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Portfolio | General Engineering
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 General Fabrication- Case Studies
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- Over the past 30 years, Windsor has often embarked upon projects which have not traditionally been considered within our scope of experience. As with all our projects, our reputation for delivering on time, every time a winning solution allows our engineering team to continue offering a wide range of services.
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General Fabrication
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Our engineering capabilities include:
Pressure Vessel design to AS1200, AS1210, OSH Code of Practice for Pressure Equipment
Pressure piping design to AS4041, ASME B31.3
Structural design to AS1170, AS 4100, NZ 3404, AS 1664 (Alum)
Finite Element Analysis - Cosmos Works
Structural Frame Analysis Spacegass
7 BE qualified engineers (Mech, Elec) (1 CPEng, 3 Registered), 2 NZCE
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- And our design capabilities include:
Draughting / Design AutoCAD 2010 - Solid Modeling Solidworks & ProEngineer
3 NZCE qualified designers plus 3 Industry experienced designers
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Our fabrication capabilities include:Fully equipped factory of 20-30 trade staff.
| Floor area: |
2500m2 with an additional 3000m2 secure yard space |
| Materials: |
Carbon and stainless (austenitic, ferritic and duplex) steels, 5000 and 6000 series aluminium |
| Lifting: |
3 x 5 tonne overhead cranes, max working height (2 x 8.0m, 1 x 4.5m underhook) |
| Guillotine: |
6 mm x 3.6m mild steel, 3 mm x 3.6m stainless steel |
| Folding: |
4.8m CNC Press brake - 220 tonne. |
| Welding: |
MIG / TIG / MMAW |
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Carbon Steel, Stainless steel (including Duplex), Aluminium |
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Pressure vessel and piping welding to AS3992, ASME 9 |
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Structural steel welding to NZS 4711, AS1554 |
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Aluminium welding to AS 1665 |
| Turning: |
Centre lathes, maximum swing 400 mm over bed, 1000mm in gap, 3000 mm between centres |
| Milling: |
Cincinnati universal, dividing head/table Surface and cylindrical grinding |
| Plasma: |
2 m x 6 m bed strong>| 16 mm max mild steel strong>| 12 mm max stainless steel / aluminium holes in pipe and beams |
| Rolling: |
10 mm MS x 2 m |
Case Studies
 Heat Exchangers
Noise Control
Design and Build
Curing and Drying Chambers Sheep Washers
Case Study - Heat Exchangers
Problem: Fonterra decision to replace their heatplants with new 40 barg boilers meant that they would need a reliable New Zealand supplier for replacement heat exchangers.Solution: Windsor designed and built new stainless steel coils and the associated high-pressure pipe work.
Other applications: Windsor has used this technology to build similar heat exchangers for fibre dryers, process heating systems and heat dumps, as well as for energy recovery from waste heat streams.
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Case Study - Noise Control
Problem: Transfield Worley needed an acoustically silenced ventilation system for two compressor stations on a gas field. The compressors were inside a building and were very noisy. The pumps also generated a lot of heat, so Transfield Worley needed a ventilation system that would keep the building cool while minimising noise emissions on the site. Safety and reliability were primary concerns for this design.
Solution: Windsor designed and manufactured a ventilation system that met all of the requirements for the site.
Other applications: Windsor has used this technology for acoustic screens for condensers at Haywards sub-station and for acoustic enclosures for noisy machines and operator control rooms.
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Case Study - Design and Build
Opportunity: With the introduction of a new Inter-island ferry, Centreport needed to quickly install a new passenger gangway.
Solution: Windsor designed and built a new ferry gangway with a section that telescopes out and can pivot vertically and slew sideways. This involved extensive co-operation with companies building other parts of the project as well as managing subcontractors to deliver the gangway to a very tight timeframe.
Other applications: Windsor has applied this technology to a variety of other applications including a machine to cut cigarette filters, a vacuum cleaner that cleans a bus from the front doorway, and light traps to reduce beetle infestation at pulp mills
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Case Study - Curing and Drying Chambers
Problem: A Wellington battery manufacturer needed a large scale curing oven to make lead oxide battery plates. These are made of a special paste, supported by a moulded frame, and must be cured in a carefully controlled atmosphere to achieve the necessary quality standards.
Solution: Windsor provided a solution to meet the client's particular needs. A special cart-loaded curing chamber was designed and built, complete with heating, humidification and control systems necessary for controlled atmosphere curing. The finished product meets all the client's quality and performance needs.
Other applications: Windsor has subsequently used this technology to design a drying chamber for electric traction motor windings, and steaming chambers for Humes of Te Rapa for curing concrete pipes.
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Case Study - Sheep Washers
Problem: Klenzion had developed a patented stock washing system that improved visual cleanliness, reduced bacterial counts and used less water than existing stock-washing systems. They needed someone to develop this into a reliable commercial solution so they teamed up with Windsor in 2003.
Solution: Windsor developed the machine that automatically conveys sheep through a wash tunnel where specially placed nozzles firstly wash off the high levels of organic matter and then rinse each animal clean with potable water. Windsor also assisted with marketing the system.
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