Wear and Erosion Studies and Assessments

Industrial equipment can continue operating while significant wear develops inside chutes, pipes, hoppers, tanks, ducts and other difficult-to-inspect areas. By the time the damage becomes visible, maintenance teams may be dealing with reduced performance, material leakage, damaged liners or an unplanned shutdown.

Hamilton By Design provides engineering-led wear and erosion studies to help identify where material loss is occurring, assess its extent and support practical maintenance, repair and replacement decisions.

Our approach can combine 3D laser scanning, dimensional inspection, thickness measurements, CAD comparison and mechanical engineering analysis. The objective is to turn existing-condition information into usable engineering outcomes.

The Problem with Unmeasured Wear

Maintenance teams may know that an asset is wearing, but they may not know:

Where the most severe wear is located
How much material has been lost
Whether wear is localised or widespread
Whether a liner is approaching the end of its service life
Whether the underlying structure has been affected
Whether the wear rate is increasing
Which areas should be repaired during the next shutdown
Whether the original equipment geometry is contributing to the problem

Manual inspections can identify obvious damage, but they may not provide sufficient information to quantify complex surface loss or compare the equipment with its original geometry.

A wear and erosion study provides a structured way to document the asset’s current condition and identify the areas that require further investigation.

What Is a Wear and Erosion Study?

A wear and erosion study investigates the location, extent, pattern and likely causes of material loss from industrial equipment.

Wear can be caused by repeated contact, sliding, impact or abrasion. Erosion is commonly associated with particles, droplets or fluids moving across or striking a surface.

Depending on the asset and operating environment, the study may investigate:

Abrasive wear caused by bulk materials
Impact wear at transfer and discharge points
Sliding wear along chutes and liners
Erosion caused by particles carried in air, gas or liquid
Erosion-corrosion in piping and process equipment
Cavitation damage near pumps and valves
Corrosion beneath liners or protective coatings
Fretting or contact wear between moving components
Deformation caused by uneven material loss
Reduction in plate, pipe or liner thickness
Changes in equipment capacity or internal clearances

The study can form part of a broader engineering study and assessment or be completed as a focused investigation of a particular asset.

Who Uses Wear and Erosion Studies?

Wear and erosion studies can support:

Maintenance managers
Reliability engineers
Mechanical engineers
Asset-integrity engineers
Shutdown planners
Fixed-plant supervisors
Processing-plant managers
Project engineers
Maintenance contractors
Equipment manufacturers
Fabricators and liner suppliers

The findings can help these teams determine what should be repaired, what should be monitored and what may require redesign.

Where Can Wear and Erosion Studies Be Applied?

Chutes and Transfer Stations

Material transfer systems are frequently exposed to impact, abrasion and sliding wear.

A study may investigate:

Chute walls
Impact plates
Hood and spoon arrangements
Rock boxes
Deflector plates
Dead boxes
Diverter gates
Loading zones
Discharge sections
Replaceable wear liners
Skirt systems
Transfer-point transitions

Where poor material flow contributes to wear, the findings may also support a revised chute and transfer-point design.

Hoppers, Bins and Silos

Hoppers and bins can experience localised wear where material repeatedly impacts or slides across the same surfaces.

Potential problem areas include:

Hopper transitions
Discharge openings
Internal corners
Flow channels
Liner joints
Support interfaces
High-impact loading zones
Areas affected by material hang-up

Conveyors and Feed Equipment

Wear studies may be used for:

Conveyor loading zones
Apron feeders
Screw conveyors
Vibrating feeders
Belt cleaners
Conveyor skirts
Feeder pans
Discharge pulleys
Transfer interfaces

Pipes and Slurry Systems

Piping systems may experience concentrated erosion at changes in direction, velocity or cross-sectional area.

Typical inspection areas include:

Pipe bends
Elbows
Tees
Reducers
Valves
Slurry lines
Pump suction lines
Pump discharge lines
Nozzles
Branch connections

Pumps, Cyclones and Process Equipment

Wear and erosion may affect:

Pump casings
Impellers
Volutes
Hydrocyclones
Launders
Agitators
Mixing vessels
Fan blades
Ductwork
Dust-extraction equipment

Mobile and Mining Equipment

Wear studies can also support the assessment of:

Haul-truck trays
Excavator buckets
Loader buckets
Dozer blades
Dragline components
Wear plates
Bucket teeth
Crusher components
Mobile equipment liners

Industries We Support

Hamilton By Design can apply wear and erosion studies across:

Mining
Coal handling and preparation plants
Mineral processing
Quarrying
Bulk materials handling
Manufacturing
Steelmaking
Smelting
Water and wastewater
Power generation
Food and process manufacturing
Ports and ship-loading facilities
Recycling and waste-processing plants

Our broader engineering services are suited to brownfield plants, equipment upgrades, shutdown work and refurbishment projects where existing conditions must be understood before decisions are made.

How Is a Wear and Erosion Study Completed?

1. Define the Operational Problem

The first stage is to understand the equipment, its operating environment and the maintenance concern.

Information reviewed may include:

Equipment function
Material being handled
Material hardness and particle size
Moisture content
Flow rate
Material velocity
Operating temperature
Existing liner material
Original plate thickness
Maintenance history
Previous failures
Replacement frequency
Available drawings
Shutdown constraints

This helps determine what information must be captured and which inspection methods are appropriate.

2. Review Existing Information

Available information may include:

Original equipment drawings
Manufacturer’s documentation
Previous inspection reports
Maintenance photographs
Earlier thickness measurements
CAD models
Liner replacement records
Failure reports
Process data
Previous 3D scans

Existing documentation is assessed to determine whether it accurately represents the asset in its current condition.

3. Inspect and Capture the Existing Condition

The equipment can be inspected using one or more measurement methods.

These may include:

3D LiDAR laser scanning
Handheld 3D scanning
Ultrasonic thickness testing
Manual dimensional measurement
Photography
Photogrammetry
Borescope inspection
Visual inspection
Drone-based inspection
Existing-condition survey

Hamilton By Design provides engineering-grade 3D laser scanning to capture plant, equipment and surrounding interfaces as they exist at the time of inspection.

4. Establish the Nominal or Baseline Geometry

To measure wear, the current condition must be compared with an appropriate reference.

The baseline may be established from:

The original CAD model
Manufacturer’s drawings
An unworn replacement component
A previous 3D scan
Known original plate thickness
A symmetrical unworn surface
A reconstructed nominal surface
A newly manufactured liner or wear plate

Where drawings are unavailable or unreliable, reverse-engineering methods may be used to reconstruct the nominal geometry.

5. Compare the Existing and Nominal Conditions

The captured condition can be aligned with the baseline to identify dimensional differences.

This comparison may be used to produce:

Colour-coded deviation maps
Wear-depth maps
Cross-sections
Surface profiles
Minimum-thickness locations
Material-loss calculations
Missing-volume estimates
Areas of deformation
Areas requiring further testing

The results allow maintenance teams to see where wear is concentrated rather than relying only on isolated measurements.

6. Investigate the Likely Causes

Identifying wear does not necessarily explain why it is happening.

Possible contributing factors include:

Direct material impact
Excessive particle velocity
Unfavourable impact angle
Material sliding over unprotected surfaces
Turbulent flow
Recirculation
Material build-up
Poorly positioned liners
Gaps between liner plates
Loose or damaged liners
Incorrect liner material
Inadequate liner thickness
Equipment misalignment
Changes in process conditions
Corrosion behind liners
Localised vibration
Cavitation
Poor transfer geometry

For bulk materials-handling equipment, the study may identify opportunities to modify the flow path or improve the chute design.

7. Develop Engineering Recommendations

The study may recommend:

Immediate repairs
Localised liner replacement
Full liner replacement
Increased liner thickness
Alternative liner materials
Replaceable wear panels
Hardfacing or protective coatings
Changes to chute geometry
Revised impact-plate positions
Improved access for inspection
Additional thickness-monitoring points
Changes to maintenance intervals
Repeat scanning after a defined period
Further engineering analysis
Replacement component design

Tools That Can Assist with Wear and Erosion Studies

3D LiDAR Laser Scanning

LiDAR scanning can capture millions of measurement points across large plant areas and equipment surfaces.

It is particularly useful for:

Large chutes and hoppers
Transfer stations
Conveyor interfaces
Tanks and vessels
Ductwork
Plant layouts
Surrounding structures
Difficult-to-measure brownfield installations

A scan can also record adjacent structures, pipework, access platforms and equipment interfaces that may affect repair or replacement work.

Learn more about our 3D laser scanning services.

Handheld 3D Scanning

Handheld scanners may be suitable for smaller components or surfaces requiring detailed local capture.

Applications may include:

Pump casings
Impellers
Pipe bends
Wear plates
Machine components
Buckets
Teeth and cutting edges
Small chute sections
Replacement components

Ultrasonic Thickness Testing

Ultrasonic thickness testing can help determine the remaining wall thickness of equipment where access is available from only one side.

Typical applications include:

Pipes
Chutes
Tanks
Hoppers
Ductwork
Platework
Pressure-containing equipment

Thickness testing can complement 3D scanning because a surface scan records the accessible geometry but does not, by itself, measure the remaining thickness of a closed plate or pipe wall.

CAD and Surface-Comparison Software

Point clouds, meshes and measured surfaces can be compared with CAD geometry using specialist engineering and inspection software.

This can assist with:

Aligning scan data to CAD
Producing deviation maps
Creating cross-sections
Measuring surface loss
Calculating missing volume
Modelling replacement liners
Reconstructing original geometry
Preparing repair and fabrication drawings

Hamilton By Design can convert captured geometry into usable CAD data through its reverse-engineering and 3D scanning workflow.

Repeat Scanning and Change Detection

Repeat scanning can help identify how an asset changes over time.

For meaningful comparisons, the scans should be aligned using stable reference geometry or permanent survey targets.

Repeat datasets may help estimate:

Changes in wear depth
Changes in material-loss volume
Progression of localised wear
Areas of accelerating degradation
Approximate wear rate
Likely future repair locations

Wear rates should be treated carefully because operating conditions may change between inspection periods.

Discrete Element Modelling

Discrete element method modelling can simulate how bulk particles move through chutes, hoppers and transfer systems.

DEM may assist in identifying:

High-impact zones
Sliding-wear zones
Particle trajectories
Material velocities
Recirculation
Dead zones
Uneven material distribution
Potential geometry improvements

DEM does not replace physical inspection. It can, however, help investigate why particular areas are experiencing repeated wear.

Computational Fluid Dynamics

Computational fluid dynamics may assist where erosion is associated with:

Slurries
Liquids
Gas-borne particles
Turbulent flow
High-velocity fluids
Pipe bends
Valves
Cyclones
Pumps
Ducts

CFD can help identify high-velocity or turbulent regions that may correspond with field-observed erosion.

Expected Deliverables

The deliverables will depend on the equipment, available information and purpose of the study.

They may include:

Existing-condition point cloud
Registered 3D scan data
Inspection photographs
Wear-location drawings
Colour-coded deviation maps
Ultrasonic thickness map
Minimum measured thicknesses
Cross-sections through critical areas
Surface-profile comparisons
Estimated material-loss volume
Comparison with nominal CAD geometry
Identification of critical wear zones
Assessment of likely wear mechanisms
Repair and replacement priorities
Revised liner designs
Replacement-component models
Fabrication drawings
Recommended monitoring locations
Proposed repeat-inspection intervals
Engineering report

Common point-cloud and CAD deliverables may include E57, RCP, RCS, LAS, DWG, DXF, STEP, SAT or native CAD formats, depending on project requirements.

Benefits of a Wear and Erosion Study

A structured study can help maintenance and engineering teams:

Locate wear before it causes a major failure
Improve shutdown planning
Define repair quantities more accurately
Avoid replacing serviceable areas unnecessarily
Prioritise critical repairs
Compare alternative liner arrangements
Improve replacement-component fit
Establish a baseline for future inspections
Reduce reliance on outdated drawings
Understand whether geometry contributes to wear
Improve maintenance documentation
Support asset-life-extension decisions

Engineering-Led Existing-Condition Assessment

Hamilton By Design does more than collect measurement data.

Our approach combines:

Site inspection
Engineering-grade reality capture
Mechanical engineering knowledge
CAD modelling
Reverse engineering
Materials-handling experience
Fabrication and maintenance understanding

This enables the captured information to be assessed in the context of how the equipment operates, how it is maintained and how it may be repaired or improved.

Our experience includes mining, materials handling, industrial plants, processing facilities and brownfield engineering projects across Australia.

When Should a Wear Study Be Completed?

A wear and erosion study may be appropriate:

Before a planned shutdown
Before ordering replacement liners
After repeated liner failures
When leakage or breakthrough is suspected
When equipment performance has declined
Before refurbishing an asset
Before modifying a chute or transfer point
When original drawings are unavailable
When manual measurements are inconsistent
After an unexpected failure
When establishing a long-term monitoring program
When comparing alternative liner materials
Before preparing fabrication drawings

Discuss Your Wear or Erosion Problem

The most appropriate study method depends on the equipment, access, operating conditions and decisions that must be made.

Hamilton By Design can help assess the existing condition, identify suitable capture methods and convert the findings into practical maintenance or engineering recommendations.

Contact Hamilton By Design to discuss a wear and erosion study for your plant or equipment.

Frequently Asked Questions

What is the difference between wear and erosion?

Wear is a broad term for the gradual removal or deformation of material caused by contact, sliding, impact, abrasion or repeated movement.

Erosion normally refers to material loss caused by moving particles, droplets or fluids striking or flowing across a surface. Industrial equipment may experience several wear mechanisms at the same time.

Can 3D laser scanning measure equipment wear?

Yes, where the worn surface is visible to the scanner and a suitable reference geometry is available.

The scan can be compared with an original CAD model, an earlier scan, an unworn component or a reconstructed nominal surface. This comparison can show where the surface has changed and how the wear is distributed.

However, laser scanning does not directly measure the remaining thickness of a closed wall. Ultrasonic thickness testing may also be required.

Can wear be measured without original drawings?

Yes. Several methods may be used when original drawings are unavailable.

The baseline may be developed from:

An unworn replacement component
A previous scan
Known plate thicknesses
A symmetrical unworn area
Manufacturer’s information
A reconstructed nominal surface
Reverse-engineered geometry

The reliability of the comparison will depend on the quality of the available reference.

Can a wear study determine remaining service life?

A single inspection can identify current material loss, but it may not establish a reliable wear rate.

Estimating remaining service life generally requires:

Known original dimensions
Repeat measurements
Stable operating conditions
Suitable acceptance criteria
Knowledge of the material
Understanding of the failure mechanism

Any service-life estimate should account for uncertainty and possible changes in operating conditions.

How often should equipment be scanned?

The inspection interval depends on:

Severity of wear
Equipment criticality
Operating hours
Material being handled
Previous wear rate
Shutdown frequency
Consequences of failure
Accessibility
Existing monitoring data

A heavily worn, safety-critical asset may require more frequent inspections than equipment with stable and predictable wear.

Can scanning be completed during a shutdown?

Yes. Shutdowns often provide the best access to internal chute surfaces, hoppers, tanks, pipes and process equipment.

The equipment normally needs to be:

Isolated
Cleaned sufficiently for inspection
Safe to access
Free of moving material
Available for the agreed inspection period

Access and isolation requirements should be reviewed during project planning.

Does the equipment need to be cleaned before scanning?

Generally, yes.

Material build-up, mud, product residue and loose corrosion can obscure the true equipment surface. The required level of cleaning depends on the purpose of the study.

If the objective is to measure plate or liner wear, the underlying surface must normally be visible.

Can scanning identify corrosion behind a liner?

Not directly if the corrosion is hidden behind an installed liner.

Scanning can identify visible deformation, missing liners, gaps or changes in exposed geometry. Hidden corrosion may require liner removal, ultrasonic testing or another nondestructive inspection method.

Can you compare scans taken at different times?

Yes, provided the datasets contain reliable common reference geometry or permanent survey controls.

The scans must be accurately registered before changes are assessed. Movement of the equipment, structures or reference points must also be considered.

Can a wear study help redesign a chute?

Yes.

Where wear is associated with material impact, velocity or poor flow geometry, the findings can support changes such as:

Repositioned impact plates
Revised chute angles
Improved liner coverage
Replaceable wear panels
Reduced particle impact
Improved flow direction
Alternative liner materials
Modified hood-and-spoon geometry

Further analysis, including DEM, may be recommended for complex bulk-material flow problems.

What information is needed before providing a proposal?

Useful initial information includes:

Equipment type
Site location
Description of the problem
Available drawings
Photographs
Approximate equipment size
Access limitations
Shutdown dates
Cleaning arrangements
Required deliverables
Previous inspection results
Known liner or plate thickness
Preferred CAD and point-cloud formats

A site visit or preliminary discussion may be recommended where the required scope is not yet clear.

What file formats can be supplied?

Depending on the project, deliverables may include:

E57
RCP
RCS
LAS
DWG
DXF
STEP
SAT
Parasolid
SolidWorks files
PDF drawings
Inspection reports
Deviation maps
Cross-section drawings

The required formats should be agreed before data processing and modelling begin.

Do you provide fabrication drawings for replacement liners?

Yes. Where included in the scope, scan data and engineering measurements can be used to produce:

Replacement liner models
Wear-plate layouts
Cutting profiles
Fabrication drawings
Installation drawings
General arrangements
Sections and details
Bills of materials

Additional engineering review may be required where the replacement changes the original equipment design.

Can you inspect operating equipment?

External LiDAR capture may sometimes be completed while surrounding plant remains operational, subject to site access and safety requirements.

Internal wear inspection normally requires the equipment to be isolated, cleaned and made safe for entry. Hot, moving or material-filled equipment may require specialised remote monitoring methods outside the scope of conventional terrestrial scanning.

Is LiDAR scanning accurate enough for a wear study?

LiDAR can be suitable for mapping broad wear patterns and measuring larger equipment surfaces.

The required accuracy depends on:

Expected wear depth
Equipment size
Surface condition
Scanning distance
Line of sight
Scanner type
Registration method
Required engineering decision

Small components or shallow wear may require a higher-resolution handheld scanner, ultrasonic testing or precision measurement equipment.

Can a study identify why liners are failing early?

It may help identify likely contributing factors such as:

Concentrated impact
Inadequate liner coverage
Poor liner support
Gaps between liners
Incorrect material selection
Loose fasteners
Unexpected material trajectories
Excessive particle velocity
Changes in feed conditions
Corrosion behind liners

Laboratory testing, process data or specialist materials advice may also be required before selecting a replacement material.

What areas of Australia does Hamilton By Design support?

Hamilton By Design supports industrial, mining and infrastructure projects across Australia, including Sydney, the Central Coast, Newcastle, the Hunter Valley, Brisbane, Melbourne, Perth and regional mining locations.

Project requirements, travel arrangements and site access can be discussed during the proposal stage.