Altus Aluminium

Altus Aluminium
Te Rapa, Hamilton, Waikato NZ
9 Months
OMAV aluminium extrusion line


Altus Aluminium sought Hennessy’s experience and expertise for the electrical installation of a new OMAV aluminium extrusion line at their Te Rapa Hamilton site. The project included a new main switch board to service the site’s offices, extrusion line, billet heaters, die ovens, compressors, cooling tower, overhead gantry, solar power supply, ageing ovens, ventilation, cooling quench, general purpose power and future power factor correction.

A flexible and agile approach was required to meet rapidly changing timeframes, to ensure the job could be completed to Altus deadlines. This agility was critically important due to a factory demolition date that could not be moved and shipping delays changing the date of equipment arrival and impacting on resourcing requirements.

Altus Extrusion Line Install
Altus Extrusion Line


With a lot of moving parts, our team needed to stay agile. We identified resourcing requirements and appropriate timing to ensure equipment being shipped from overseas, contractors and staff would line up and put in place a process that would speed up the installation to meet our tight deadline.

Using our team’s experience, we confirmed timeframes for key milestones, including the arrival of the mains transformer and working with WEL networks. We used a systematic approach to installation to allow the electrical components to be installed alongside the mechanical installation, undertaken by the team at DKJ welding services.

Working with a client who wanted to supply their own materials required flexibility and foresight. Being able to interpret the brief and supplied materials, our knowledgeable team were able to identify where componentry was missing, and our relationships with key providers meant we could source these quickly to deliver quality results for Altus’s needs in the future.

The delay in delivery of the press to site compounded many project timeframes, with an automation team from all different parts of the world due to arrive when certain project stages were reached. Our team had to manoeuvre statutory holidays, pulling in additional staff, and considered implementing night shifts to commit to deadlines and ensure Altus could have as limited downtime as possible while the build took place.


The OMAV extrusion line was designed and constructed on the other side of the world, so we navigated a raft of challenges, overcoming language barriers and time zones to ensure the line could meet NZ requirements on site.

We used the expert team at Industrial Switchboards Limited (ISL) to design, build and install the main switchboard on-site. The project required several considerations, including incoming load, fault current, load calculations and cable routes and lengths to sub-boards and auxiliary equipment.


Working amongst a team with a variety of experience levels, we teamed up people to work together through technical drawing and aspects of the job, with a separate team member verifying work to pick up any missing elements.

Once the main switchboard was installed by ISL, we used a separate temporary supply to make it live while we awaited the delivery of the transformer and ring main and switching gear, which was delayed by international shipping timeframes.

To make the most of the time, we moved onto installing services which would no longer be accessible once the plant was installed, and as the plant arrived, proceeded with installing the control boards and unloading containers.

We outsourced some of our cable flashing and guards to protect important components in high impact areas, which was carried out by our trusted local, experienced contractor, United Sheetmetals.

Space was at a minimum with the installation occurring alongside the mechanical installation completed by DKJ. Being able to share resources and knowledge across both teams was essential to installing the plant in a timely and efficient manner.


We delivered a quality industrial plant that will help Altux produce premium aluminium extrusions for New Zealand and the export market.

We are very proud to receive great feedback from the project manager at OMAV after navigating a challenging deadline, international suppliers, equipment delays, multiple on-site contractors, and sourcing materials at short notice.

All in a day’s work for the experienced team at Hennessy.

open quotes
Simone told me about the excellent job Hennessy is doing there, so far we are on line with our ambitious schedule. I think that would represent an absolute world record for the wiring operation for a 20 MN press.
Project Manager

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