3D Scanning Services for CHPP – Reduce Rework, Maximise Uptime

Australian coal operations depend on reliable Coal Handling & Preparation Plants (CHPP), wash facilities, conveyors and mechanical systems. Every shutdown, upgrade and modification must be delivered quickly and safely to protect production. The most effective way to achieve this is through engineering-led 3D scanning services that capture real site conditions before a single component is fabricated.

Hamilton By Design specialises in FARO LiDAR and structured-light 3D scanning for the coal sector, turning complex brownfield sites into accurate digital models that drive practical engineering outcomes. Our focus is simple: maximise plant uptime by reducing rework.

Why Shutdowns Need Better Information

Coal wash plants are dynamic environments. Over decades of modifications:

drawings no longer match reality
structures move under load
pipe routes are altered
access becomes restricted

Relying on tape measures and sketches during a shutdown invites risk. A bracket that is 20 mm wrong or a spool that fouls an existing service can cost days of lost production. Accurate 3D scanning before the outage removes those unknowns.

Coal wash plant shutdown workflow from delays to scan-led success using LiDAR.

Hamilton By Design 3D Scanning Services

Our scanning services are built specifically for industrial and mining applications:

FARO LiDAR As-Built Capture

full plant and conveyor surveys
transfer stations, bins and pump boxes
structural steel and foundations
tie-in points for new pipework
clearance verification for maintenance

Structured-Light Scanning (EinScan)

motors, gearboxes and legacy parts
guards, covers and small assemblies
reverse engineering for obsolete components
detailed capture for first-time-fit design

Point Cloud to CAD Workflows

modelling in SolidWorks & Fusion
fabrication drawings for local workshops
clash detection and installation planning
digital twins for ongoing maintenance

These services ensure that design decisions are based on measured reality, not assumptions.

Engineering-led LiDAR scanning sequence from downtime to online restart.

FARO LiDAR for CHPP As-Builts

Terrestrial LiDAR creates a high-density point cloud of the entire coal wash facility. Engineers can:

design new chutes and spools directly over site geometry
confirm conveyor alignments
plan access platforms and walkways
test installation sequences digitally

By linking scanning to engineering, components arrive on site ready to install — protecting uptime and reducing rework during critical shutdown windows.

Practical Outcomes for Coal Plants

Conveyor & Transfer Upgrades

accurate chute replacements
skirt and belt line verification
drive and pulley modifications
minimal site adjustments

Pump Boxes & Pipework

prefabricated spools that fit first time
reverse engineering of worn equipment
safe tie-ins without surprises

Structural & Access Works

platform and handrail retrofits
screen support modifications
crane and lifting planning

Every task is driven by 3D scan data so workshops fabricate with confidence.

Visual comparison of EinScan object scanner and LiDAR terrestrial laser scanner in matching sketch style.

Engineering-Led, Not Just Surveying

Hamilton By Design treats scanning as part of the engineering process:

3D capture of the live plant
engineering review of critical datums
point cloud modelling in parametric CAD
fabrication drawings for Australian workshops
shutdown planning to ensure first-time fit

This approach directly supports the goal of maximum plant uptime.

Supporting Australian Capability

Scan-driven design keeps work local. Regional fabricators receive accurate models and drawings that reflect the real CHPP environment, enabling:

faster workshop production
fewer site variations
safer installations
reduced dependence on imported components

Committed to the Coal Sector

Hamilton By Design supports coal operations across NSW, the Central Coast, Sydney and regional Queensland including Mount Isa. Our 3D scanning services enhance every stage of shutdown planning and brownfield upgrades by eliminating guesswork and cutting rework.