Scan to CAD Brisbane

Scan to CAD Brisbane – Turning Real Site Conditions into Buildable Engineering

Brisbane has become one of Australia’s leading centres for digital engineering delivery. While many mining, industrial, and infrastructure assets are located across Queensland and remote regions of Australia, the engineering that supports them is increasingly completed in Brisbane using accurate digital site data.

At the centre of this shift is Scan to CAD Brisbane—a workflow that converts real-world site conditions into reliable 3D CAD models that engineers can design, analyse, and document from with confidence.

Hamilton By Design specialises in engineer-led scan to CAD workflows in Brisbane, combining on-site 3D laser scanning with Brisbane-based mechanical and structural engineering, 3D CAD modelling, FEA, and fabrication-ready drafting. This approach allows projects to progress without repeated site attendance, reducing risk and improving constructability.

Brisbane as a Scan to CAD engineering hub

Brisbane engineering teams support a wide range of assets, including:

Remote mining operations and CHPPs
Bulk materials handling systems
Ports and energy infrastructure
Brownfield industrial facilities

What makes Brisbane unique is its ability to process site data digitally and convert it into buildable engineering outcomes. Rather than relying on assumptions or legacy drawings, engineers work from accurate 3D models generated through scan to CAD processes.

By capturing site conditions once and completing engineering in Brisbane, projects benefit from:

Reduced travel and site exposure
Improved design coordination
Lower risk during fabrication and installation

Scan to CAD Brisbane: starting with accurate point clouds

Every successful scan to CAD project starts with high-quality point cloud data. 3D laser scanning captures millions of spatial measurements, creating a detailed digital representation of existing assets.

The importance of this data is explained in
3D Point Clouds Are a Game-Changer for Your Projects, where expert modelling from point clouds is shown to significantly improve accuracy, coordination, and constructability.

For Brisbane-based engineers, point clouds enable:

Design based on real geometry
Reduced reliance on outdated drawings
Early clash detection and fit-up verification
Fewer site changes and rework

This is the foundation of effective scan to CAD in Brisbane.

3D laser scanning feeding Scan to CAD Brisbane workflows

Hamilton By Design delivers high-accuracy 3D Scanning across mining and industrial sites throughout Queensland and Australia. Scanning is typically completed during short, controlled site visits, minimising disruption to operations.

3D laser scanning is particularly valuable for scan to CAD projects involving:

Remote or FIFO-based mining sites
Brownfield industrial environments
Assets with incomplete or outdated documentation
Tight shutdown and installation windows

Once scanning is complete, all data is transferred back to Brisbane for processing and modelling.

Engineer-led Scan to CAD Brisbane, not just drafting

A key difference in scan to CAD outcomes is whether the process is engineering-led or treated as a drafting exercise. Hamilton By Design integrates scanning, modelling, and engineering as a single workflow.

This approach is detailed in
Your Experts in 3D Laser Scanning & Mechanical Design, where scan data is used to directly inform mechanical and structural design decisions.

By combining scan to CAD with engineering expertise, Brisbane-based engineers can:

Design directly from real site geometry
Understand existing load paths and constraints
Optimise layouts for constructability and access

This is especially important for mining and heavy industry projects where accuracy and fit-for-purpose design are critical.

3D CAD modelling built from real site conditions

Scan data is converted into detailed 3D CAD Modelling using SolidWorks and related platforms. These models reflect what actually exists on site, forming a reliable digital baseline for future work.

Scan to CAD Brisbane workflows support:

Mechanical upgrades and plant modifications
Structural additions such as platforms and walkways
Integration of new equipment into existing facilities
Long-term asset documentation and reuse

Working from accurate models significantly reduces uncertainty and downstream design changes.

Reducing site attendance through Scan to CAD Brisbane

With reliable scan-derived CAD models available, most engineering work can be completed remotely from Brisbane. This allows:

Mechanical and structural design without repeated site visits
Digital design reviews with stakeholders
Reduced FIFO travel and project costs
Improved safety by limiting on-site exposure

For asset owners, scan to CAD Brisbane workflows deliver faster, more predictable project outcomes.

Coordinated engineering and verification from CAD models

Working within a single digital environment allows Brisbane engineers to coordinate mechanical and structural design efficiently. This reduces clashes, improves constructability, and limits late-stage design changes—particularly in congested brownfield environments.

Scan-derived CAD models also support engineering verification, including load checks, fatigue assessment, and compliance review, ensuring designs perform as intended.

Fabrication-ready outputs from Scan to CAD Brisbane

Final designs are issued as fabrication-ready drawings developed directly from coordinated 3D CAD models. This improves clarity for workshops and installation teams and reduces errors during fabrication and installation.

Because everything is based on verified site geometry, components are far more likely to fit first time.

Scan to CAD Brisbane supporting projects across Queensland

As digital engineering becomes standard practice, Brisbane’s role as a scan to CAD delivery hub continues to grow. Hamilton By Design uses scan to CAD Brisbane workflows to support mining and industrial projects across Queensland and Australia—capturing site reality once and engineering with confidence.

By integrating 3D scanning, point clouds, CAD modelling, and engineering verification, scan to CAD Brisbane delivers practical, buildable outcomes that work in the real world.

Our clients:

10 December 202510 December 2025

3D Scanning & Engineering in Hervey Bay

Hervey Bay’s Coastal Advantage: How 3D LiDAR Scanning, Engineering & Digital Modelling Are Powering Smarter Regional Projects

Hervey Bay is known worldwide for its calm waters, iconic whale encounters and its role as the gateway to K’gari (Fraser Island). But behind the postcard coastline lies a fast-growing regional city with expanding infrastructure, marine industries, coastal engineering needs and ongoing urban development. As Hervey Bay continues to grow, so does its need for accurate mapping, reliable engineering and smarter digital-based project delivery.

Hamilton By Design is proud to support the region with 3D LiDAR laser scanning, mechanical and structural engineering services, 3D modelling and CAD drafting — tools that help reduce construction risk, improve upgrade planning, support marine and coastal infrastructure, and streamline fabrication and installation.

Whether you’re upgrading a jetty, renovating a foreshore asset, documenting a marina, expanding a workshop or designing new coastal facilities, our digital engineering approach ensures precision and confidence from the very beginning.

Why Hervey Bay Is a Unique Environment for Engineering & 3D Scanning

Hervey Bay stands apart from other Queensland cities because of its geographical protection, marine behaviour, ecological sensitivity and coastal development patterns. These unique conditions make accurate spatial data and robust engineering essential.

Here’s what sets the region apart:

1. Calm, Protected Waters Created by K’gari (Fraser Island)

Hervey Bay sits behind the world’s largest sand island, which shields the city from ocean swell. This rare geographic feature enables:

ideal boating and marine-access conditions
predictable marine construction windows
lower wave stress on coastal structures
consistent eco-tourism operations

Few places on earth have this natural barrier, making precise coastal modelling essential for designing long-life marine assets.

2. World-Famous Whale Nursery

Hervey Bay is the world’s first Whale Heritage Site, known for the behaviour of humpback whales who stop here with their calves.

Environmental sensitivity means many projects require:

accurate as-built documentation
ecological planning
digital modelling to minimise impacts
detailed engineering reports for compliance

3. Rapid Coastal Development and Urban Expansion

The region is one of Queensland’s fastest-growing coastal centres. New marinas, foreshore upgrades, residential developments and tourism infrastructure require accurate ground modelling and precise design.

4. A Strong Marine, Fabrication & Light-Industrial Sector

Slipways, fabrication yards, marine workshops and coastal civil contractors all depend on precise measurements and accurate drafting to minimise rework.

This mix of marine, civil and light-industry projects is exactly why 3D LiDAR scanning and digital engineering matter in Hervey Bay.

3D LiDAR Laser Scanning — The Foundation of Accurate Coastal & Industrial Projects

Coastal infrastructure often includes complex geometry, ageing assets, variable terrain and environmental constraints that make traditional surveying slow and unreliable. That’s where 3D LiDAR scanning becomes a game-changer.

Hamilton By Design provides high-accuracy scanning that captures:

marinas, jetties, pontoons and foreshore structures
workshops, fabrication sheds and industrial sites
terrain, drainage channels and coastal slopes
mechanical equipment, platforms and walkways
existing buildings for upgrades or conversions
complex pipework, tanks and utility lines

The result is a millimetre-accurate digital representation of your site — a data-rich foundation for design, clash detection, feasibility studies and fabrication planning.

Learn more about scanning capabilities here:
3D Laser Scanning

For Hervey Bay clients, this means:

fewer site visits
faster design turnaround
improved coordination between contractors
reduced rework and installation errors
clearer visualisation for approvals and planning

In a region where weather, tides and tourism windows matter, efficient and accurate design matters even more.

3D Modelling & Drafting — Turning Point Clouds into Build-Ready Designs

Once your site is scanned, Hamilton By Design transforms the data into full 3D CAD models and fabrication-ready drawings. This is essential for:

marine structures and coastal engineering
industrial and fabrication workshops
building upgrades or repurposing
mechanical equipment layout and installation
compliance and safety documentation

We deliver:

structural steel models
mechanical assemblies
GA and detail drawings
pipework and flow system layouts
workshop fit-outs
clash detection and interference checks
complete drawing packages with BOMs

In Hervey Bay, where many facilities evolve in stages over time — marinas, boating facilities, industrial sheds, tourist infrastructure — having an accurate digital model avoids expensive mistakes.

Engineering Services Tailored to Hervey Bay’s Coastal & Industrial Landscape

Hervey Bay’s engineering needs are shaped by:

coastal exposure
saltwater corrosion
tidal influences
marine loading
environmental sensitivity
ageing civil assets
strong fabrication and workshop activity

Hamilton By Design supports these needs with comprehensive mechanical and structural engineering including:

Mechanical Engineering

equipment layout and optimisation
marine-grade design modifications
conveyor, pump, motor and mechanical upgrades
fatigue and stress analysis
flow and process improvements

Structural Engineering

wharf and jetty modifications
platform and walkway design
structural integrity assessments
corrosion management & replacement design
footings, mounting and support structures
upgrades for load, access or compliance

Every project is grounded in real, verified site data, delivered through laser scanning.

Where Our Services Add the Most Value in Hervey Bay

1. Foreshore, Marina & Coastal Infrastructure Upgrades

Scanning provides exact geometry for:

seawalls
boardwalks
jetties
pontoons
boat ramps
retaining structures
marine-service assets

2. Workshop, Fabrication & Light-Industrial Facilities

Accurate capture of existing layouts helps:

optimise machinery placement
design new steelwork
eliminate fit-up errors
streamline fabrication

3. Tourism & Eco-Experience Infrastructure

Projects near sensitive environmental zones benefit from:

low-impact, non-intrusive scanning
terrain modelling
digital planning documentation

4. Council & Civil Infrastructure

LiDAR supports:

drainage upgrades
road and footpath modelling
structural assessments
coastal resilience planning

5. Building Renovations & Commercial Upgrades

Perfect for:

repurposed spaces
cafes, tourism centres, warehouses
multi-stage redevelopment projects

End-to-End Workflow for Bundaberg Projects

Hamilton By Design delivers a fully integrated service:

3D LiDAR scanning
Point-cloud processing & accuracy verification
3D CAD modelling
Mechanical & structural engineering
Fabrication-ready drawings
Digital QA & documentation

There’s one team, one workflow and one level of accountability — reducing delays, confusion and rework.

Hervey Bay’s Future Is Digital — And Hamilton By Design Is Ready

Hervey Bay is transforming. With coastal development, marina upgrades, eco-tourism expansion, workshop growth and rising residential infrastructure, the region needs accurate, digital, engineering-grade solutions more than ever.

Hamilton By Design is here to provide:

precision 3D LiDAR scanning
engineering for marine, civil and industrial facilities
3D modelling and drafting
digital quality assurance
fabrication-ready deliverables

Whether you’re planning a new coastal asset, redesigning a workshop, improving a facility or upgrading existing infrastructure, our team ensures accuracy, safety and efficiency every step of the way.

Our Clients

2 December 20257 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

Would you Like to Know more?

Accuracy of 3D LiDAR Scanning With FARO

Why Shutdown Parts Don’t Fit

Engineering Services

Coal Chute Design

Chute Design

3D CAD Modelling | 3D Scanning

15 October 202516 October 2025

Bridging Reality and Design: How 3D Scanning + 3D Modelling Supercharge Mining Process Plants

In mining and mineral processing environments, small mis-fits, outdated drawings, or inaccurate assumptions can translate into shutdowns, costly rework, or worse, safety incidents. For PMs, superintendents, engineering managers and plants operating under heavy uptime and safety constraints, combining 3D scanning and 3D modelling isn’t just “nice to have” — it’s becoming essential. At Hamilton By Design, we’ve leveraged this combination to deliver greater predictability, lower cost, and improved safety across multiple projects.

What are 3D Scanning and 3D Modelling?

3D Scanning (via LiDAR, laser, terrestrial/mobile scanners): captures the existing geometry of structures, equipment, piping, chutes, supports, tanks, etc., as a dense point cloud. Creates a digital “reality capture” of the plant in its current (often messy) state.
3D Modelling: turning that data (point clouds, mesh) into clean, usable engineering-geometry — CAD models, as-built / retrofit layouts, clash-detection, wear mapping, digital twins, etc.

The power comes when you integrate the two — when the reality captured in scan form feeds directly into your modelling/design workflows rather than being a separate survey activity that’s then “interpreted” or “assumed.”

Why Combine Scanning + Modelling? Key Benefits

Here are the main advantages you get when you deploy both in an integrated workflow:

Benefit	What it Means for PMs / Engineering / Plant Ops	Examples / Impacts
Accuracy & Reality Verification	Verify what’s actually in the plant vs what drawings say. Identify deformations, misalignments, wear, obstructions, or changes that weren’t captured in paper drawings.	Mill liner wear profiles; chute/hopper buildup; misaligned conveyors or supports discovered post-scan.
Reduced Risk, Safer Access	Scanning can be done with limited or no shutdown, and from safer vantage points. Less need for personnel to enter hazardous or confined spaces.	Scanning inside crushers, under conveyors, or at height without scaffolding.
Time & Cost Savings	Faster surveying; fewer repeat field trips; less rework; fewer surprises during shutdowns or retrofit work.	Scan once, model many; clashes found in model instead of in the field; pre-fabrication of replacement parts.
Better Shutdown / Retrofit Planning	Use accurate as-built models so new equipment fits, interferences are caught, installation time is optimized.	New pipelines routed without conflict; steelwork/supports prefabricated; shutdown windows shortened.
Maintenance & Asset Lifecycle Management	Scan history becomes a baseline for monitoring wear or deformation. Enables predictive maintenance rather than reactive.	Comparing scans over time to track wear; scheduling relining of chutes; monitoring structural integrity.
Improved Decision Making & Visualisation	Engineers, superintendents, planners can visualise the plant as it is — space constraints, access routes, clearances — before making decisions.	Clash-detection between new and existing frames; planning maintenance access; safety audits.
Digital Twin / Integration for Future-Ready Plant	Once you have accurate geometric models you can integrate with IoT, process data, simulation tools, condition monitoring etc.	Digital twins that simulate flow, energy use, wear; using scan data to feed CFD or FEA; feeding into operational dashboards.

Challenges & How to Overcome Them

Of course, there are pitfalls. Ensuring scanning + modelling delivers value requires attention to:

Planning the scanning campaign (scan positions, control points, resolution) to avoid shadow zones or missing data.
Choosing hardware and equipment that can operate under plant conditions (dust, vibration, temperature, restricted access).
Processing & registration of point clouds, managing the large data sets, and ensuring clean, usable models.
Ensuring modelling workflow aligns with engineering design tools (CAD systems, formats, tolerances) so that the scan data is usable without excessive cleanup.
Maintaining the model: when plant layouts or equipment change, keeping the scan or model up to date so your decisions are based on recent reality.

At Hamilton By Design we emphasise these aspects; our scan-to-CAD workflows are built to align with plant engineering needs, and we help clients plan and manage the full lifecycle.

Real World Applications in Mining & Process Plants

Here’s how combined scanning + modelling is applied (and what you might look for in your own facility):

Wear & Relining: scanning mill, crusher liners, chutes or hoppers to model wear profiles; predict failures; design replacement parts that fit exactly.
Retrofits & Expansions: mapping existing steel, pipe racks, conveyors, etc., creating accurate “as built” model, checking for clashes, optimizing layouts, prefabricating supports.
Stockpile / Volumetric Monitoring: using scans or LiDAR to measure stockpile volumes for planning and reporting; integrating with models to monitor material movement and flow.
Safety & Clearance Checking: verifying that walkways, egress paths, platforms have maintained their clearances; assess structural changes; check for deformation or damage.
Shutdown Planning: using accurate 3D models to plan the scope, access, scaffold/frame erection, pipe removal etc., so shutdown time is minimised.

Why Choose Hamilton By Design

To get full value from the scan + model combination, you need more than just “we’ll scan it” or “we’ll make a model” — you need a partner who understands both the field realities and the engineering rigour. Here’s where Hamilton By Design excels:

Strong engineering experience in mining & processing plant settings, so we know what level of detail, what tolerances, and what access constraints matter.
Proven tools & workflows: from LiDAR / laser scanner work that captures site conditions even under harsh conditions, to solid CAD modelling/reporting that aligns with your fabrication/installation requirements.
Scan-to-CAD workflows: not just raw point clouds, but models that feed directly into design, maintenance, procurement and operations.
Focus on accuracy, safety, and reduced downtime: ensuring that field work, design, installation etc., are as efficient and risk-averse as possible.
Use of modern digital techniques (digital twins, clash detection etc.) so that data isn’t just stored, but actively used to drive improvements.

Practical Steps to Get Started / Best Practice Tips

If you’re managing a plant or engineering project, here are some steps to adopt scanning + modelling optimally:

Define Clear Objectives: What do you want from this scan + model? Wear profiles, retrofit, layout changes, safety audit etc.
Survey Planning: Decide scan positions, control points, resolution (density) based on the objectives and site constraints. Consider access, safety, shutdown windows.
Use Appropriate Hardware: Choose scanners suited to environment (dust, heat), also ensure regulatory and IP protection etc.
Data Processing & Modelling Tools: Have the capacity/software to register, clean, mesh or extract CAD geometry.
Integrate into Existing Engineering Processes: Ensure the outputs are compatible with your CAD standards, procurement, installation etc.
Iterate & Maintain: Frequent scans over time to track changes; update models when plant changes; feed maintenance, design and operations with new data.

Conclusion

In mining process plants, time, safety, and certainty matter. By combining 3D scanning with sound 3D modelling you don’t just get a snapshot of your plant — you gain a powerful toolset to reduce downtime, avoid rework, improve safety, and enhance decision-making.

If you’re responsible for uptime, capital works, maintenance or process improvements, this integration can reshape how you plan, maintain, and operate. At Hamilton By Design, we’re helping clients in Australia harness this power — turning reality into design confidence, and giving stakeholders peace of mind that the layout, equipment, and safety are aligned not to yesterday’s drawings but to today’s reality.

29 September 20251 December 2025

Choosing the Right 3D Scanner for Construction, Manufacturing, and Mining Projects

At Hamilton By Design, we know that 3D scanning has become an essential tool for modern engineering — from capturing as-built conditions on construction sites to modeling complex processing plants and validating manufacturing layouts. But not all scanners are created equal, and selecting the right technology is crucial to getting reliable data and avoiding costly surprises later in the project.

3D Scanning for Construction Sites

For construction and infrastructure projects, coverage and speed are the top priorities. Terrestrial Laser Scanning (TLS) and LiDAR systems like the FARO Focus S70 are ideal for quickly capturing entire job sites with millimetre-level accuracy. These scanners allow engineers and project managers to:

Verify as-built conditions against design models
Detect clashes early in the process
Support accurate quantity take-offs and progress documentation

TLS works well in tough environments — dust, sunlight, and complex geometry — making it a perfect fit for active building sites.

3D Scanning for Manufacturing & Processing Plants

When it comes to manufacturing facilities and mining processing plants, accuracy and detail matter even more. Scans are often used for:

Retrofit planning and clash detection in tight plant rooms
Structural steel and conveyor alignment checks
Equipment layout for expansion projects

Here, combining TLS with feature-based CAD modeling allows us to deliver data that is usable for engineering design, ensuring that new equipment fits exactly as intended.

Infographic titled ‘Choosing the Right 3D Scanner for Your Project’ with the tagline ‘Not Selling, Just Helping.’ The left side shows a construction site with a tripod-mounted 3D scanner and benefits listed: fast coverage, millimetre accuracy, and clash detection, leading to BIM model or digital twin outputs. The right side shows a manufacturing and processing plant with a scanner and benefits: retrofit planning, equipment layout, and alignment verification, leading to CAD model overlay results

Seeing the Unseen: How LiDAR Scanning is Transforming Mining Process Plants

In modern mining, where uptime is money and safety is non-negotiable, understanding the geometry of your process plant is critical. Every conveyor, chute, pipe rack, and piece of equipment must fit together seamlessly and operate reliably — but plants are messy, dusty, and constantly changing. Manual measurement with a tape or total station is slow, risky, and often incomplete.

nfographic showing how LiDAR scanning is used in mining process plants, with illustrations of conveyors, crushers, tanks, mills and chutes. Labels highlight applications such as stockpile volumetrics, crusher inspections, safety and risk management, chute wear and blockages, mill wear measurement, tank deformation monitoring and creating digital twins.

This is where LiDAR scanning (Light Detection and Ranging) has become a game-changer. By capturing millions of precise 3D points per second, LiDAR gives engineers, maintenance planners, and operators an exact digital replica of the plant — without climbing scaffolds or shutting down equipment. In this post, we’ll explore how mining companies are using LiDAR scanning to solve real problems in processing plants, improve safety, and unlock operational efficiency.

What Is LiDAR Scanning?

LiDAR is a remote sensing technology that measures distance by firing pulses of laser light and recording the time it takes for them to return. Modern terrestrial and mobile LiDAR scanners can:

Capture hundreds of thousands to millions of points per second
Reach tens to hundreds of meters, depending on the instrument
Achieve millimeter-to-centimeter accuracy
Work in GPS-denied environments, such as inside mills, tunnels, or enclosed plants (using SLAM — Simultaneous Localization and Mapping)

The output is a point cloud — a dense 3D dataset representing surfaces, equipment, and structures with stunning accuracy. This point cloud can be used as-is for measurements or converted into CAD models and digital twins.

Why Process Plants Are Perfect for LiDAR

Unlike greenfield mine sites, processing plants are some of the most geometry-rich and access-constrained areas on site. They contain:

Complex networks of pipes, conveyors, tanks, and structural steel
Moving equipment such as crushers, mills, and feeders
Dusty, noisy, and hazardous environments with limited safe access

All these factors make traditional surveying difficult — and sometimes dangerous. LiDAR enables “no-touch” measurement from safe vantage points, even during operation. Multiple scans can be stitched together to create a complete model without shutting down the plant.

Applications of LiDAR in Process Plants

1. Wear Measurement and Maintenance Planning

LiDAR has revolutionized how mines measure and predict wear on critical process equipment:

SAG and Ball Mill Liners – Portable laser scanners can capture the exact wear profile of liners. Comparing scans over time reveals wear rates, helping maintenance teams schedule relines with confidence and avoid premature failures.
Crusher Chambers – Scanning inside primary and secondary crushers is now faster and safer than manual inspections. The resulting 3D model allows engineers to assess liner life and optimize chamber profiles.
Chutes and Hoppers – Internal scans show where material buildup occurs, enabling targeted cleaning and redesign to prevent blockages.

Result: Reduced downtime, safer inspections, and better forecasting of maintenance budgets.

2. Retrofit and Expansion Projects

When modifying a plant — installing a new pump, rerouting a pipe, or adding an entire circuit — having an accurate “as-built” model is crucial.

As-Built Capture – LiDAR provides an exact snapshot of the existing plant layout, eliminating guesswork.
Clash Detection – Designers can overlay new equipment models onto the point cloud to detect interferences before anything is fabricated.
Shutdown Optimization – With accurate geometry, crews know exactly what to cut, weld, and install — reducing surprise field modifications and shortening shutdown durations.

3. Inventory and Material Flow Monitoring

LiDAR is not just for geometry — it’s also a powerful tool for tracking material:

Stockpile Volumetrics – Mounted scanners on stackers or at fixed points can monitor ore, concentrate, and product stockpiles in real time.
Conveyor Load Measurement – Stationary LiDAR above belts calculates volumetric flow, giving a direct measure of throughput without contact.
Blending Control – Accurate inventory data improves blending plans, ensuring consistent plant feed quality.

4. Safety and Risk Management

Perhaps the most valuable application of LiDAR is keeping people out of harm’s way:

Hazardous Floor Areas – When flooring or gratings fail, robots or drones with LiDAR payloads can enter the area and collect data remotely.
Fall-of-Ground Risk – High walls, bin drawpoints, and ore passes can be scanned for unstable rock or buildup.
Escape Route Validation – Scans verify clearances for egress ladders, walkways, and platforms.

Every scan effectively becomes a permanent digital record — a baseline for monitoring ongoing structural integrity.

5. Digital Twins and Advanced Analytics

A plant-wide LiDAR scan is the foundation of a digital twin — a living, data-rich 3D model connected to operational data:

Combine scans with SCADA, IoT, and maintenance systems
Visualize live process variables in context (flow rates, temperatures, vibrations)
Run “what-if” simulations for debottlenecking or energy optimization

As AI and simulation tools mature, the combination of geometric fidelity and operational data opens new possibilities for predictive maintenance and autonomous plant operations.

Emerging Opportunities

Looking forward, there are several promising areas for LiDAR in mining process plants:

Autonomous Scan Missions – Using quadruped robots (like Spot) or SLAM-enabled drones to perform routine scanning in high-risk zones.
Real-Time Change Detection – Continuous scanning of critical assets with alerts when deformation exceeds thresholds.
AI-Driven Point Cloud Analysis – Automatic object recognition (valves, flanges, motors) to speed up model creation and condition reporting.
Integrated Planning Dashboards – Combining LiDAR scans, work orders, and shutdown schedules in a single interactive 3D environment.

Best Practices for Implementing LiDAR

To maximize the value of LiDAR scanning, consider:

Define the Objective – Are you measuring wear, planning a retrofit, or building a digital twin? This affects scanner choice and resolution.
Plan Scan Positions – Minimize occlusions and shadow zones by preplanning vantage points.
Use Proper Registration – Tie scans to a control network for consistent alignment between surveys.
Mind the Environment – Dust, fog, and vibration can degrade data; choose scanners with appropriate filters or protective housings.
Invest in Processing Tools – The raw point cloud is only the start — software for meshing, modeling, and analysis is where value is extracted.
Train Your Team – Build internal capability for scanning, processing, and interpreting the results to avoid vendor bottlenecks.

Infographic showing a 3D LiDAR scanner on a tripod surrounded by eight best-practice principles: start with clear objectives, plan your scanning campaign, prioritize safety, optimize data quality, ensure robust registration and georeferencing, establish repeatability, integrate with downstream systems, and train people with documented procedures

LiDAR scanning is no longer a niche technology — it is rapidly becoming a standard tool for mining process plants that want to operate safely, efficiently, and with fewer surprises. From mill liners to stockpiles, from shutdown planning to digital twins, LiDAR provides a clear, measurable view of assets that was impossible a decade ago.

For operations teams under pressure to deliver more with less, the case is compelling: better data leads to better decisions. And in a high-stakes environment like mineral processing, better decisions translate directly to improved uptime, reduced costs, and safer workplaces.

The next time you’re planning a shutdown, a retrofit, or even just trying to understand why a chute is plugging, consider pointing a LiDAR scanner at the problem. You may be surprised at how much more you can see — and how much time and money you can save.

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