Engineering-Led 3D Scanning for Brownfield Industrial Upgrades
Safer Shutdowns, Smarter Design, and More Done With Fewer Resources
Brownfield industrial upgrades are some of the highest-risk engineering activities in mining and heavy industry. Existing assets, live plant interfaces, limited access, and tight shutdown windows leave little room for error.
At Hamilton By Design, we deliver engineering-led 3D LiDAR scanning to support brownfield upgrades—providing accurate site data that enables safer design, efficient shutdown execution, and reliable outcomes when upgrading critical assets such as hoppers, chutes, pump boxes, conveyor transfers, and vertical shaft units.

Why Brownfield Upgrades Fail Without Accurate Site Data
Many brownfield failures trace back to the same root cause:
Design decisions made on assumptions, not reality.
Common issues include:
- Outdated or incomplete drawings
- Hidden interferences and undocumented modifications
- Restricted access for survey and measurement
- Time pressure during shutdowns
Engineering-led reality capture removes uncertainty before fabrication and installation begin.
Safety Starts Before the Shutdown
Safety in brownfield environments is largely determined during the design phase, not on site.
3D LiDAR scanning allows engineers to:
- Design modifications without repeated site access
- Reduce manual measurements in live plant areas
- Identify clashes and pinch points early
- Improve access, guarding, and maintainability outcomes
By reducing exposure hours and unplanned rework, scanning directly supports safer shutdown execution.
Typical Assets Upgraded in Brownfield Environments
Hamilton By Design supports upgrades to a wide range of industrial assets, including:
Hoppers & Chutes
- ROM hoppers
- Transfer chutes
- Surge bins
- Wear-prone interfaces
Conveyors & Transfer Stations
- Conveyor head and tail stations
- Transfer points
- Discharge transitions
- Supporting steelwork
Pump Boxes & Process Interfaces
- Pump boxes and sumps
- Pipework interfaces
- Structural supports
- Access platforms
Vertical Shaft & Drop Structures
- Vertical shaft hoppers
- Ore passes
- Gravity-fed transfer systems
These assets are often deeply integrated into existing plant, making accurate as-built data critical.
Engineering-Led Scan-to-CAD for Upgrade Design
Our scan-to-CAD workflows are built around engineering outcomes, not just visual models.
This includes:
- High-accuracy LiDAR capture of existing conditions
- Engineering-intent CAD modelling
- Design for fabrication and installation
- Clash reduction across mechanical and structural scopes
The result is buildable design that aligns with real-world constraints.
Reliable Support for Shutdown-Driven Projects
Shutdowns demand precision. There is no time for re-measurements or redesign on site.
Engineering-led 3D scanning supports shutdown success by:
- Allowing design to be completed well before shutdown
- Supporting pre-fabrication of steelwork and chutes
- Reducing RFIs and site queries
- Increasing the amount of work completed per shutdown
When time and labour are limited, better information delivers better outcomes.

Getting More Done With Fewer Resources
In today’s industrial environment, engineering teams are under pressure to:
- Do more with fewer people
- Reduce shutdown durations
- Control capital and maintenance costs
Accurate digital site data allows teams to:
- Minimise engineering rework
- Reduce site-based labour
- Improve coordination between disciplines
- Make confident decisions faster
Reality capture becomes a force multiplier, not just a documentation tool.
Australian Engineering Quality You Can Rely On
Hamilton By Design’s approach reflects Australian engineering standards and site experience.
We don’t just scan — we:
- Understand how plant is built and maintained
- Design with fabrication and installation in mind
- Take responsibility for engineering outcomes
This sets our work apart from low-cost capture services that leave risk unresolved.

Speak With an Engineer
If you’re planning a brownfield upgrade involving:
- Hoppers or chutes
- Conveyor transfers
- Pump boxes or sumps
- Vertical shaft or drop structures
- Shutdown-critical works
Hamilton By Design provides engineering-led 3D LiDAR scanning to support safer, more reliable brownfield upgrades.



























