Mackay’s Industrial Edge

Mackay’s Industrial Edge — How 3D LiDAR, Modern Engineering & Digital Modelling Supercharge Regional Projects

Located on the tropical Queensland coast but powering heavy industry, mining support and agricultural logistics, Mackay stands as a unique regional powerhouse. With its massive sugar industry, proximity to the Bowen Basin coalfields, thriving fabrication sector, marine and port operations — plus a growing push toward industrial expansion — the city’s infrastructure demands are both diverse and complex.

At Hamilton By Design, we recognise that projects in Mackay need more than “old-school” drawings or rough-site surveys. That’s why we offer state-of-the-art 3D LiDAR laser scanning, comprehensive mechanical and structural engineering, advanced 3D modelling, and fabrication-ready drafting — all designed to meet Mackay’s rigorous industrial, mining-support and agricultural demands.

If you’re planning an upgrade to a processing facility, expanding a plant or fabricating complex steelwork, our services ensure precision, efficiency and reliability from start to finish.

Why Mackay Is a Perfect Fit for Digital Engineering & 3D Scanning

Mackay’s blend of industries — sugar mills, mining, fabrication, marine, port logistics and heavy machinery — means that most facilities are a patchwork of legacy infrastructure, ongoing modifications and high-demand production cycles.

That brings challenges like:

undocumented pipework, conveyors or structural changes;
tight tolerances for retrofits or new installations;
heavy mechanical equipment requiring accurate alignment and structural support;
short windows for shutdowns or maintenance;
mixed use of fabrication, mining-grade components, and agricultural processing equipment.

For these reasons, the old ways of tape-measure site surveys and manual sketches are often not enough.

Enter 3D LiDAR scanning. By capturing the entire facility geometry with millimetre-level accuracy, you get a complete digital “as-built” record — capturing everything from structural steel, ductwork, conveyors, foundations, and terrain, to existing equipment and utilities.

Through Hamilton By Design’s professional scanning services, Mackay clients receive real-world data that supports safer, faster and more accurate project planning, design and fabrication.

From Point Cloud to Precision Design: 3D Modelling & Drafting

Once your site is scanned, our team converts the raw scan data into intelligent 3D CAD models — delivering:

accurate mechanical and structural layouts;
fabrication-ready drawings (GA, detail drawings, isometrics, BOMs);
clash detection and interference checking before fabrication starts;
easy visualisation for stakeholders, clients and contractors;
digital archives for future modifications or maintenance.

This kind of precision work dramatically reduces risk — especially for brownfield sites or mixed-use facilities common in Mackay’s industrial sector.

Engineering Support Built for Mackay’s Key Industries

Whether it’s a sugar mill retrofit, mining support workshop, marine fabrication yard, or industrial workshop expansion — the range of engineering challenges in Mackay is enormous. Hamilton By Design brings specialist mechanical and structural engineering expertise to the table, offering:

structural assessments (supports, platforms, load-bearing frames, foundations)
alignment and vibration analysis for conveyors, heavy machinery, pumps
design of new equipment layouts, piping, ducting and supports
fatigue, stress and load-bearing analysis (FEA) when needed
compliance-ready drawings and design documentation for local regulations and safety standards

This level of engineering support is often critical for projects involving heavy loads, mining-grade equipment, or large-scale fabrication — exactly the types of projects abundant across Mackay.

3D LiDAR Laser Scanning — The Game Changer for Mackay Projects

Especially when plants are being upgraded, new modules added, or older sites refurbished, accurate spatial data is the foundation for success.

Our 3D LiDAR laser scanning service ensures:

complete, precise capture of existing site geometry — steelwork, structure, terrain, utilities;
minimal site downtime — faster capture than manual survey;
safer field operations (less need for manual measurements in active plants);
high-fidelity base for design, modelling and fabrication;
better coordination between contractors, fabricators and engineers.

Learn more about our 3D LiDAR services here: https://www.hamiltonbydesign.com.au/home/3d-lidar-scanning-digital-quality-assurance/3d-laser-scanning/

For a city like Mackay — with fast-paced industrial demand, tight tolerances, and high-volume production — this technology isn’t just beneficial, it’s essential.

One Integrated Workflow: From Scan to Delivery

What sets Hamilton By Design apart is our seamless, end-to-end service:

Conduct 3D LiDAR scan of the facility or site
Process point-cloud data and clean up for modelling
Build detailed 3D CAD models — mechanical, structural, architectural
Perform engineering assessments, structural/ mechanical analysis or modifications as needed
Produce fabrication-ready drawings and documentation
Provide digital reports, QA data and as-built records for the client

Having a single point of accountability — scan, model, engineer, deliver — reduces miscommunication, avoids rework and ensures that every part of the project is aligned, documented, and traceable.

Why Mackay Businesses Should Use Hamilton By Design

Whether you’re running a sugar mill, a fabrication workshop servicing Bowen Basin mines, a workshop for heavy equipment repairs, or a marine engineering facility servicing port exports — Mackay’s industrial landscape is complex.

By using cutting-edge 3D laser scanning, accurate modelling, and expert engineering, Hamilton By Design helps you:

save time and money on site surveys;
avoid costly rework from inaccurate measurements;
ensure tighter tolerances, safer installations and compliance;
speed up design, fabrication and installation;
maintain digital records for ongoing maintenance or future upgrades.

For industries in Mackay that deal with heavy loads, tight schedules, and high-volume production — this is a competitive advantage.

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2 December 202517 December 2025

Why Shutdown Parts Don’t Fit — And How 2 mm LiDAR Scanning Stops the Rework

When Parts Don’t Fit, Shutdowns Fail

Every shutdown fitter, maintenance crew member, and supervisor has lived the same nightmare:

A critical part arrives during shutdown.
The old part is removed.
Everyone gathers, ready to install the new one.
Production is waiting.
The pressure is on.

And then—
the part doesn’t fit.

Not 2 mm out.
Not 10 mm out.
Sometimes 30–50 mm out, wrong angle, wrong bolt pattern, wrong centreline, or wrong geometry altogether.

The job stops.
People get frustrated.
Supervisors argue.
Fitters cop the blame.
The plant misses production.
And someone eventually says the words everyone hates:

“Put the old worn-out chute back on.”

This blog is about why shutdowns fall apart like this… and how 2 mm LiDAR scanning finally gives fitters a system that gets it right the first time.

The Real Reason Parts Don’t Fit

Most shutdown failures have nothing to do with the fitter, nothing to do with the workshop, and nothing to do with the installation crew.

Parts don’t fit because:

Wrong measurements
Bad drawings
Outdated as-builts
Guesswork
Fabricators “eyeballing” dimensions
Cheap non-OEM parts purchased without geometry verification
Designers who have never seen the site
High staff turnover with no engineering history
Wear profiles not checked
Intersection points impossible to measure manually

Fitters are then expected to make magic happen with a tape measure and a grinder.

It’s not fair. It’s not professional. And it’s completely avoidable.

Shutdown Pressures Make It Even Worse

When a part doesn’t fit during a shutdown:

The entire job stalls
Crews stand around waiting
The supervisor gets hammered
The fitter gets the blame
Other shutdown tasks cannot start
The clock ticks
Production loses thousands per hour
Everyone becomes stressed and angry

And the worst part?

You were only replacing the part because the existing one was worn out.
Now you’re bolting the worn-out one back on.

This isn’t good enough.
Not in 2025.
Not in heavy industry.
Not when there is technology that eliminates this problem completely.

Why Manual Measurement Fails Every Time

Fitters often get asked to measure:

Inside chutes
Wear sections
Pipe spools with intersection points
Tanks too large to measure from one position
Walkways too long for tape accuracy
Geometry with no records
Components 10+ metres above ground
Hard-to-reach bolt patterns
Angles and centrelines distorted by wear

But some measurements simply cannot be taken safely or accurately by hand.

You can’t hang off an EWP 20 metres up measuring a worn flange angle.
You can’t crawl deep inside a chute trying to measure intersecting surfaces.
You can’t take a 20-metre walkway measurement with a tape measure and hope for precision.

This is not a measurement problem.
This is a method problem.

Manual measurement has hit its limit.
Shutdowns have outgrown tape measures.

This Is Where 2 mm LiDAR Scanning Changes Everything

Hamilton By Design uses 2 mm precision LiDAR scanning to capture the exact geometry of a site — even in areas that are:

Too high
Too big
Too unsafe
Too worn
Too complex
Too tight
Too distorted to measure manually

From the ground, up to 30 metres away, we can capture:

Wear profiles
Flange positions
Bolt patterns
Pipe centrelines
Chute geometry
Conveyor interfaces
Complex intersections
Ductwork transitions
Mill inlet/outlet shapes
Tank dimensions
Walkway alignment
Structural deflection
Existing inaccuracies

No tape measure. No guesswork. No EWP. No risk.

The result is a perfect 3D point cloud accurate within 2 mm — a digital version of real life.

2 mm Scanning + Fitter-informed Design = Parts That Fit First Time

This is where Hamilton By Design is different.

We don’t just scan and hand the files to a drafter who’s never set foot on-site.

We scan and your parts are modelled by someone who:

Has been a fitter
Understands how parts are installed
Knows what goes wrong
Knows how to design parts that actually fit
Knows where shutdowns fail
Knows what to check
Knows what NOT to trust
And most importantly — knows where the real-world problems are hidden

This fitter-informed engineering approach is why our parts fit the first time.

And why shutdown crews trust us.

Digital QA Ensures Fabrication Is Correct Before It Leaves the Workshop

Once the new chute, spool, or component is modelled, we run digital QA:

Fit-up simulation
Clash detection
Tolerance analysis
Wear profile compensation
Reverse engineering comparison
Bolt alignment verification
Centreline matching
Flange rotation accuracy
Structural interface checks

If something is out by even 2–3 mm, we know.

We fix it digitally — before the workshop cuts steel.

This stops rework.
This stops shutdown delays.
This stops blame.
This stops stress.

This is the future of shutdown preparation.

Accuracy of 3D LiDAR Scanning With FARO

When the Part Fits, Everything Runs Smooth

Here’s what actually happens when a chute or spool fits perfectly the first time:

The plant is back online faster
No rework
No reinstalling old worn-out parts
No arguing between fitters and supervisors
No unexpected surprises
No extra access equipment
No late-night stress
No grinding or “making it fit”
Other shutdown tasks stay on schedule
Everyone looks good
Production trusts the maintenance team again

Shutdowns become predictable.
Fitters become heroes, not last-minute problem-solvers.

Shutdown Example (Anonymous but Real)

A major processing plant needed a large chute replaced during a short shutdown window.
Access was limited.
The geometry was distorted.
Measurements were impossible to take safely.
The workshop needed exact dimensions, fast.

Hamilton By Design scanned the entire area from the ground — no EWP, no risk.

We produced:

Full 2 mm point cloud
As-built 3D model
New chute design
Digital fit-up validation
Workshop-ready drawings

The new chute arrived on site.
The old chute came out.
The new chute went straight in.
Zero rework.
Zero stress.
Plant online early.

The supervisor called it the smoothest shutdown they’d had in 10 years.

Why Fitters Should Reach Out Directly

Sometimes fitters know more about what’s really happening on-site than anyone in the office.

Fitters see the problems.
Fitters carry the blame.
Fitters deal with the rework.
Fitters just want parts that fit.

So we’re making this simple:

If you’re tired of fitting parts that don’t fit —
If you’re tired of fixing other people’s mistakes —
If you’re tired of shutdown stress —

Call Hamilton By Design.

We scan it.
We model it.
We get it right.
Every time.

Services Featured

Hamilton By Design offers:

3D LiDAR laser scanning (2 mm precision)
3D modelling by a fitter-engineer who understands real-world installation
Digital QA before fabrication
Reverse engineering of worn components
Shutdown planning support
Fabrication-ready drawings
Fit-up simulation
Clash detection between old and new parts

This is how shutdowns run smooth.

Call to Action

Are you a Fitter: tired of parts that don’t fit?

Email or Call Hamilton By Design.

Email – info@hamiltonbydesign.com.au

Phone – 0477002249

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3D CAD Modelling | 3D Scanning

21 September 20256 December 2025

Why 3D Point Clouds + Expert Modelers Are a Game-Changer for Your Projects

Infographic illustrating the 3D project data workflow, showing LiDAR scanners and drones capturing millions of data points, a designer modelling on a computer, and project teams validating accurate 3D data, highlighting benefits such as speed, accuracy, cost savings and project success.

Level Up your 3D Scans

In today’s world, accuracy and efficiency can make or break a project. Whether you’re working in architecture, construction, engineering, or product design, you need reliable data — and you need it fast. That’s where 3D point clouds come in.

But there’s an important catch: not all scans are created equal. The difference between an average scan and a great one often comes down to the person behind the scanner. Having someone who understands 3D modeling take the scans can dramatically improve your project’s accuracy, reliability, and overall success.

Let’s break down why.

The Power of 3D Point Clouds

Point clouds are essentially millions of tiny data points that capture the shape of an object, room, or entire site. Together, they create a highly detailed digital snapshot of the real world.

Here’s why this matters:

Precision you can trust – Point clouds deliver incredibly detailed measurements, capturing even the smallest curves and angles.
Nothing gets missed – Multiple scan angles ensure a full, 360° view of your site or object.
Speed and efficiency – What used to take hours (or days) with manual measurements can be captured in minutes.
Built-in context – You’re not just getting numbers; you’re getting a complete digital environment to work inside.
Future-proof data – Once you have a scan, you have a permanent record of your space, ready to use months or years later.

From clash detection to as-built verification, point clouds save time, reduce errors, and make collaboration across teams smoother than ever.

Why the Person Taking the Scan Matters

While technology is powerful, experience is what makes the results reliable. Having a skilled 3D modeler operate the scanner can be the difference between a good project and a great one.

Here’s why an expert makes all the difference:

They know what matters – A modeler understands which details are critical for your project and ensures they’re captured.
Fewer gaps, fewer surprises – Experienced pros know how to plan scan positions to cover every angle and avoid blind spots.
Cleaner, more accurate data – They reduce common issues like noise, misalignment, or missing sections that can throw off your model.
Time saved, headaches avoided – No one wants to redo a scan halfway through a project. A professional ensures you get it right the first time.
Confidence from start to finish – When you know your model is accurate, you can move forward with design and construction decisions without second-guessing.

In short: a great scanner operator doesn’t just deliver data — they deliver peace of mind.

The Bottom Line

3D point clouds are already transforming how projects are planned and delivered. But pairing them with an experienced 3D modeler takes things to the next level.

You’ll get better data, faster turnarounds, and a far lower risk of costly mistakes. And when your goal is to deliver projects on time, on budget, and with zero surprises, that’s an edge you can’t afford to miss.

3D Modelling | 3D Scanning | Point Cloud Scanning

20 September 20256 December 2025

Chute Design in the Mining Industry

Infographic showing Hamilton By Design’s engineering workflow, including millimetre-accurate LiDAR reality capture, material-flow simulation, optimised chute designs, and safer, more efficient production outcomes. Two workers in PPE highlight reliable design and longer liner life, with icons representing time, cost and quality benefits.

Getting Coal, Hard Rock, and ROM Material Flow Right

Chute design is one of the most critical yet challenging aspects of mining and mineral processing. Whether you are handling coal, hard rock ore, or raw ROM material, chutes and transfer stations are the unsung workhorses of every operation. When designed well, they guide material smoothly, minimise wear, and keep conveyors running. When designed poorly, they cause blockages, spillage, excessive dust, and expensive downtime.

Modern chute design has moved far beyond rules of thumb and back-of-the-envelope sketches. Today, successful projects rely on accurate as-built data, particle trajectory analysis, and advanced Discrete Element Method (DEM) simulation to predict, visualise, and optimise material flow before steel is cut. In this article, we explore why these tools have become essential, how they work together, and where software can — and cannot — replace engineering judgement.

Illustration showing common problems with poorly designed material-handling chutes. A chute discharges material onto a conveyor while issues are highlighted around it: unpredictable material flow, material spillage, maintenance challenges, high wear, blockages, and dust and noise. Warning icons for downtime and cost appear on the conveyor, and workers are shown dealing with the resulting hazards and maintenance tasks.

The Challenge of Chute Design

Coal and hard rock have very different flow behaviours. Coal tends to be softer, generate more dust, and be prone to degradation, while hard rock is more abrasive and can damage chutes if impact angles are not controlled. ROM material adds another level of complexity — oversize lumps, fines, and moisture variation can cause hang-ups or uneven flow.

Chute design must balance several competing objectives:

Control the trajectory of incoming material to reduce impact and wear
Prevent blockages by maintaining flowability, even with wet or sticky ore
Manage dust and noise to meet environmental and workplace health requirements
Fit within existing plant space with minimal modification to conveyors and structures
Be maintainable — liners must be accessible and replaceable without excessive downtime

Meeting all these goals without accurate data and simulation is like trying to design in the dark.

Illustrated graphic showing a tripod-mounted 3D laser scanner capturing millimetre-accurate as-built data in an industrial plant with conveyors and walkways. Speech bubbles highlight issues such as “Outdated drawings don’t tell the full story” and “Modifications rarely get documented.” The scan data is shown being visualised on a laptop, with notes describing full coverage of conveyors, walkways, and services. Benefits listed along the bottom include faster data collection, fewer site revisits, safer shutdowns, accurate starting point for design simulation, and safer outcomes that ensure designs fit first time.

Capturing the Truth with 3D Scanning

The first step in any successful chute project is to understand the as-built environment. In many operations, drawings are outdated, modifications have been made over the years, and the real plant geometry may differ from what is on paper. Manual measurement is slow, risky, and often incomplete.

This is where 3D laser scanning changes the game. Using tripod-mounted or mobile LiDAR scanners, engineers can capture the entire transfer station, conveyors, surrounding steelwork, and services in a matter of hours. The result is a dense point cloud with millimetre accuracy that reflects the true state of the plant.

From here, the point cloud is cleaned and converted into a 3D model. This ensures the new chute design will not clash with existing structures, and that all clearances are known. It also allows maintenance teams to plan safe access for liner change-outs and other work, as the scanned model can be navigated virtually to check reach and access envelopes.

Understanding Particle Trajectory

Once the physical environment is known, the next challenge is to understand the particle trajectory — the path that material takes as it leaves the head pulley or previous transfer point.

Trajectory depends on belt speed, material characteristics, and discharge angle. For coal, fine particles may spread wider than the coarse fraction, while for ROM ore, large lumps may follow a ballistic path that needs to be controlled to prevent impact damage.

Accurately modelling trajectory ensures that the material enters the chute in the right location and direction. This minimises impact forces, reducing wear on liners and avoiding the “splash” that creates spillage and dust. It also prevents the material from hitting obstructions or dead zones that could lead to build-up and blockages.

Modern software can plot the trajectory curve for different loading conditions, providing a starting point for chute geometry. This is a critical step — if the trajectory is wrong, the chute design will be fighting against the natural path of the material.

The Power of DEM Simulation

While trajectory gives a first approximation, real-world flow is far more complex. This is where Discrete Element Method (DEM) simulation comes into play. DEM models represent bulk material as thousands (or millions) of individual particles, each following the laws of motion and interacting with one another.

When a DEM simulation is run on a chute design:

You can visualise material flow in 3D, watching how particles accelerate, collide, and settle
Impact zones become clear, showing where liners will wear fastest
Areas of turbulence, dust generation, or segregation are identified
Build-up points and potential blockages are predicted

This allows engineers to experiment with chute geometry before fabrication. Angles can be changed, ledges removed, and flow-aiding features like hood and spoon profiles or rock-boxes optimised to achieve smooth, controlled flow.

For coal, DEM can help ensure material lands gently on the receiving belt, reducing degradation and dust. For hard rock, it can ensure that the energy of impact is directed onto replaceable wear liners rather than structural plate. For ROM ore, it can help prevent oversize lumps from wedging in critical locations.

Illustration of an optimised chute design showing material flow represented by green particles, with check marks and gear icons indicating improved efficiency and engineered performance.

🖥 Strengths and Limitations of Software

Modern DEM packages are powerful, but they are not magic. Software such as EDEM, Rocky DEM, or Altair’s tools can simulate a wide range of materials and geometries, but they rely on good input data and skilled interpretation.

Key strengths include:

Ability to model complex, 3D geometries and particle interactions
High visualisation power for communicating designs to stakeholders
Capability to run multiple scenarios (different feed rates, moisture contents, ore types) quickly

However, there are limitations:

Material calibration is critical. If the particle shape, friction, and cohesion parameters are wrong, the results will not match reality.
Computational cost can be high — detailed simulations of large chutes with millions of particles may take hours or days to run.
Engineering judgement is still needed. Software will not tell you the “best” design — it will only show how a proposed design behaves under given conditions.

That’s why DEM is best used as part of a holistic workflow that includes field data, trajectory analysis, and experienced design review.

From Model to Real-World Results

When the simulation results are validated and optimised, the design can be finalised. The point cloud model ensures the chute will fit in the available space, and the DEM results give confidence that it will perform as intended.

This means fabrication can proceed with fewer changes and less risk. During shutdown, installation goes smoothly, because clashes have already been resolved in the digital model. Once commissioned, the chute delivers predictable flow, less spillage, and longer liner life.

Why It Matters More Than Ever

Today’s mining operations face tighter production schedules, stricter environmental compliance, and increasing cost pressures. Downtime is expensive, and the margin for error is shrinking.

By combining 3D scanning, trajectory modelling, and DEM simulation, operations can move from reactive problem-solving to proactive improvement. Instead of waiting for blockages or failures, they can design out the problems before they occur, saving both time and money.

Partnering for Success

At Hamilton by Design, we specialise in turning raw site data into actionable insights. Our team uses advanced 3D scanning to capture your transfer stations with precision, builds accurate point clouds and CAD models, and runs calibrated DEM simulations to ensure your new chute design performs from day one.

Whether you’re working with coal, hard rock, or ROM ore, we help you deliver designs that fit first time, reduce maintenance headaches, and keep production running.

Contact us today to see how our integrated scanning and simulation workflow can make your next chute project safer, faster, and more reliable.

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4 July 202520 December 2025

3D Laser Scanning and CAD Modelling Services | Hamilton By Design

There are two things we’ve always believed at Hamilton By Design:

Accuracy matters.
If you can model it before you make it, do it.

That’s why when the FARO Focus S70 hit the scene in 2017, we were early to the party — not just because it was shiny and new (though it was), but because we knew it would change how we support our clients in mining, processing, and manufacturing environments.

The S70 didn’t just give us a tool — it gave us a superpower: the ability to see an entire site, down to the bolt heads and pipe supports, in full 3D before anyone picked up a wrench. Dust, heat, poor lighting — no problem. With its IP54 rating and extended temperature range, this scanner thrives where other tools tap out.

And we’ve been putting it to work ever since.

“Measure Twice, Cut Once” Just Got a Whole Lot More Real

Laser scanning means we no longer rely on outdated drawings, forgotten markups, or that sketch someone did on the back of a clipboard in 2004.

We’re capturing site geometry down to millimetres, mapping full plant rooms, structural steel, conveyors, tanks, ducts — you name it. And the moment we leave site, we’ve already got the data we need, registered and ready to drop into SolidWorks.

Which, by the way, we’ve been using since 2001.

Yes — long before CAD was cool, we were deep into SolidWorks building models, simulating loads, tweaking fit-ups, and designing smarter mechanical solutions for complex environments. It’s the other half of the story — scan it, then model it, all in-house, all under one roof.

Safety by Design – Literally

Here’s the part people often overlook: 3D laser scanning isn’t just about accuracy — it’s about safety.

We’ve worked across enough plants and mine sites to know that the real hazards are often the things you don’t see in a drawing. Tight access ways. Awkward pipe routing. Obstructions waiting to drop something nasty when a shutdown rolls around.

By scanning and reviewing environments virtually, we can spot those risks early — hazard identification before boots are even on the ground. We help clients:

Reduce time-on-site
Limit the number of field visits
Minimise exposure to high-risk zones
Plan safer shutdowns and installations

That’s a big win in any plant or processing facility — not just for compliance, but for peace of mind.

SolidWorks 3D Modelling
CAD model from site scan

From Point Cloud to Problem Solved

Since 2017, our scanning and modelling workflows have supported:

Brownfield upgrade projects
Reverse engineering of legacy components
Fabrication and installation validation
Creation of digital twins
Asset audits and documentation updates

And when you pair that with 24 years of SolidWorks expertise, you get more than just a pretty point cloud — you get practical, buildable, fit-for-purpose engineering solutions backed by deep industry knowledge.

Thinking about your next project? Let’s make it smarter from the start.

We’ll scan it, model it, and engineer it as we have been doing for decades — with zero guesswork and full confidence.

www.hamiltonbydesign.com.au

Mechanical Engineering | Structural Engineering

Mechanical Drafting | Structural Drafting

3D CAD Modelling | 3D Scanning

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13 December 202429 September 2025

Maximizing Equipment Efficiency with ISO 18436.2 Maintenance Strategies

At Hamilton By Design, we know that keeping your equipment running efficiently isn’t just about quick fixes; it’s about adopting the right maintenance strategies to ensure long-term reliability and performance. With advancements in condition monitoring and diagnostic techniques, the ISO 18436.2 standard has become a cornerstone for effective maintenance practices—and it’s at the heart of how we help our clients optimize their operations.

In this blog post, we’ll explore the major maintenance strategies aligned with ISO 18436.2 and how they can transform your plant’s productivity.

What is ISO 18436.2?

ISO 18436.2 is an internationally recognized standard that defines the competencies required for personnel performing condition monitoring and diagnostics. It focuses on advanced tools like vibration analysis, helping engineers identify equipment issues before they lead to costly downtime.

At Hamilton By Design, our team is ISO 18436.2-certified, meaning we bring the highest level of expertise to your maintenance needs.

Maintenance Strategies That Deliver Results

ISO 18436.2 aligns with several key maintenance strategies designed to improve reliability, minimize downtime, and optimize equipment performance. Here’s how they work:

1. Reactive Maintenance

Reactive maintenance is the traditional “run-to-failure” approach where repairs are made after a breakdown. While not ideal for critical assets, tools like vibration analysis can still play a role by identifying root causes post-failure. This can help inform more proactive strategies in the future.

2. Preventive Maintenance (PM)

Preventive maintenance involves scheduling regular maintenance tasks to prevent failures. While effective to some extent, PM can lead to over-maintenance. By incorporating vibration analysis and other condition monitoring techniques, preventive measures can be more precisely targeted, reducing unnecessary downtime.

3. Condition-Based Maintenance (CBM)

Condition-Based Maintenance uses real-time equipment data to identify issues as they arise. This strategy is central to ISO 18436.2 and includes tools like vibration analysis, thermography, and ultrasonic testing. CBM ensures that maintenance is performed only when necessary, saving time and money.

Benefits:

Reduces unplanned downtime.
Optimizes maintenance schedules.
Extends equipment lifespan.

4. Predictive Maintenance (PdM)

Predictive Maintenance takes CBM a step further, using data trends and analytics to predict when failures are likely to occur. With the expertise of ISO 18436.2-certified personnel, PdM uses advanced tools to detect subtle signs of wear or stress, allowing for intervention before a problem becomes critical.

Key Tools:

Vibration analysis for early detection of imbalance or misalignment.
Infrared thermography to spot heat anomalies.
Ultrasonic testing to identify leaks and material defects.

5. Reliability-Centered Maintenance (RCM)

RCM focuses on understanding the specific failure modes of critical assets and tailoring maintenance strategies accordingly. This approach integrates condition monitoring insights to prioritize tasks that align with operational goals.

Benefits:

Aligns maintenance efforts with production priorities.
Reduces the risk of unexpected equipment failures.

6. Proactive Maintenance

Proactive maintenance identifies and addresses root causes of recurring issues. By analyzing data from vibration and other diagnostic tools, engineers can resolve underlying problems like misalignment, improper lubrication, or material fatigue.

Impact:

Prevents repetitive failures.
Improves long-term equipment reliability.

7. Total Productive Maintenance (TPM)

TPM involves a plant-wide effort, from operators to management, to ensure optimal equipment effectiveness. ISO 18436.2-certified personnel can support TPM by providing actionable condition monitoring insights and training operators in basic diagnostic techniques.

How Hamilton By Design Helps

At Hamilton By Design, we bring these strategies to life through tailored maintenance solutions that align with your plant’s needs. Here’s how we can help:

1. Advanced Condition Monitoring:
Our team uses state-of-the-art tools to monitor equipment health, including vibration analysis, thermography, and ultrasonic testing.

2. Tailored Maintenance Plans:
Every plant is unique. We develop maintenance strategies based on your specific equipment, production goals, and operational priorities.

3. Expert Training and Certification:
We empower your team by offering ISO 18436.2 training, giving them the skills to sustain and enhance maintenance programs.

4. Ongoing Support:
Maintenance is a journey, not a destination. We provide continuous support to refine and optimize your practices as your operations evolve.

The Hamilton By Design Advantage

Adopting advanced maintenance strategies aligned with ISO 18436.2 isn’t just about improving equipment reliability—it’s about unlocking greater productivity and profitability for your business.

With our expertise, you can transition from reactive to predictive maintenance, reduce unplanned downtime, and extend the lifespan of your critical assets.

Ready to take your plant’s maintenance strategy to the next level? Contact Hamilton By Design today to find out how we can help.