How Smart Mechanical Strategies Extend CHPP Life

Every coal wash plant in Australia tells the same story: constant throughput pressure, harsh operating conditions, and the never-ending battle against wear, corrosion, and unplanned downtime. The reality is simple — if you don’t engineer for reliability, you’ll spend your time repairing failure.

At Hamilton By Design, we specialise in mechanical engineering, 3D scanning, and digital modelling for coal handling and preparation plants (CHPPs). Our goal is to help site teams transition from reactive maintenance to a precision, data-driven strategy that keeps production steady and predictable.

Design for Reliability — Not Reaction

Reliability begins with smart mechanical design. Poor geometry, limited access, and undersized components lead to fatigue and repeated downtime. Instead, modern CHPP maintenance programs start by engineering for fit, lift, and life:

• Fit: Design components that align with the existing structure — every bolt, flange, and mating face verified digitally before fabrication.
• Lift: Incorporate certified lifting points that comply with AS 4991 Lifting Devices, and ensure clear access paths for cranes or chain blocks.
• Life: Select wear materials suited to the physics of the process — quenched and tempered steel for impact, rubber or ceramic for abrasion, and UHMWPE for slurry lines.

It’s not just about parts; it’s about engineering foresight. A well-designed plant component is safer to install, easier to inspect, and lasts longer between shutdowns.

Scan What You See — Not What You Think You Have

Over time, every wash plant drifts from its original drawings. Field welds, retrofits, and corrosion mean that “as-built” and “as-exists” are rarely the same thing.

That’s where LiDAR scanning transforms maintenance. Using sub-millimetre accuracy, 3D laser scans capture your plant exactly as it stands — every pipe spool, every chute, every bolt hole.

With this data, our engineers can:

• Overlay new models directly into your point cloud to confirm fit-up before fabrication.
• Identify alignment errors, corrosion zones, and clearance conflicts before shutdowns.
• Generate true digital twins that allow for predictive maintenance and simulation.

LiDAR scanning isn’t just a measurement tool; it’s an insurance policy against rework and lost production.

Corrosion: The Hidden Killer in Every CHPP

Coal and water don’t just move material — they create acidic environments that eat through untreated or aging steel. In sumps, launders, and under conveyors, corrosion silently compromises strength until a structure is no longer safe to walk on.

Regular inspections are the first line of defence. At Hamilton By Design, we recommend combining:

• Daily visual checks by operators for surface rust and coating damage.
• Thickness testing during shutdowns to track wall loss on chutes and pipes.
• 3D scan comparisons every 6–12 months to quantify deformation and corrosion in critical structures.

With modern tools, you can see corrosion coming long before it becomes a failure.

From Data to Decision: Predictive Maintenance in Action

A coal wash plant produces a river of data — motor loads, vibration levels, pump pressures, liner thickness, and flow rates. The key is turning that data into insight.

By integrating scanning results, maintenance records, and sensor data, plant teams can identify trends that point to future breakdowns. For example:

• Vibration trending can reveal bearing fatigue weeks before failure.
• Load monitoring can detect screen blinding or misalignment.
• Scan data overlays can show sagging supports or displaced chutes.

When you understand what your plant is telling you, you move from reacting to problems to predicting and preventing them.

Shutdowns: Planned, Precise, and Productive

Every shutdown costs money — the real goal is to make every hour count. The best shutdowns start months ahead with validated design data and prefabrication QA.

Before you cut steel or mobilise cranes, every component should be digitally proven to fit. Trial assemblies, lifting studies, and bolt access checks prevent costly surprises once you’re on the clock.

At Hamilton By Design, our process combines:

• LiDAR scanning to confirm as-built geometry.
• SolidWorks modelling and FEA for mechanical verification.
• Pre-installation validation to ensure bolt holes, flanges, and lift paths align on day one.

That’s how you replace chutes, spools, and launders in a fraction of the usual time — safely, and with confidence.

The Payoff: Reliability You Can Measure

The plants that invest in engineering-led maintenance see results that are tangible and repeatable:

Reliability isn’t luck — it’s engineered.

Your Next Step: A Confidential Mechanical Assessment

Whether your plant is in the Bowen Basin, Hunter Valley, or Central West NSW, our team can deliver a confidential mechanical and scanning assessment of your wash plant.

We’ll benchmark your current maintenance strategy, identify high-risk areas, and provide a clear roadmap toward predictive, engineered reliability.

📩 For a confidential assessment of your current wash plant, contact:
info@hamiltonbydesign.com.au

Stop reacting. Start engineering. Build reliability that lasts.

Mechanical Engineering | Structural Engineering

Mechanical Drafting | Structural Drafting

3D CAD Modelling | 3D Scanning

Chute Design

The Cost of Guesswork in Shutdowns

Every shutdown comes with pressure — time, budget, and safety. When mechanical upgrades or maintenance are based on outdated drawings or manual measurements, the risk of error skyrockets. A misaligned chute, an incorrectly measured pipe, or a bracket that doesn’t quite fit can turn a planned three-day outage into a five-day scramble.
In industries where every hour offline costs tens of thousands of dollars, guesswork is expensive.

3D Laser Scanning: Seeing the Plant as It Really Is

That’s where 3D laser scanning and LiDAR technology change the game. Using a FARO or similar high-accuracy scanner, Hamilton By Design captures millions of data points in a matter of minutes — creating a precise digital replica of your plant or structure.
This point cloud model forms the foundation for all design work. Every pipe, beam, and bracket is located exactly where it exists in the real world, not where an old drawing says it should be.

From Scan to SolidWorks: Accurate Models, Confident Designs

Once the scan is complete, the data is reverse-modelled into SolidWorks or similar 3D design environments.
This means upgrades, chutes, handrails, and structural supports can be designed within the scanned environment — guaranteeing they fit perfectly on installation day.
Our clients use this workflow to plan shutdowns with confidence, knowing that every fabricated part will bolt straight in.

Eliminating Fit-Up Errors and Rework

Traditional upgrade projects rely on tape measures, rough sketches, or outdated general arrangement drawings. Even a 10 mm error can cause weeks of rework once site access is restricted.
With 3D scanning, those errors disappear.
Before fabrication begins, engineers can check for:

• Clashes and interferences between new and existing plant structures.
• Clearances for maintenance and access.
• Alignment with conveyors, supports, and existing chutes.

That level of insight is impossible with 2D drawings alone.

Shorter Shutdowns, Safer Teams

Fewer surprises mean faster, safer installations.
When every component is designed and verified within the scanned model, shutdown crews spend less time cutting, grinding, or reworking in the field.
That’s not only a productivity win, it’s a safety win — fewer sparks, less manual handling, and minimal hot work in confined spaces.

Applications Across Mining and Processing

Hamilton By Design’s scanning and modelling process is trusted across the Bowen Basin, Surat Basin, Hunter Valley, and Central West NSW.
Typical projects include:

• CHPP upgrades — chute replacements, diverter modifications, and screen structure changes.
• Conveyor realignments — ensuring belt runs are perfectly centred before shutdown.
• Pipework and pump station retrofits — avoiding rework when tie-ins occur.
• Structural verification — validating as-built conditions before new platforms or walkways are installed.

Real-World ROI

Clients routinely report saving days of downtime and thousands in rework costs by scanning before fabrication.
When you consider that a typical CHPP shutdown might cost $20,000–$50,000 per hour in lost production, the return on investment is obvious.
A few hours spent scanning can mean days of avoided delay.

Stop Guessing, Start Scanning

If your next shutdown involves tight spaces, limited access, or unknown conditions — don’t rely on old drawings or assumptions.
Hamilton By Design provides LiDAR scanning, point-cloud modelling, and SolidWorks-based mechanical design to ensure your upgrades install exactly as intended.

👉 Book a site scan before your next shutdown.
Visit www.hamiltonbydesign.com.au or contact us to discuss your upcoming project.

3D CAD Modelling | 3D Scanning

Chute Design

Mechanical Engineering | Structural Engineering

Safety and Precision in Mechanical Engineering Lifts

In the fast-paced world of Sydney construction and infrastructure, precision lifting is an everyday necessity. From hoisting prefabricated modules on high-rise towers to positioning steel frameworks and heavy plant components, each lift depends on one critical factor — the integrity of the lifting device.

A mechanical engineering lift is more than just machinery; it’s the result of careful design, analysis, and compliance with national safety standards. The Australian Standard AS 4991: Lifting Devices provides the engineering framework to ensure that every lifting beam, clamp, and spreader frame is designed, tested, and certified for safe performance.

In the dynamic environment of Sydney’s construction and manufacturing sectors, adhering to AS 4991 is not only a compliance issue — it’s essential to safety, reliability, and professional reputation.

What AS 4991 Means for Mechanical Engineering in Sydney

AS 4991: Lifting Devices is the Australian benchmark for the design, manufacture, proof testing, and maintenance of all mechanically engineered lifting attachments used with cranes and hoists.

It covers:

• Design verification by qualified engineers
• Proof load testing (typically 1.5 times the Working Load Limit)
• Identification markings such as WLL, serial number, and manufacture date
• Regular inspection and maintenance schedules
• Documented certification and traceability

For Sydney-based mechanical engineering projects — from Parramatta’s commercial developments to the infrastructure of the Eastern Suburbs — these requirements ensure every lift is carried out with confidence and safety.

The Role of Mechanical Engineers in Safe Lifting

Mechanical engineers play a vital role in ensuring every lifting device performs predictably under real-world conditions. Each lifting beam, frame, or clamp must be:

• Designed for static and dynamic loading
• Resistant to fatigue, buckling, and corrosion
• Built from materials tested for strength and durability
• Verified through engineering analysis and proof testing

By applying AS 4991, mechanical engineers in Sydney create lifting devices that not only meet technical standards but also withstand the operational demands of construction, mining, and industrial settings across New South Wales.

Why Non-Compliance is Never Worth the Risk

Sydney’s worksites are under strict safety scrutiny, and incidents involving lifting equipment failures have resulted in serious injuries, fatalities, and prosecutions.

Examples from across Australia include:

• Unmarked or uncertified lifting beams that failed under load due to poor design.
• Vacuum lifters that detached unexpectedly after seals deteriorated from lack of inspection.
• Improvised lifting points on machinery leading to crush injuries and WHS enforcement actions.

These events share a common cause: failure to meet the design, inspection, and documentation requirements of AS 4991.

For any mechanical engineering lift in Sydney, non-compliance risks not just equipment damage but also:

• Work Health and Safety (WHS) prosecutions
• Civil negligence claims
• Loss of accreditation and contracts
• Damage to professional reputation

Compliance as a Legal and Professional Obligation

While AS 4991 is not legislation, it defines the expected standard of care under Australia’s WHS laws. Regulators such as SafeWork NSW use compliance with standards like AS 4991 as evidence of due diligence.

For mechanical engineers, fabricators, and construction managers, compliance means:

• Designs verified by competent engineers
• Devices tested and certified to meet load requirements
• Inspection records that prove ongoing safety
• Training to ensure operators understand correct usage

In Sydney’s competitive engineering market, adherence to AS 4991 isn’t just about avoiding penalties — it’s about demonstrating leadership in professional safety.

Building a Culture of Inspection and Traceability

A key part of AS 4991 is documentation. Each lifting device should have a design verification report, proof load certificate, and inspection record.
This traceability ensures that every lift on a Sydney site can be traced back to certified engineering.

Companies should maintain:

• A register of lifting devices with serial numbers and inspection dates
• Clear tagging systems for quick identification
• Routine re-certification for high-use environments
• Operator awareness training on compliance indicators

These processes turn safety standards into practical habits that protect workers and ensure smooth site operations.

Mechanical Engineering Lift Sydney: Innovation Meets Safety

Sydney is a hub of engineering innovation, with advanced tools like 3D scanning, LiDAR, and Finite Element Analysis (FEA) enhancing how lifting devices are designed and validated.

At Hamilton By Design, our mechanical engineers use these technologies to create custom lifting systems for complex sites across Sydney — from tight urban projects in Chatswood and Parramatta to industrial installations in the Inner West.

Yet, even with the latest modelling tools, every design is checked against AS 4991 to guarantee that each lift meets both engineering and safety expectations.

Conclusion: Lifting Sydney Safely

In mechanical engineering, safety begins long before the crane hook rises. It starts with standards — and in Australia, AS 4991 is the foundation.

For every mechanical engineering lift in Sydney, compliance ensures more than safety: it provides reliability, traceability, and peace of mind. By following the standard, engineers not only protect lives but also elevate the quality and professionalism of Sydney’s construction and manufacturing industries.

At Hamilton By Design, our commitment is simple: lift Sydney safely, lift with engineering excellence, and lift to the standard — AS 4991.

Mechanical Engineers in Sydney

Mechanical Engineering | Structural Engineering

3D Scanning Sydney

Engineering Services