Laminex's resin lines and vessels into a new line at their Auckland Board plant.

Ballance Agri-Nutrients

Ballance Waipukurau Dispatch Plant

Ballance Waipukurau Dispatch Plant Upgrade. Maintenance | Industry

Ballance Waipukurau Dispatch Plant Upgrade.

Ballance

Fertco Flail Mill

Specialist design and fabrication of a new mill to replace the crusher roller used to process fertilizer into a finer more consistent size by removing lumps. Contract Manufacturing | Industry

Specialist design and fabrication of a new mill to replace the crusher roller used to process fertilizer into a finer more consistent size by removing lumps.

Inghams

Platforms to Inghams Feedmill

Close to Ruakura, Inghams have several grain silos to process and store feed for their facilities in the Waikato. The access platforms and stairs to these silos were improved. Maintenance | Industry

Close to Ruakura, Inghams have several grain silos to process and store feed for their facilities in the Waikato. The access platforms and stairs to these silos were improved.

GEA

Horotui Steam and Condensate Piping

Fabricated and installed steam and condensate piping to the new Open Country Dairy dryer plant facility while being built at Horotui. Maintenance | Dairy

Fabricated and installed steam and condensate piping to the new Open Country Dairy dryer plant facility while being built at Horotui.

Evonik Peroxide Limited

Evonik De-Bottlenecking Project

There was a bottleneck in the process plant producing peroxide. The solution was to increase the size of the two peroxide pressure vessels. Maintenance | Power & Energy

There was a bottleneck in the process plant producing peroxide. The solution was to increase the size of the two peroxide pressure vessels.

Miraka

Steam & Air Piping Upgrade

Miraka milk powder plant upgrade work. Maintenance | Dairy

Miraka milk powder plant upgrade work.

Bishop Construction

Napier Tank Farm - Fire System Upgrade

Spooled galvanised piping for the Fire System on the Napier Tank Farm. Maintenance | Dairy

Spooled galvanised piping for the Fire System on the Napier Tank Farm.

OJI Fibre Solutions

Kinleith #5 Recovery Boiler

In a shut in November 2019, refurbishment work on the #5 Recovery Boiler, Superheater. Also worked on the #8 Primary Boiler. Maintenance | Pulp & Paper

In a shut in November 2019, refurbishment work on the #5 Recovery Boiler, Superheater. Also worked on the #8 Primary Boiler.

OJI

Kinleith #4 Recovery Boiler

Cut out existing airports and replaced with straight tubes. Maintenance | Pulp & Paper

Cut out existing airports and replaced with straight tubes.

OJI Fibre Solutions

Kinleith #8 Primary Boiler

PFS has for years during the annual shuts done refurbishment work on the OJI boilers. In the shut in late 2019 PFS worked on both the #8 Primary Boiler and the #5 Recovery boiler. Maintenance | Pulp & Paper

PFS has for years during the annual shuts done refurbishment work on the OJI boilers. In the shut in late 2019 PFS worked on both the #8 Primary Boiler and the #5 Recovery boiler.

Carter Holt Harvey

Tasman #2 Recovery Boiler

PFS Manufactured and installed a super heater and screen tubes for the No.2 Recovery Boiler upgrade. Maintenance | Pulp & Paper

PFS Manufactured and installed a super heater and screen tubes for the No.2 Recovery Boiler upgrade.

Tetrapak

Powder Bins

Capability | Dairy

Fletcher Wood Products

Cyclone Project – Taupō, New Zealand

PFS Engineering was engaged to manufacture 13 large-scale material-sorting cyclones for Fletcher Wood Products, supporting the new Laminex wood panel manufacturing line in Taupō. Contract Manufacturing | Engineering

PFS Engineering was engaged to manufacture 13 large-scale material-sorting cyclones for Fletcher Wood Products, supporting the new Laminex wood panel manufacturing line in Taupō.

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Our Projects Engineering excellence