Engineering Studies and Assessments

Practical Engineering Information for Better Project Decisions

Engineering projects often begin with questions.

Is the existing equipment suitable for continued service?
Will a proposed modification work?
What is causing the recurring problem?
Do the existing drawings match the installed plant?
Can an asset be repaired, upgraded or safely replaced?

Hamilton By Design provides practical engineering studies and assessments for industrial machinery, mining equipment, materials-handling systems, manufacturing facilities and existing plant.

Our studies help clients understand existing conditions, investigate engineering problems and make informed decisions before progressing into detailed design, fabrication or site installation.

Engineering Studies for Existing Industrial Assets

Existing equipment and industrial facilities do not always match their original drawings.

Assets may have been modified, repaired, relocated or altered over many years. Drawings may be incomplete, outdated or unavailable. Operating conditions may also have changed since the equipment was originally installed.

Hamilton By Design can combine site inspections, engineering measurements, 3D LiDAR scanning, CAD modelling and engineering analysis to establish a clearer understanding of the asset and the problem being investigated.

Depending on the project, an engineering study may support:

Maintenance planning
Plant modifications
Equipment upgrades
Replacement projects
Shutdown preparation
Failure investigations
Safety improvements
Fabrication planning
Asset-life extension
Capital-project development

Our Engineering Studies and Assessments

Existing-Condition Studies

Existing-condition studies establish what is currently installed on site.

This may involve reviewing available drawings, completing site measurements, capturing 3D scan data and comparing the physical asset against existing documentation.

Typical applications include:

Brownfield plant modifications
Existing-drawing verification
Equipment replacement
Plant-layout confirmation
Structural and mechanical documentation
Development of as-built CAD models

Feasibility Studies

A feasibility study helps determine whether a proposed engineering solution is practical before significant resources are committed to detailed design.

The study may consider:

Existing site constraints
Available installation space
Access and maintainability
Preliminary equipment selection
Constructability
Indicative engineering requirements
Potential project risks
Alternative design concepts

Mechanical Equipment Assessments

Mechanical-equipment assessments examine the condition, arrangement or suitability of existing machinery and components.

Assessments may be completed for:

Conveyors
Chutes and transfer stations
Hoppers and bins
Rotating equipment
Machine frames
Guards and access systems
Fabricated equipment
Production machinery
Mining and materials-handling equipment

The assessment can help identify visible damage, deformation, wear, alignment concerns, access limitations and opportunities for improvement.

Dimensional and Geometric Assessments

Manual measurements can be difficult when equipment is large, complex, obstructed or irregularly shaped.

Hamilton By Design can use engineering-grade 3D LiDAR scanning and CAD comparison techniques to assess:

Equipment geometry
Alignment
Clearances
Deformation
Mounting locations
Interface dimensions
Fabrication fit-up
Available installation envelopes

This information can support replacement components, modification work, prefabrication and installation planning.

Kinematic and Motion Studies

Kinematic studies examine how mechanical components move and interact through their operating range.

These studies can be used to investigate:

Mechanical linkages
Moving machinery
Hydraulic-cylinder travel
Equipment articulation
Component clearances
Potential mechanical interference
Operating envelopes
Maintenance and removal paths

Existing equipment can be captured using 3D scanning and recreated in CAD to assist with motion analysis and design development.

Finite Element Analysis and Structural Assessment

Finite element analysis can be used to investigate how a component or structure may respond to applied loads.

Depending on the available information and project requirements, an assessment may consider:

Stress distribution
Deflection
Load paths
Localised stress concentrations
Connection behaviour
Proposed design changes
Existing damage or deterioration
Reinforcement concepts

Finite element analysis should be supported by suitable engineering assumptions, load information, material data and clearly defined assessment criteria.

Failure and Root-Cause Investigations

Repeated equipment failures should not always be treated as isolated maintenance events.

An engineering investigation can help examine the underlying factors contributing to a problem.

The investigation may consider:

Operating conditions
Equipment geometry
Load paths
Material selection
Wear patterns
Misalignment
Fatigue-sensitive details
Maintenance history
Previous repairs or modifications
Interaction with surrounding equipment

The objective is to establish the available facts, identify likely contributing factors and develop practical recommendations.

Reliability and Asset-Condition Assessments

Reliability assessments can help maintenance and operations teams understand recurring equipment problems and prioritise improvement work.

Depending on the asset, the assessment may include:

Visual condition review
Review of maintenance information
Wear and deformation assessment
Vibration-related observations
Alignment and support conditions
Maintainability review
Replacement or refurbishment considerations
Recommendations for further investigation

Safety and Compliance Assessments

Existing machinery and access systems may no longer reflect current operating practices, site requirements or applicable engineering standards.

Hamilton By Design can assist with engineering reviews relating to:

Machine guarding
Maintenance access
Platforms and walkways
Stairs and ladders
Handrails
Equipment isolation considerations
Mechanical hazards
Proposed safety modifications

The scope and applicable standards should be clearly established before the assessment begins.

Reverse-Engineering Assessments

When original drawings, models or manufacturer information are unavailable, reverse engineering can be used to document an existing component or assembly.

The process may involve:

Site measurement
3D laser scanning
Component scanning
Point-cloud processing
CAD reconstruction
Material and manufacturing review
Development of replacement drawings
Design improvement recommendations

Engineering Tools That Support Our Studies

The tools used will depend on the asset, available information and purpose of the assessment.

Hamilton By Design may use:

3D terrestrial LiDAR scanning
Point-cloud registration and analysis
Traditional engineering measurements
SolidWorks
SolidWorks Simulation
Autodesk Inventor
AutoCAD
Autodesk ReCap
FARO SCENE
Navisworks
Finite element analysis
CAD interference and motion analysis
Existing-drawing comparison
Engineering calculations and technical documentation

The purpose of these tools is not simply to produce more data. It is to convert site information into practical engineering information that supports a decision.

Typical Engineering Study Deliverables

Deliverables will be selected to suit the purpose and agreed scope of the study.

They may include:

Engineering study report
Existing-condition assessment
Site-inspection findings
Point-cloud dataset
Existing-condition CAD model
Marked-up drawings
General arrangement drawings
Dimensional comparison
Photographic record
Preliminary calculations
FEA results
Concept-design options
Risk and constraint register
Recommended further investigations
Repair, replacement or improvement recommendations

Our Engineering Study Process

1. Define the Question

We begin by establishing the engineering problem, the required decision and the intended use of the study.

2. Review Available Information

Existing drawings, photographs, maintenance records, equipment information and previous reports are reviewed where available.

3. Inspect and Capture Existing Conditions

Depending on the project, this may involve a site inspection, traditional measurements, photographs, 3D laser scanning or component scanning.

4. Analyse the Information

The collected information is reviewed using appropriate engineering calculations, CAD modelling, dimensional comparison, motion analysis or finite element analysis.

5. Document the Findings

The findings, assumptions, limitations and recommendations are documented in a format suited to the project.

6. Support the Next Stage

The completed study can support feasibility development, detailed design, budgeting, procurement, fabrication, maintenance or shutdown planning.

Why Work With Hamilton By Design?

Hamilton By Design combines engineering analysis with practical experience in drafting, manufacturing, fabrication, site measurement and existing industrial assets.

Our approach is focused on producing information that can be used by:

Asset owners
Engineering managers
Maintenance teams
Project engineers
Reliability engineers
Fabricators
Installation contractors
Operations personnel

We aim to provide practical, clearly documented engineering information that helps clients understand the problem and determine the next appropriate step.

Industries We Support

Our engineering studies and assessments can support projects across:

Mining and mineral processing
Materials handling
Steelmaking and smelting
Manufacturing
Food and beverage production
Water and wastewater
Power generation
Transport infrastructure
Heavy industrial facilities
Bulk-material storage and handling

Hamilton By Design supports projects throughout Australia, including New South Wales, Queensland, Victoria, Western Australia, South Australia and regional mining locations.

Not Sure Which Engineering Study You Need?

You do not need to know the exact name of the study before contacting us.

Tell us:

What asset or equipment is involved
What problem has been observed
What information is currently available
What decision needs to be made
When the information is required

We can then help define an appropriate scope for the engineering study or assessment.

Discuss Your Engineering Study

Hamilton By Design provides practical engineering studies, site assessments, 3D scanning, CAD modelling and engineering analysis for existing industrial assets.

Contact our team to discuss your equipment, engineering problem or proposed project.