High-Accuracy As-Built Capture for CHPP Wash Plants, Coal Handling & Heavy Industry
Emerald and the Bowen Basin are home to some of Queensland’s busiest and most demanding coal-handling and processing facilities. With aging infrastructure, tight shutdown windows, and constant production pressures, accurate site information is critical.
Hamilton By Design provides precise 3D laser scanning to CHPP wash plants, prep plants, conveyors, transfer towers, pump stations, structural frames and pipe networks throughout Emerald and the surrounding mining regions.
Our goal is simple:
Eliminate tape-measure guesswork and deliver millimetre-accurate, fabrication-ready data for every upgrade, repair and shutdown.
Why CHPP Wash Plants in Emerald Need 3D Laser Scanning
CHPP facilities are complex, congested and constantly changing. When engineers or contractors rely on tape measures, handwritten notes or rough sketches, the risk of error is extremely high.
This often leads to:
- Components not fitting during installation
- Bolts or flange centres misaligned
- Pipes being the wrong length
- Chutes or liners fouling on existing steelwork
- Rework during shutdowns
- Lost production hours
- Costly on-site modifications by fitters and boilermakers
In coal processing, even small dimensional errors quickly become big operational headaches.
3D laser scanning removes these risks entirely.
The Problems With Tape-Measure Field Measurement
Traditional measurement methods struggle in CHPP environments:
1. Human Error
Heat, dust, noise, confined spaces and poor visibility create inaccuracies.
2. Inconsistent Reference Points
Different people measure from different spots — results vary every time.
3. No True Geometry Capture
Angles, offsets, diagonals and complex mating surfaces are almost impossible to measure with a tape.
4. Difficult or Unsafe Access
Platforms, hoppers, overhead conveyors, vibrating screens and sumps often require working at heights or around operational machinery.
5. No Digital Record
Paper notes get lost, damaged, or misinterpreted.
3D scanning gives you a permanent digital asset.
The result?
Tape measurements introduce errors so large they can jeopardise an entire shutdown.
How 3D Laser Scanning Solves These Problems
Hamilton By Design uses high-accuracy FARO Focus LiDAR scanners to capture millions of real-world points in minutes.
Benefits for CHPP and Coal Handling Facilities
- Millimetre-level accuracy of all structures, machinery, and clearances
- Capture large areas quickly — even during partial operation
- Improved safety — most scanning is done from the ground
- True geometry of chutes, screens, pumps, frames and conveyors
- Reduced shutdown time by ensuring parts fit the first time
- Perfect data for reverse engineering and redesign
- Digital twins for planning future upgrades
- Better contractor communication using real 3D models
- No need to revisit site to re-measure
The scan becomes your “source of truth” for all engineering decisions.
Applications of 3D Scanning in Emerald CHPP & Coal Handling
Chute, Hopper & Diverter Redesign
Capture accurate geometry of wear areas, impact zones and constrained spaces.
Conveyor & Transfer Tower Upgrades
Scan head pulleys, take-ups, guards, floors, beams, stringers and chutes.
Pipe Spools & Pump Stations
Produce correct spool lengths, flange positions and alignment geometry.
Structural Platforms & Walkways
Verify fitment before steel fabrication.
Screen & Crusher Areas
Capture high-vibration, difficult-to-access zones safely.
Shutdown Planning & Digital QA
Scan new components before shipping and confirm exact fit before installation.
Scan-to-CAD for Engineering & Fabrication
Your scanned site can be converted into:
- SolidWorks 3D models
- Fabrication-ready drawings
- Layout & GA models
- BOMs and take-offs
- Navisworks models for clash detection
- Digital twins for future maintenance
No more “hope it fits” — we deliver data you can trust.
Why Mining Companies in Emerald Choose Hamilton By Design
- Deep experience with CHPP wash plants, conveyors and coal handling systems
- Rapid mobilisation to Emerald and Bowen Basin sites
- Precise, millimetre-accurate digital capture
- Clean, fabrication-ready models for contractors and workshops
- Reduced shutdown risk and rework
- Practical engineering knowledge, not just scanning technology
- 3D scanning + mechanical/structural engineering under one roof
We work with maintenance crews, shutdown coordinators, engineering managers, fabricators and OEM suppliers to ensure every upgrade, repair or replacement fits perfectly the first time.
Book 3D Laser Scanning in Emerald
If your CHPP or coal handling operation needs accurate measurement for a chute redesign, conveyor upgrade, pump station modification or shutdown preparation, Hamilton By Design is ready to deliver fast, precise and safe 3D scanning support.
Book a scan today or request a free project review.
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