Finite Element Analysis (FEA) & Mechanical Assessment

Independent engineering insight for critical assets and brownfield upgrades

At Hamilton By Design, we use Finite Element Analysis (FEA) and practical mechanical assessment to help mining, processing and industrial operators answer three simple questions:

Is it strong enough?
Will it last long enough?
What’s the smartest way to fix or upgrade it?

Whether you’re planning a shutdown, chasing a recurring failure, or trying to squeeze more life out of ageing equipment, we provide consultant-level FEA backed by real plant experience – not just pretty stress plots.

How our FEA & mechanical assessment helps your site

We act as your independent engineering partner, using FEA and mechanical diagnostics to:

Validate new or modified designs before you commit to fabrication
Diagnose cracking, distortion, misalignment and vibration issues in existing assets
Assess the impact of capacity increases, speed changes or new duty cycles
Demonstrate compliance with relevant codes, standards and site requirements
Identify low-risk, high-value modifications that reduce downtime and rework

We combine sound engineering judgement with modern simulation tools (e.g. SolidWorks Simulation) and, where needed, 3D laser scanning of as-built conditions to make sure the model actually matches reality.

Typical equipment and structures we assess

We regularly support projects across mining, bulk materials handling and heavy industry, including:

Conveyors, transfer towers and gallery structures
Chutes, hoppers, bins and wear-lined components
Screens, crushers, feeders and vibrating equipment
Tanks, vessels, pipework and support steelwork
Access platforms, walkways, maintenance stands and handling frames
Custom skids, frames, jigs and lifting/maintenance tooling

Our role is to advise – helping you understand what’s actually happening in your equipment, and what to do about it.

What we analyse (and how we advise)

Our team can apply a range of analysis types to suit the problem being solved, including:

Linear static stress & deflection

To check whether parts and assemblies can safely carry their loads under normal operation, maintenance or upset conditions.

Consulting outcome: Clear utilisation ratios, critical locations, and practical options – increase thickness, change material, add local stiffening, or adjust load paths.

Fatigue & life assessment

For components subjected to cyclic loading – such as vibrating equipment, high-cycle load paths, start/stop duty or thermal cycling.

Consulting outcome: Estimated life, critical details, and redesign strategies to extend life (geometry changes, weld detail upgrades, load reduction, or operational changes).

Modal / vibration / dynamic response

To understand natural frequencies, mode shapes and the risk of resonance with operating speeds or excitation sources.

Consulting outcome: Recommendations on stiffening, mass changes, support conditions or operating speed windows to minimise vibration problems and fatigue risk.

Buckling & stability

For slender members, frames and plated structures subjected to compressive or combined loading.

Consulting outcome: Buckling factors, governing modes and targeted stiffening schemes or load-path changes to secure an acceptable factor of safety.

Thermal & combined loading

Where temperature gradients or thermal cycling contribute to stress, distortion or fatigue.

Consulting outcome: Advice on insulation, supports, expansion joints, sliding connections or geometry changes to manage thermal effects.

We don’t just send a report – we walk through the results with your team and discuss what it means for operations, maintenance and capital planning.

A practical, plant-focused assessment process

Define the problem and context
We start by listening – understanding your equipment history, failure modes, operating conditions, constraints and shutdown windows.
Capture accurate geometry
- Use existing models and drawings where suitable
- Or generate as-built geometry from 3D LiDAR scans when legacy documentation is missing or unreliable
Build and verify the FEA model
- Appropriate element types (solid / shell / beam)
- Realistic supports, contacts and load paths
- Sensible meshing with refinement where it actually matters
Apply realistic load cases
- Operating loads, dead loads, impact factors and start-up/transient effects where relevant
- Site-specific conditions and any applicable code requirements
Interpret results – not just pictures
- Identify genuine hot-spots vs numerical noise
- Compare with known behaviour (crack locations, deflections, vibration reports)
- Sanity-check results against classical calculations and experience
Recommend clear, buildable actions
- Strengthening or geometry changes
- Material or thickness changes
- Operational or procedural adjustments
- Prioritised options: quick fixes vs long-term solutions
Deliver traceable documentation
- Calculation report (including assumptions and load cases)
- Marked-up drawings or revised 3D models
- Inputs for internal approvals, OEM engagement or regulator submissions

Where FEA & mechanical assessment adds the most value

Our consulting approach works particularly well when:

You’re planning a shutdown upgrade and want confidence before fabrication
You’re seeing repeated cracking or failures and need root-cause clarity
You’re increasing capacity (throughput, speed, tonnage) on ageing assets
Documentation is incomplete and you need as-built + analysis to make decisions
You need to justify continued operation of existing assets to internal stakeholders or regulators

Because we work across both design and site support, we’re always focused on solutions you can actually build and install, not theoretical perfection.

Why work with Hamilton By Design?

Engineer-led analysis – Your project is led by engineers experienced in both FEA and real plant behaviour.
Strong brownfield capability – We specialise in brownfield and retrofit work where access, geometry and history are complex.
Integrated scanning + modelling + FEA – We can take you from point cloud, to model, to assessment, to fabrication-ready drawings.
Industry-specific understanding – Mining, CHPPs, hard-rock plants, ports and heavy industry are our home ground.
Clear, practical recommendations – We focus on actions, not just colourful stress plots.

Let’s talk about your next assessment

If you have an asset that’s:

Cracking, vibrating or underperforming
About to be modified or uprated
Nearing the end of its design life

we can help you make informed, defensible decisions using Finite Element Analysis and grounded mechanical engineering.

Get in touch via the Hamilton By Design website to discuss your FEA and mechanical assessment needs, or to scope an initial review ahead of your next shutdown.

Email – info@hamiltonbydesign.com.au

Phone – (+61) 0477 002 249