Mechanical, Structural & Digital Engineering Support for Crushing, Milling & Conveying

Hard rock processing plants work hard – high loads, extreme abrasion, constant vibration and tight production targets. When something doesn’t fit, breaks or wears out too fast, the cost in lost tonnes adds up quickly.

Hamilton By Design supports gold, copper, zinc, lead, nickel, lithium and iron ore operations with a combination of:

• 3D laser scanning (LiDAR) & point cloud capture
• 3D modelling & drafting (SolidWorks / CAD)
• Mechanical & structural engineering
• Digital QA & fit-checking before shutdowns

Our goal is simple:
Your upgrades fit first time, run reliably, and are backed by accurate data.

What We Do at Hard Rock Processing Plants

We support site-based engineering, maintenance and project teams with practical, fabrication-ready outcomes.

1. 3D Laser Scanning & As-Built Modelling

We use high-accuracy 3D laser scanners to capture:

• Crusher stations (primary, secondary, tertiary)
• SAG & ball mill areas
• Screen decks & screen houses
• Feed bins, hoppers & chutes
• Conveyors, transfer towers & galleries
• Pump skids, slurry lines & cyclones
• Thickener tanks, drives and surrounds

Deliverables:

• Registered point clouds
• Clean, usable 3D models
• Updated layouts and GA drawings
• As-built documentation for future projects

Accurate measurement is the foundation for every successful upgrade.

2. Mechanical Engineering for Crushing & Grinding Circuits

We assist mechanical engineers and project teams with:

• Crusher upgrades (jaw, cone, gyratory)
• SAG and ball mill component changes
• Feed chute redesigns and access improvements
• Screen and feeder modifications
• Pump and slurry pipeline changes
• Drive, gearbox and motor layout adjustments

We turn your concepts, plant issues and improvement ideas into 3D models, drawings and engineering deliverables that fabricators and installers can rely on.

3. Structural Engineering & Access Improvements

Hard rock plants generate heavy dynamic loads and vibration. We provide:

• Structural assessments around crushers, mills and screens
• Strengthening and modification of support steelwork
• New access walkways, stairs and platforms
• Upgraded supports for new or heavier equipment
• Verification of supports for screens, feeders and drives

Outputs include 3D models, structural drawings and engineering calculations suitable for site approval and fabrication.

4. Wear Management, Chutes & Liner Design

Wear is inevitable – but how you manage it is critical.

We help improve reliability and reduce downtime by:

• Redesigning chutes and hoppers for smoother flow
• Optimising liner layouts (rubber, ceramic, steel, composite)
• Improving feed presentation to crushers and mills
• Adjusting drop heights, impact angles and impact zones
• Reducing spillage, build-up and blockages

All designs are created in 3D against accurate scan data, so your new liners and chutes fit first time.

5. Shutdown Planning, Digital QA & Fit-Checking

Shutdowns are expensive and stressful – especially if something doesn’t fit.

Hamilton By Design supports shutdowns with:

• Pre-shutdown 3D scanning of the work area
• Digital fit-checks of new components against the point cloud
• Clash detection for new chutes, structures and equipment
• Fabrication-ready drawings with clear tolerances
• On-call engineering support during installation
• Updated as-built models and drawings afterwards

This approach reduces rework, cuts time on the tools and improves shutdown predictability.

6. Failure Investigation & Root Cause

When equipment fails, we help you understand why and what to change:

• Cracked screen decks and frames
• Broken chute structures
• Worn-through liners and hoppers
• Pump, gearbox and drive failures
• Misalignment and vibration-related issues
• Repeated seal, bearing or coupling failures

We combine site observations, 3D modelling and engineering analysis to recommend practical, long-term solutions.

7. Reliability & Continuous Improvement Support

For sites working on long-term performance and reliability, we can assist with:

• Measurement and modelling for debottlenecking projects
• Layout optimisation for future upgrades
• Standardisation of chute, support and access designs
• Better documentation for repeatable work packs and scopes
• Digital records (models/drawings) you can reuse across multiple projects

Our role is to add engineering and digital capability to the team you already have on site.

How We Work With Your Team

Hamilton By Design is set up to support:

• Site mechanical and structural engineers
• Reliability engineers and planners
• Project and shutdown managers
• Fabrication shops and drafting teams
• OEMs and service providers needing accurate site data

A typical engagement looks like:

1. Define the problem or upgrade
   – e.g. new chute, mill feed change, crusher access, conveyor transfer change.
2. Scan the area
   – capture the plant using 3D laser scanning to remove guesswork.
3. Develop 3D models & concepts
   – mechanical/structural concepts developed directly on the point cloud.
4. Final design, drawings & engineering
   – fully detailed fabrication drawings and engineering calculations.
5. Digital QA & shutdown support
   – fit-check before fabrication; support installers during shutdown.
6. As-built update
   – update models/drawings so your next project starts with accurate information.

Where We Work

Hamilton By Design supports hard rock operations and fabrication partners across Australia, including (but not limited to):

• Queensland
• New South Wales
• Victoria
• Northern Territory
• Remote mining hubs and regional processing plants

We can work directly with site teams or through your preferred fabrication and maintenance contractors.

Ready to Talk About Your Plant?

If you’re planning:

• A crusher, mill or screen upgrade
• A new chute, hopper or transfer
• Access and structural improvements
• A shutdown that must go right the first time
• Better, more reliable measurement and documentation

Hamilton By Design can help you measure, model and engineer the solution.

Our clients:

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