Mechanical Engineering | 3D Scanning | 3D Modelling
Tag: Engineering-Grade Scanning
Engineering-grade scanning refers to 3D laser scanning and reality capture delivered to a defined engineering accuracy, intent, and use case.
This tag groups content where scanning is specified, executed, and validated with engineering judgement to ensure point-cloud and model outputs are fit-for-purpose for mechanical and structural design, scan-to-CAD workflows, fabrication detailing, installation fit-up, and shutdown-critical works
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.
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.
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.
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.
Our Services
FARO LiDAR scanning for CHPP as-builts
EinScan component capture
Point cloud to CAD modelling
Fabrication drawings & DXF outputs
Clash detection and digital twin support
Maximise your plant uptime by reducing rework — talk to us before your next shutdown.
Refineries, Heritage Buildings & Industrial Retrofits Done Right
The Inner West of Sydney is home to some of the city’s most complex refurbishment environments. From legacy refinery and industrial sites through to heritage-listed warehouses, factories, and commercial buildings, these assets were never designed with modern codes, loading requirements, or services in mind.
Yet today, they’re being asked to support:
New plant and equipment
Adaptive re-use and change of occupancy
Heavier floor loads
Updated fire, seismic, and structural standards
Modern services routing in very old structures
This is where many refurbishment projects run into trouble — not because the design is poor, but because the starting information is wrong or incomplete.
The Inner West Problem: Old Buildings, New Standards
Much of the Inner West’s industrial and heritage building stock was constructed:
Under superseded Australian Standards
With unknown material properties
Using construction methods no longer permitted
With undocumented modifications over decades of use
What often looks acceptable visually may be:
Structurally marginal under modern load cases
Locally compromised due to corrosion, settlement, or fatigue
Modified in ways that no longer match original drawings
When these issues are discovered late in the design process, the outcome is almost always the same:
Redesign
Strengthening
Programme delays
Budget escalation
Why Waiting Until “Detailed Design” Is Too Late
A common scenario we see in Inner West refurbishments:
Concept design proceeds based on legacy drawings or assumptions
Floor layouts, equipment, and architectural intent are developed
Engineering review begins
Structural checks identify:
Inadequate floor capacity
Unsupported penetrations
Changed load paths
Degraded or altered members
Design is forced to change — often significantly
At this point, the engineer isn’t blocking creativity — they’re responding to reality.
The issue isn’t engineering input. The issue is when the true condition of the structure becomes visible.
Start With a Scan: Let Designers Create With Confidence
Engineering-grade 3D laser scanning at the very beginning of a refurbishment changes the entire dynamic of a project.
Instead of reacting to unknowns later, the project team starts with:
Verified geometry
True floor levels and deflection
Structural alignment and deformation
Accurate column, beam, and slab positions
Measured deviations from original drawings
This gives architects and designers something powerful:
Freedom to design within known constraints — not guessed ones.
Heritage & Industrial Retrofits: Why Scanning Matters Even More
Heritage Buildings
Heritage structures often prohibit invasive investigation early on. 3D scanning allows:
Non-intrusive verification of geometry
Identification of movement or deformation
Assessment of tolerance drift over time
Planning of sympathetic strengthening solutions
Refineries & Legacy Industrial Sites
Inner West refinery and process facilities bring additional challenges:
Tight access
Live plant interfaces
Safety-critical environments
Brownfield congestion
Scanning provides:
Safe remote measurement
Clash-free retrofit design
Confidence before shutdowns
Reduced rework during construction
When Standards Change, Reality Matters
One of the most common late-stage surprises in refurbishments is floor capacity.
Buildings that performed adequately for decades may no longer comply with:
Current live load requirements
Change-of-use provisions
Equipment point loads
Modern safety factors
Without accurate structural geometry and context, engineers are forced to:
Assume worst-case scenarios
Over-design strengthening
Restrict layouts unnecessarily
Early scanning supports informed engineering judgement, often resulting in:
Targeted strengthening instead of blanket solutions
Retention of original fabric where possible
Reduced material and construction costs
From Point Cloud to Engineering Decisions
At Hamilton By Design, scanning is not a standalone service — it’s an engineering tool.
Our process typically supports:
Structural verification of existing buildings
Floor flatness, level, and deflection assessment
Alignment checks of columns and frames
Scan-to-CAD models for design integration
Fit-for-purpose information for refurbishment decisions
This is especially critical in Inner West projects, where:
Every millimetre matters
Access is limited
Heritage considerations are real
Late changes are costly
Design With Knowledge, Not Surprises
Refurbishments don’t fail because buildings are old. They fail because assumptions survive too long.
By starting with an engineering-led scan:
Designers get space to create
Engineers get data they can trust
Asset owners avoid late-stage shocks
Projects move forward with confidence
If you’re planning a refinery upgrade, heritage refurbishment, or adaptive re-use project in Inner West Sydney, the smartest decision you can make is to scan first — before concept becomes constraint.
Thinking about a refurbishment or retrofit in the Inner West?
Engineering-grade 3D scanning at the start gives your project clarity, confidence, and creative freedom — not limitations.
AS 1100 & LiDAR Scanning: Compliant Engineering Drawings from Point Clouds
If you’ve ever tried to update old plant drawings, verify a brownfield tie-in, or issue “as-built” documentation after a shutdown, you’ll know the pain: the site never matches the drawings, access is limited, and the smallest dimensional miss can cascade into rework, clashes, and schedule blowouts.
That’s where engineering-grade LiDAR scanning and AS 1100 (the Australian Standard for technical drawing) make a powerful combination. LiDAR gives you truth data (reality capture), and AS 1100 gives you a shared language for turning that truth into clear, consistent, contract-ready documentation.
AS 1100 standardises the way we communicate engineering information through drawings: layout, line types, projection methods, dimensioning rules, tolerancing conventions, symbols, notes, and drawing presentation.
In practice, AS 1100 helps you answer questions like:
Which edges are visible vs hidden? (line conventions)
How are views arranged and interpreted? (projection and view layout)
How do we dimension so the fabricator can’t misread it? (dimensioning rules)
How do we document what matters vs what’s “reference only”? (notes and drawing hierarchy)
How do we keep drawing sets consistent across multiple contributors? (formatting + standards)
That consistency is exactly what’s needed after a scan—because point clouds are rich, but they’re not automatically “communicable” in the way a compliant drawing set is.
What LiDAR scanning adds that drawings alone can’t
A LiDAR scanner captures millions (often billions) of spatial points that represent real surfaces—steel, concrete, pipe, equipment, structure—creating a point cloud that can be registered into a unified coordinate system.
In the engineering context, the big advantages are:
Speed: capture complex geometry quickly, often with minimal disruption
Coverage: see what’s hard to measure with tape/total station (overhead services, congested pipe racks, odd geometry)
Context: capture “everything,” not just what someone remembered to measure
Traceability: you can always “go back” to the scan for verification and queries
Clash prevention: scan-to-CAD makes it far easier to design upgrades that actually fit
But here’s the key: a point cloud isn’t a deliverable most trades can fabricate from directly. That’s why AS 1100 becomes the bridge between capture and construction.
The combined workflow: Point cloud → model → AS 1100 drawings
1) Capture the site as it really is
We scan the area of interest and register scans into a coordinated dataset. This becomes the base truth for everything that follows. If the project is shutdown-driven, we plan scanning around access windows and risk controls (often capturing adjacent tie-in zones too, because “nearby” services are where surprises live).
2) Establish intent: “What are we delivering?”
Not every project needs the same output. Typical outcomes include:
As-built drawings for existing assets
As-found models to support new design work
Dimensional verification for fit-up and prefabrication
Digital QA against design intent (scan-vs-model comparison)
3) Convert scan data into engineering geometry (as much as needed)
Sometimes the best output is a controlled 3D model (plant layout, pipe spools, structural members). Other times the project is best served by 2D drawings extracted from a model.
We’ll typically create:
key datums and grids
primary steel / structure
equipment envelopes and critical interfaces
piping runs and connection points (where relevant)
floor levels, platforms, access constraints, clearance zones
4) Document to AS 1100 so the drawing set is unambiguous
This is where AS 1100 shines. We turn geometry into drawings that read cleanly and consistently across teams.
drawing borders, title blocks, revision control, and drawing register discipline
In short: LiDAR gives accuracy, AS 1100 gives clarity.
Where AS 1100 + LiDAR scanning delivers immediate value
Brownfield upgrades and tie-ins
Tie-ins fail when the “as-built” condition is wrong. A scan gives you real geometry; AS 1100 drawings package it so designers, fabricators, and installers share the same reference. This is especially useful when multiple contractors are interfacing.
Fabrication and spool accuracy
If you’re fabricating offsite (pipe spools, platform steel, handrail sections, ducting), you need dependable dimensions and an agreed drawing language. Scan-derived models support accuracy; AS 1100 drawings support fabrication interpretation and QA sign-off.
Shutdown planning and constructability
A point cloud is a brilliant planning tool—access routes, crane clearances, removal paths, temporary works, and “what’s in the way.” But shutdown packages still need compliant drawings for permits, isolations, install workpacks, and handover packs. AS 1100 keeps those packages readable and defensible.
Verification and “what changed?”
Sites evolve. A scan provides a timestamped snapshot. Drawings updated to AS 1100 become the controlled record: what was there, what was installed, and what the current state is. That matters for maintenance, safety, and future projects.
Practical example: Turning a congested pipe rack into a buildable upgrade
Imagine you’re adding a new line through an existing pipe rack:
Scan the rack to capture all existing services, supports, cable trays, and steel
Model critical geometry (existing plus proposed) to check routing and supports
Clash check before fabrication begins
Issue AS 1100 drawings for:
support details
spool isometrics (if applicable)
arrangement drawings showing tie-in locations
sections through congestion zones
installation notes and tolerances where appropriate
Verify post-install with a follow-up scan if required for QA/closeout
That’s the “work together” part: the scan stops guesswork, and AS 1100 stops misinterpretation.
Common mistakes when scanning isn’t tied back to AS 1100
Delivering point clouds without a drawing strategy (stakeholders can’t use them effectively)
Over-modelling everything (time is spent modelling non-critical items instead of delivering useful documentation)
Unclear dimensioning (scan accuracy is wasted if dimensions are presented ambiguously)
No controlled datums (people argue about “where zero is” and models drift between disciplines)
Weak revision control (the drawing set becomes untrustworthy fast)
A standards-led drawing approach prevents most of these.
How we approach it at Hamilton By Design
Our angle is simple: engineering-led scanning—not scanning for its own sake.
We capture reality with LiDAR.
We translate it into the level of model detail the project actually needs.
We document outputs with the discipline and consistency expected in Australian engineering environments.
Closing thought: accuracy is only valuable if it’s understandable
LiDAR scanning can deliver millimetre-grade spatial truth. But in real projects, truth still has to travel through people—engineers, drafters, fabricators, installers, supervisors, and asset owners.
AS 1100 makes that truth readable. LiDAR makes it reliable.
Together, they turn messy real-world geometry into clear, controlled documentation that supports safer installs, faster shutdowns, and fewer surprises.
Accurate site data is the difference between a smooth upgrade and a shutdown full of surprises. At Hamilton By Design, we provide engineering-grade 3D laser scanning (LiDAR) across the Central Coast NSW — including Wyong, Gosford, Tuggerah and Somersby — and convert that data into design-ready CAD and 3D models for industrial and building projects.
If you’re planning equipment upgrades, new conveyors, structural modifications or fabrication packages, scanning gives you reliable geometry before steel is cut or contractors mobilise.
Who this service is for
Our Central Coast scanning services are typically used by:
Project engineers planning plant or building upgrades
Maintenance teams preparing shutdown scopes
Fabricators needing accurate tie-in dimensions
Asset owners updating as-built records
Consultants managing brownfield modifications
If drawings don’t match reality — or don’t exist at all — scanning becomes the safest and fastest way to establish an accurate baseline.
From scan to CAD: turning site data into buildable designs
A point cloud on its own doesn’t solve project risk. What matters is converting scan data into usable engineering outputs.
Our workflow supports:
2D CAD drawings (plans, sections, elevations)
3D CAD models for layout and clash detection
Tie-in modelling for new equipment and structures
Verification of clearances and access zones
Fabrication-ready geometry for workshop drawings
This scan-to-CAD process is especially valuable for retrofit projects where new components must integrate with existing assets.
Why 3D scanning is ideal for brownfield upgrades
Most Central Coast industrial and commercial sites are brownfield environments — tight access, legacy equipment and undocumented modifications.
3D laser scanning helps to:
Reduce site re-visits and manual re-measuring
Identify clashes early in the design phase
Support off-site prefabrication
Shorten shutdown windows
Improve safety by limiting exposure time on site
When combined with engineering design, scanning becomes a risk-reduction tool, not just a survey method.
Where Central Coast workshops are producing components for remote sites.
Local coverage: Wyong, Gosford, Tuggerah and Somersby
Being based on the Central Coast means we can support:
Rapid site capture
Staged scanning across multiple areas
Follow-up verification scans as scope evolves
That flexibility is important when designs change during live projects or shutdown preparation.
How accurate is engineering-grade LiDAR scanning?
Accuracy depends on site conditions and scope, but scanning provides consistent, repeatable geometry across complex environments that would be difficult and time-consuming to measure manually.
More importantly, it captures:
Spatial relationships
Real clearances
True equipment alignment
which are critical for retrofit engineering and fabrication.
When is scanning worth the investment?
Scanning typically delivers the best value when:
Drawings are outdated or incomplete
Fabrication must fit first time
Shutdown time is expensive
Access is restricted or unsafe
Multiple trades must coordinate in tight spaces
In many projects, preventing one major clash or rework cycle pays for the scan many times over.
Planning an upgrade or fabrication project on the Central Coast?
If you’re preparing for a shutdown, equipment upgrade or fabrication package across the Central Coast, early scanning can significantly reduce downstream risk.
Talk to Hamilton By Design about 3D laser scanning and point cloud to CAD support for your project. We’ll help define the scope and deliverables that best suit your engineering and construction needs.
3D Scanning Engineering Simplified in Kalgoorlie–Boulder
Kalgoorlie–Boulder is unlike any other city in Australia. Built on one of the richest goldfields on Earth, it remains a powerhouse of heavy industry, large-scale mining, metallurgical processing, mechanical maintenance and fabrication. With vast open-cut mines, underground networks, processing plants, workshops, rail infrastructure and expanding industrial precincts, the region demands precision, resilience and engineering that can stand up to harsh environmental conditions.
Hamilton By Design supports these exact needs with 3D LiDAR laser scanning, advanced engineering services, accurate 3D CAD modelling, and fabrication-ready drafting. For brownfield upgrades, shutdown planning, structural assessment or new installations, we simplify engineering by delivering millimetre-accurate digital data and industry-grade design documentation.
Why Kalgoorlie–Boulder Is Unique for Engineering Projects
Kalgoorlie–Boulder is shaped by extreme conditions and complex industrial systems. Its uniqueness comes from:
1. One of the world’s largest open-cut mines
The Super Pit and surrounding operations involve large-scale mechanical systems, crushers, conveyors, structural platforms, heavy mobile equipment and intricate processing facilities. These environments change frequently as operations evolve, making as-built accuracy critical.
2. Harsh, abrasive and high-wear environments
Dust, vibration, heat and heavy loading accelerate wear on structural steel, machinery and plant systems. Engineering assessments and redesigns must factor in high fatigue cycles and abrasive service.
3. A dense concentration of fabrication & maintenance workshops
Kalgoorlie–Boulder supports workshops specialising in mill relining, crusher repairs, structural fabrication, heavy-haul equipment maintenance and mining components. These businesses rely on accurate geometry for reverse-engineering and fit-out of parts.
4. Constant brownfield upgrades
Processing plants, conveyors, crushers, pump stations and underground infrastructure undergo frequent modifications—making 3D scanning and digital twins essential for reducing shutdown time and project risk.
5. Remote-region reliability demands
Any mistake in fabrication or installation results in delays, lost production and major cost impacts. That’s why engineering certainty is paramount.
How Hamilton By Design Supports Kalgoorlie–Boulder Industries
We bring an engineer-led, accuracy-driven approach to projects across gold processing plants, mining workshops, underground facilities, industrial yards and remote infrastructure.
High-Accuracy 3D LiDAR Laser Scanning
Our first step is capturing your site or equipment with millimetre-level precision using 3D laser scanning. This allows your team to design, fabricate and install with full confidence. Laser scanning is perfect for crushers, platforms, conveyor systems, tanks, mechanical rooms, structural steel and plant upgrades.
Better coordination between engineers, fabricators & installers
Perfect for rebuilds, relocations, shutdown works and equipment optimisation.
Engineering & FEA for Mining-Grade Demands
Kalgoorlie–Boulder’s high-load and high-fatigue environments require engineering that goes beyond standard design. Hamilton By Design provides mechanical and structural assessment, optimisation, and FEA-based verification.
This ensures your equipment remains safe, compliant and production-ready.
Fabrication-Ready Drafting for Workshops & Site Installations
From detailed drawings to GA layouts and isometrics, we deliver drafting packages suited for mining workshops, fabrication yards and onsite installation teams.
Clear documentation means fewer fabrication errors, less rework and a smoother installation process.
Real-World Use Cases in Kalgoorlie–Boulder
Hamilton By Design supports projects such as:
Plant expansion and shutdown upgrades
Crusher and conveyor rebuilds
Structural assessments and remediations
Mill, tank and chute upgrades
Workshop fit-outs and equipment design
Remote infrastructure and facility upgrades
With accurate scanning, engineering certainty and integrated modelling, your team can make confident decisions at every stage.
Why Hamilton By Design Is a Strong Fit for Kalgoorlie–Boulder
Engineer-led scanning ensures precision and technical oversight
Mining-grade modelling and engineering
Reduced rework, faster fabrication and safer installations
End-to-end workflow from scan → model → engineer → draft
Ideal for remote or high-complexity environments
Kalgoorlie–Boulder projects demand reliability, clarity and accuracy — and that’s exactly what we deliver.
Our Clients
Manage Consent
To provide the best experiences, we use technologies like cookies to store and/or access device information. Consenting to these technologies will allow us to process data such as browsing behaviour or unique IDs on this site. Not consenting or withdrawing consent, may adversely affect certain features and functions.
Functional
Always active
The technical storage or access is strictly necessary for the legitimate purpose of enabling the use of a specific service explicitly requested by the subscriber or user, or for the sole purpose of carrying out the transmission of a communication over an electronic communications network.
Preferences
The technical storage or access is necessary for the legitimate purpose of storing preferences that are not requested by the subscriber or user.
Statistics
The technical storage or access that is used exclusively for statistical purposes.The technical storage or access that is used exclusively for anonymous statistical purposes. Without a subpoena, voluntary compliance on the part of your Internet Service Provider, or additional records from a third party, information stored or retrieved for this purpose alone cannot usually be used to identify you.
Marketing
The technical storage or access is required to create user profiles to send advertising, or to track the user on a website or across several websites for similar marketing purposes.
