3D LiDAR Scanning for As-Built & Brownfield Engineering

At Hamilton By Design, we use engineering-grade 3D LiDAR scanning to capture the true as-built condition of your plant, structures and equipment — so you can design, fabricate and install with confidence.

From coal handling preparation plants (CHPP) and hard rock processing lines, through to power stations, manufacturing plants and commercial buildings, our engineer-led scanning process gives you accurate, clash-ready data for every brownfield project.

Why 3D LiDAR Scanning Matters for Brownfield Projects

Brownfield engineering is never “like the drawings”.

Over years of operation, plants twist, deflect, corrode and get modified during shutdowns. Legacy drawings are often incomplete or out of date. That’s where 3D LiDAR scanning changes the game:

Capture real geometry, not assumptions
Record every beam, pipe, chute, cable tray and accessway as it actually exists today.
See deformations and historic repairs
Pick up deflections, sagging, wear, corrosion loss and undocumented modifications that don’t appear in old drawings.
De-risk shutdowns and fit-ups
Use the scan-based model to check new designs for clashes, access, maintenance and installation sequence before you cut steel.
Improve safety and compliance
Support structural integrity assessments, access/egress reviews and compliance checks with a trusted, measurable digital record.
Reduce site time for designers
Capture everything once, then let your engineering and drafting team work from the digital plant model instead of repeated site visits.

What We Scan

Hamilton By Design can scan and model:

CHPP and coal handling infrastructure
- Screens, crushers, transfer towers, chutes, hoppers, conveyors, tripper gantries, stackers and reclaimers
Hard-rock and mineral processing plants
- Mills, cyclones, crushers, bins, slurry pipework, support structures
Power stations and energy infrastructure
- Boiler houses, turbine halls, pipe racks, cable trays, access platforms
Manufacturing and industrial facilities
- Production lines, material handling systems, automation cells, storage areas
Commercial and building services
- Plant rooms, risers, roof services, façades and structural frames

If it’s built and you need to understand it, we can scan it.

Engineer-Led Scanning, Not Just Survey

What sets Hamilton By Design apart is that our scanning is driven by mechanical engineers, not just surveyors.

That means we plan each scan campaign based on:

The future design work you need to do
The critical interfaces (bolt patterns, flanges, centre-lines, datum points)
The tolerances needed for fabrication and installation
The shutdown and access constraints on site

Because the same team that scans your plant is also involved in modelling, design and checking, we make sure the data captured is actually usable for engineering and drafting — not just a pretty point cloud.

Typical Workflow: From Scan to Engineering Model

Scope & Planning
- Define the upgrade, problem area or shutdown scope
- Agree survey tolerances, required deliverables and file formats
- Plan access, shutdown windows and safety requirements
On-Site 3D LiDAR Scanning
- Set up control and scanning positions for full coverage
- Capture high-density scans of structures, equipment and services
- Minimise disruption to operations where possible
Registration & Quality Checks
- Register and align scans into a single, unified point cloud
- Apply QA checks to confirm alignment and global accuracy
- Provide initial visualisation for client review if required
3D Modelling & As-Built Geometry
- Create engineering-ready 3D models in SolidWorks (or other CAD platforms as agreed)
- Model structural steel, mechanical equipment, chutes, pipework and key interfaces
- Prepare background models suitable for new design and layout work
As-Built & Brownfield Engineering Support
- Use the model to support new projects: upgrades, replacements, debottlenecking and layout changes
- Run fit-up checks, clash detection and access/maintenance reviews
- Prepare fabrication drawings and installation packages as required
Handover & Ongoing Use
- Provide point clouds, 3D models and drawings in agreed formats
- Support future shutdowns and projects using the same trusted digital plant model

Deliverables You Can Expect

Depending on the project, we can provide:

Registered point clouds in industry-standard formats
3D CAD models (SolidWorks or exchange formats such as STEP, IGES, DWG)
As-built drawings and GA layouts for mechanical and structural systems
Clash-check models for integration of new designs
Sections and detail views for critical interfaces (bolt patterns, flange faces, datum planes)
Visualisations to support stakeholder communication and approvals

All deliverables are produced with fabrication and construction in mind — so your fabricators, installers and site team can act on them immediately.

Applications in As-Built & Brownfield Engineering

3D LiDAR scanning directly supports:

Shutdown-driven upgrades – de-risking installation windows by checking fit-up beforehand
Chute and hopper redesign – improving flow and wear life using accurate existing geometry
Conveyor and transfer tower modifications – adding new equipment or re-routing systems
Structural remediation and strengthening – understanding real load paths and condition
Pipework reroutes and tie-ins – locating existing lines, clashes and tie-in opportunities
Compliance and audit documentation – maintaining accurate records under Australian standards and site governance

Why Choose Hamilton By Design for 3D LiDAR Scanning?

Engineer-led, not equipment-led – we start with the engineering problem, then choose the scanning approach.
Single-source accountability – one team for scanning, modelling, engineering and drawings.
Brownfield experience – extensive work in CHPPs, mineral processing plants, power stations and heavy industry.
Fabrication-ready outputs – deliverables tailored for fabricators, installers and project engineers.
National coverage – servicing sites across NSW, QLD, WA, VIC and SA.

Next Steps

Planning a shutdown, upgrade or brownfield modification?

Hamilton By Design can help you capture the plant once and then reuse that digital model across multiple projects — reducing risk, improving accuracy and cutting rework.

Contact us to discuss your 3D LiDAR scanning requirements and we’ll help you define: