Machine Guarding for Ship Loaders, Stackers & Reclaimers in Bulk Materials Handling

Machine Guarding for Ship Loaders, Stackers & Reclaimers | Bulk Materials Safety

Why guarding matters on large bulk material machines

Ship loaders, stackers and reclaimers combine elements of mobile plant, fixed plant and continuous conveying systems. Their scale, movement and operating envelopes introduce hazards that cannot be managed with ad-hoc or legacy guarding.

Most guarding failures are not caused by a single missing guard, but by brownfield modifications, undocumented changes, and loss of original design intent. This makes engineering-led guarding essential for safety, compliance and uptime.

Australian Standards framework for guarding

AS 4024 – Safety of Machinery

The AS 4024 series provides the primary principles for machine guarding, including hazard identification, risk assessment, guarding selection, and safe distances. For bulk materials handling equipment, it must be applied in context rather than as a checklist.

AS 1755 – Conveyors: Safety requirements

AS 1755 governs conveyor-specific hazards common to ship loaders, stackers and reclaimers, including:

Nip points and pulleys
Transfer and chute interfaces
Emergency stop systems
Access for inspection and maintenance

Most real-world non-conformances occur at head/tail pulleys, transitions, take-ups and return belts beneath walkways.

AS 1657 – Fixed access systems

Guarding must coexist with compliant access. AS 1657 covers walkways, stairs, ladders, handrails and edge protection. Poor integration often leads to guards being removed to regain access — undermining safety intent.

AS 4324.1 – Mobile bulk materials handling equipment

AS 4324.1 recognises ship loaders, stackers and reclaimers as integrated machines, where guarding, access, structure and maintainability must be considered together.

Guarding challenges unique to ship loaders & reclaimers

Scale and movement
These machines include slew, luff and travel motions, requiring guarding to remain effective across all operating positions.

Brownfield evolution
Temporary or reactive guarding solutions often become permanent without verification against standards.

Shutdown constraints
Guarding changes made under shutdown pressure frequently prioritise constructability over defensible engineering.

Engineering-led guarding approach

Effective guarding is based on:

Engineering-grade spatial understanding of reach, envelopes and access paths
Risk-based selection of fixed, interlocked or removable guarding in line with AS 4024
Integration with maintenance and operations, avoiding unsafe workarounds

On large machines, guarding that cannot be safely removed, reinstated or inspected will not survive long-term operation.

Common high-risk interfaces

Guarding assessment typically focuses on:

Conveyor head, tail and bend pulleys
Transfer points and chutes
Slew, luff and drive mechanisms
Gearboxes, brakes and take-ups
Return belt zones beneath accessways

Each interface must be checked against AS 4024, AS 1755, AS 1657 and AS 4324.1 as a combined framework.

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Building toward a bulk materials handling safety framework

This post forms part of a broader technical narrative around safe, maintainable bulk materials handling systems.
Future companion topics may include:

Conveyor transfer point guarding
Brownfield guarding upgrades during life-extension works
Balancing guarding and access on reclaimers
Using validated 3D data to de-risk shutdown modifications

Together, these posts naturally support a future Bulk Materials Handling / Stacker & Reclaimer Engineering landing page without forcing a sales message.

Key takeaway

On ship loaders, stackers and reclaimers, guarding must be engineered, spatially validated and operationally practical. When aligned with Australian Standards, guarding becomes an enabler of safe production — not a liability.

Discuss machine safety and guarding for bulk materials handling equipment

If you are reviewing or upgrading ship loaders, stackers, reclaimers or conveyor systems, early engineering input can reduce safety risk, rework and shutdown pressure.

For discussions relating to:

Machine guarding and conveyor safety
Brownfield compliance with Australian Standards
Engineering-led reviews for bulk materials handling equipment

Please connect with us by filling out the form below.

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AS 4324.1 Brownfield Bulk Handling Assets: Engineering Mobile Equipment for Today’s Mine Sites

AS 1755 Conveyor Safety

3D Laser Scanning for Engineering

1 January 202614 January 2026

Engineering-Led 3D Laser Scanning in Bathurst

3D laser scanner capturing an industrial structure for engineering-grade digital modelling and verification

3D Scanning Bathurst | Engineering-Grade LiDAR & Scan-to-CAD

Bathurst and the Central West region support a diverse mix of manufacturing facilities, mining operations, quarries, infrastructure assets, utilities, and heritage structures. These environments demand more than survey-grade outputs.

Hamilton By Design combines LiDAR scanning with mechanical engineering expertise, ensuring that:

Scan coverage targets critical interfaces and load paths
Accuracy supports fabrication-ready design
Models reflect real-world constraints, not assumptions

This significantly reduces rework, clashes, and site uncertainty during upgrades or expansions.

Mechanical engineering services by Hamilton By Design, featuring industrial machinery, conveyors, and maintenance engineering.

Our 3D Scanning Services in Bathurst

We provide a complete scan-to-engineering workflow, including:

High-resolution terrestrial LiDAR scanning
Registered point clouds (colourised and structured)
Scan-to-CAD modelling (SolidWorks & engineering CAD)
As-built documentation for existing assets
Clash detection & design validation
Support for mechanical, structural, and fabrication design

All deliverables are tailored to your project scope — from concept planning through to construction and installation.

Typical Bathurst Applications

Our 3D scanning services are commonly used for:

Industrial plant upgrades and brownfield modifications
Mining and quarry infrastructure
Conveyors, chutes, hoppers, and bulk materials handling systems
Mechanical equipment replacement and tie-ins
Structural steel verification and retrofits
Asset documentation and digital twins
Risk reduction for shutdown and live-site works

Where required, scanning data is integrated directly into engineering calculations, FEA models, and fabrication drawings.

Why Hamilton By Design

Engineer-Led Scanning

Your scan is planned and executed by engineers who understand loads, tolerances, constructability, and compliance, not just data capture.

Fit-for-Purpose Accuracy

We capture only the data that matters — at the accuracy required for design, fabrication, and installation.

Single-Source Accountability

One team responsible for scanning, modelling, and engineering, eliminating scope gaps between consultants.

Regional & Mobile Delivery

We regularly support projects across Bathurst, Orange, Lithgow, Dubbo, Mudgee, and the broader Central West NSW, mobilising to site as required.

Deliverables You Can Build From

Depending on your project, we can supply:

Registered point clouds (E57 / RCP / compatible formats)
3D CAD models aligned to engineering workflows
GA drawings and interface layouts
Fabrication-ready references
Digital records for asset management and future upgrades

Our clients:

3D Scanning Bathurst – Get Started

If you are planning a retrofit, upgrade, or new installation in Bathurst or Central West NSW, early 3D scanning can significantly reduce risk and cost.

Talk to an engineer about your site
Request a Bathurst 3D scanning proposal
On-site scanning available across the Central West

Engineering Services

3D Laser Scanning

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29 December 202514 January 2026

AS 4324.1 Brownfield Bulk Handling Assets: Engineering Mobile Equipment for Today’s Mine Sites

AS 4324.1 Bulk Handling Equipment | Brownfield Stacker & Reclaimer Engineering

Mobile equipment for the continuous handling of bulk materials—such as stackers, reclaimers, and ship loaders—forms the backbone of Australia’s mining and export infrastructure. Many of these assets operate continuously in demanding environments, often well beyond their original design life.

Australian Standard AS 4324.1 provides essential guidance for the design and safe operation of this class of equipment. However, on many Australian mine sites, the practical application of the standard is misunderstood or only partially implemented, particularly when dealing with legacy machines and brownfield upgrades.

For asset owners and engineering managers, the challenge is rarely about greenfield compliance. It is about managing risk, extending asset life, and implementing upgrades without unplanned downtime.

Ship loader and bulk cargo vessel with GPS monitoring units and sensor overlays illustrating controlled loading zones and engineering oversight under AS 4324.1

Understanding AS 4324.1 in a Brownfield Context

AS 4324.1 addresses mobile equipment used for continuous bulk handling, including:

Yard stackers and reclaimers
Bucket wheel reclaimers
Slewing and travelling machines
Ship loaders at export terminals

While the standard establishes a strong baseline for design and safety, many operating machines:

Pre-date the current revision of the standard
Have undergone multiple undocumented modifications
Operate under loading conditions that differ from original assumptions

In these situations, engineering judgement is required. Compliance becomes less about box-ticking and more about demonstrating that risks are understood, controlled, and managed over the asset lifecycle.

Common Challenges on Operating Mine Sites

Across coal handling plants, iron ore operations, and port facilities, several recurring issues emerge:

1. Incomplete or Outdated As-Built Information

Accurate geometry, slew limits, clearances, and structural interfaces are often unknown. This creates risk during upgrades and maintenance planning.

2. Fatigue and Structural Degradation

Large mobile machines experience cyclic loading across slewing, luffing, and travel motions. Fatigue cracking and unexpected failures require ongoing monitoring, not one-off assessments.

3. Access, Guarding, and Maintenance Compliance

Requirements evolve over time. Older machines may not meet current expectations for access systems, guarding, or safe maintenance practices.

4. Downtime Sensitivity

Stackers, reclaimers, and ship loaders are often production-critical assets. Upgrade windows are limited, and poor fit-up or rework can have significant commercial consequences.

Technology Supporting Modern Risk Management

While AS 4324.1 remains the foundation, modern technology allows asset owners to manage risk more effectively—particularly on brownfield equipment.

GPS Positioning and Controlled Operating Zones

Where GPS positioning is enabled, defined operating zones can be established to:

Prevent interaction with stockpiles during rapid translation
Automatically reduce slew or travel speed in high-risk zones
Limit impact loads on critical components such as slew rings and fluffing gears

These systems are primarily productivity-driven, but they also reduce the likelihood of high-energy impacts that contribute to mechanical damage.

LiDAR Scanning as an Emerging Risk Layer

LiDAR scanning is not a replacement for traditional controls, and it is still evolving in this application. However, it can provide:

Accurate spatial awareness of surrounding structures
Verification of clearances and exclusion envelopes
A secondary risk-management layer supporting operator decision-making

When combined with engineering-led interpretation, LiDAR contributes to a layered risk approach rather than acting as a standalone safety system.

Condition Monitoring and Real Load Understanding

Accelerometers installed across a range of frequencies can deliver valuable insight into:

Actual operating loads
Dynamic response during slewing, reclaiming, and travel
Early indicators of fatigue-related issues

This data supports more informed maintenance decisions and provides evidence of how a machine is truly being used—often revealing load cases not considered in original designs.

Engineering-Led Compliance and Asset Life Extension

For brownfield assets, compliance with AS 4324.1 is best approached as a continuous engineering process, not a single milestone. This includes:

Accurate reality capture and digital models
Verification of clearances, interfaces, and structural geometry
Informed upgrade design that fits the first time
Risk-based decision-making supported by real operating data

This approach helps asset owners extend the life of critical machines while managing risk, performance, and availability.

How Hamilton By Design Supports Bulk Handling Assets

Hamilton By Design works with asset owners and engineering teams to support:

Brownfield upgrades of stackers, reclaimers, and ship loaders
Engineering-grade LiDAR scanning and as-built documentation
Fit-for-purpose mechanical design for modifications and life-extension
Independent engineering insight across OEM and site interfaces

Our focus is on engineering clarity, practical risk reduction, and minimising disruption to operations.

Talk to an Engineer About Your Asset

If you are planning a brownfield upgrade, life-extension, or risk review of mobile bulk-handling equipment, talk to an engineer at Hamilton By Design about how accurate data and practical engineering can support your next decision.

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Engineering Services

Finite Element Analysis (FEA) & Mechanical Assessment

Mining Engineering Services Australia

27 December 202514 January 2026

AS 1755 Conveyor Safety

Engineer reviewing a guarded conveyor system with fixed side and nip-point guards designed to prevent access to moving parts.

Designing Conveyor Guarding for Compliance, Safety, and Practical Operation

Conveyors are widely used across processing, manufacturing, and materials-handling environments, but they also present some of the most persistent safety risks in industrial operations. Entrapment, nip points, rotating components, and maintenance access are all recognised hazards that must be managed through proper design and guarding.

In Australia, these risks are addressed through AS 1755 – Conveyors – Safety Requirements, which establishes the minimum safety expectations for conveyor systems across their full lifecycle, from design and installation through to operation and maintenance.

This article outlines what AS 1755 requires, why compliant conveyor guarding is critical, and how engineering-led design plays a key role in achieving practical safety outcomes.

Bulk materials conveyor with compliant safety guarding at the hopper, tail end, and along the conveyor, shown with an engineer reviewing guarding design drawings.

What Is AS 1755?

AS 1755 is the Australian Standard that defines safety requirements for belt conveyors and other conveyor systems. It addresses both new and existing installations and applies to conveyors used in industrial, commercial, and processing environments.

Rather than focusing on individual guarding components in isolation, AS 1755 considers the conveyor system as a whole, including how people interact with it during normal operation, inspection, cleaning, and maintenance.

The standard is referenced by regulators, safety professionals, and engineers as the primary benchmark for conveyor safety in Australia.

Key Safety Principles in AS 1755

AS 1755 is built around a number of core safety principles that influence how conveyor guarding should be designed.

These include eliminating hazards where possible, controlling remaining risks through engineering solutions, and ensuring that guarding does not introduce new risks by restricting access or encouraging unsafe behaviour.

In practice, this means that compliant guarding must be effective, durable, and suitable for the operating environment, while still allowing conveyors to be inspected, cleaned, and maintained safely.

Conveyor Guarding Requirements

A major focus of AS 1755 is the control of access to hazardous areas. This includes guarding of:

Drive pulleys and tail pulleys
Return rollers and idlers
Nip points and shear points
Rotating shafts and couplings
Chain drives, belt drives, and gearboxes

Guarding must be designed so that body parts cannot access hazardous zones, taking into account reach distances, openings, and the position of the conveyor relative to walkways or platforms.

Importantly, AS 1755 recognises that guarding must be fit for purpose. Poorly designed guards that are difficult to remove, inspect, or maintain are often bypassed or removed altogether, creating new safety risks.

Fixed Guards vs Interlocked Guards

AS 1755 allows for different types of guarding depending on the application and risk profile.

Fixed guards are commonly used where access is not required during normal operation. These guards must be securely fixed and require tools for removal.

Interlocked guards may be required where regular access is necessary. These systems ensure that the conveyor cannot operate while the guard is open or removed, reducing the risk of exposure to moving parts.

Selecting the appropriate guarding strategy requires an understanding of how the conveyor is used in practice, not just how it appears on drawings.

Existing Conveyors and Retrofit Challenges

Many conveyors currently in service were installed before the latest versions of AS 1755 were adopted. In these cases, compliance is often achieved through retrofit guarding rather than full replacement.

Retrofitting guarding to existing conveyors introduces additional challenges, including:

Limited space around existing equipment
Incomplete or outdated drawings
Structural constraints
Ongoing operation during upgrades

Engineering-led assessment and accurate documentation of existing conditions are critical when designing retrofit guarding solutions that comply with AS 1755 without disrupting operations.

The Role of Engineering in Conveyor Guarding Design

AS 1755 does not provide prescriptive “one-size-fits-all” guard designs. Instead, it sets performance requirements that must be interpreted and applied by competent professionals.

Engineering input is essential to ensure that conveyor guarding:

Addresses all relevant hazards
Integrates with existing mechanical and structural systems
Can be fabricated and installed accurately
Supports safe maintenance and inspection activities

Poorly engineered guarding may appear compliant on paper but fail in real-world use.

Documentation, Verification, and Ongoing Safety

Compliance with AS 1755 is not a one-time activity. Conveyor systems evolve over time as layouts change, equipment is upgraded, and operating practices shift.

Clear documentation of guarding design, installation, and assumptions provides a baseline for future modifications and safety reviews. This documentation is also critical when demonstrating due diligence to regulators or during incident investigations.

Why AS 1755 Matters

AS 1755 exists to prevent serious injuries and fatalities associated with conveyor systems. When applied correctly, it provides a structured framework for identifying hazards, implementing effective controls, and maintaining safe operation over the life of the equipment.

Achieving compliance requires more than installing mesh around moving parts. It requires understanding how people interact with conveyors and designing guarding that supports safe behaviour rather than working against it.

Conveyor guarding designed in accordance with AS 1755 is a critical component of safe industrial operations. Engineering-led design, accurate documentation, and practical consideration of maintenance and operation are essential to achieving compliance that works in practice.

When conveyor safety is treated as an engineering problem rather than a checkbox exercise, the result is safer equipment, fewer incidents, and more reliable operations.

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Machine Guarding in Australia: A Decade of Lessons for Leaders, Asset Owners, and Engineers

https://www.hamiltonbydesign.com.au/home/engineering-grade-lidar-scanning

AS 3774 – Loads on Bulk Solids Containers: Why It Matters for Safety and Compliance

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20 December 202514 January 2026

Engineering Confidence in South Yarra, Melbourne

LiDAR scanning Melbourne

Melbourne has long been recognised as one of Australia’s most advanced engineering and manufacturing centres, and inner-city hubs such as South Yarra sit at the intersection of design, industry, infrastructure, and innovation. As projects become more complex and timelines more compressed, engineering teams are increasingly seeking partners who can reduce uncertainty, improve accuracy, and provide reliable technical insight from day one.

This is where Hamilton By Design delivers genuine value.

Hamilton By Design operates as an engineer-led consultancy focused on precision, constructability, and real-world outcomes. Rather than working from assumptions or incomplete information, the business is built around capturing existing conditions accurately and transforming that data into practical engineering deliverables that support confident decision-making.

Moving Beyond Assumptions in Modern Engineering

Many engineering challenges in metropolitan Melbourne are not greenfield projects. They involve existing buildings, operating facilities, constrained spaces, legacy assets, or staged upgrades that must integrate seamlessly with what is already in place. In these environments, relying on outdated drawings or manual measurements introduces risk — misalignment, clashes, rework, and delays that can quickly erode budgets and schedules.

Hamilton By Design addresses this challenge by placing reality capture and engineering validation at the front end of projects. This ensures that every downstream decision is based on what truly exists on site, not what is assumed to exist.

For engineering teams working in and around South Yarra — whether supporting manufacturing, infrastructure, plant upgrades, or specialist facilities — this approach significantly reduces technical risk and increases confidence across all stakeholders.

LiDAR Scanning as a Foundation for Accuracy

A key capability that differentiates Hamilton By Design is its use of engineering-grade LiDAR scanning. Unlike traditional surveys that capture selective points, LiDAR scanning records millions of measurements across an entire environment, producing a high-resolution digital representation of buildings, plant, structures, and surrounding context.

This data becomes a reliable reference point for engineers, designers, fabricators, and project managers alike.

LiDAR scanning enables:

Accurate capture of complex geometries and tight spaces
Clear identification of spatial constraints and interfaces
Early detection of clashes and access issues
Reduced need for repeat site visits
Improved coordination between disciplines

By converting physical assets into precise digital data, Hamilton By Design helps teams eliminate ambiguity and work from a single source of truth.

From Scan Data to Engineering Outcomes

Importantly, Hamilton By Design does not operate as a scanning-only service. The real value lies in how scan data is interpreted, validated, and converted into engineering outputs that directly support delivery.

Scan information is used to develop structured models, layouts, and documentation that reflect real-world conditions. This supports engineering activities such as:

Mechanical and structural modifications
Plant upgrades and equipment integration
Space planning and layout optimisation
Fabrication and installation planning
Asset documentation and as-built records

Because the work is led by experienced engineers, the focus is always on what needs to be built, installed, or modified, not just on creating visually impressive models.

Supporting Engineering Teams and Decision-Makers

In a business and engineering environment like South Yarra — where projects are often time-sensitive and commercially driven — external engineering support must be reliable, efficient, and technically sound.

Hamilton By Design integrates smoothly with internal teams, consultants, and contractors, providing additional technical depth without adding unnecessary complexity. The consultancy model is deliberately structured to support decision-makers who need clarity, not noise.

This means:

Clear communication of constraints and risks
Practical recommendations grounded in real site data
Deliverables aligned with fabrication and construction needs
Engineering documentation that supports approval and execution

The result is fewer surprises downstream and a smoother path from concept through to implementation.

Engineering for Brownfield and Live Environments

One of the most challenging aspects of modern engineering is working within live or brownfield environments — facilities that cannot simply shut down for measurement, redesign, or rework. In these settings, accuracy and planning are critical.

Hamilton By Design’s LiDAR-driven workflows are particularly well suited to these conditions. Rapid data capture minimises disruption on site, while the detailed digital record allows engineering work to continue remotely with confidence.

This approach supports safer planning, better coordination, and reduced exposure to operational risk — outcomes that are highly valued by engineering leaders and project managers alike.

A Practical, Engineer-Led Philosophy

At its core, Hamilton By Design operates on a simple but powerful principle: engineering should be grounded in reality. By combining high-accuracy site data with deep engineering experience, the consultancy helps organisations make informed decisions, avoid costly mistakes, and deliver projects that work the first time.

For organisations operating in South Yarra and the broader Melbourne region, this means access to an engineering partner who understands both the technical and commercial pressures of modern project delivery.

Engineering Certainty in a Complex World

As engineering projects continue to increase in complexity, the margin for error continues to shrink. Those who invest early in accurate data and sound engineering judgement gain a clear advantage — fewer delays, lower risk, and better outcomes.

Hamilton By Design provides that advantage by bridging the gap between the physical site and the engineering office. Through precise LiDAR scanning, practical engineering insight, and a strong focus on constructability, the consultancy supports confident, efficient, and reliable project delivery across Melbourne’s most demanding environments.

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20 December 202514 January 2026

From Scan to Shutdown

Why Hamilton By Design Is the Engineering Partner of Choice in Moranbah and the Bowen Basin – Engineering where it matters most

Moranbah and the surrounding Bowen Basin sit at the centre of Australia’s coal production engine. This is not a region defined by conceptual studies or theoretical design—it is defined by tonnes per hour, shutdown windows, safety performance, and whether plant modifications fit first time.

For mining companies operating in this region—including major operators such as BHP Mitsubishi Alliance, Anglo American, Glencore, Whitehaven Coal, QCoal Group, Yancoal Australia, Coronado Global Resources, and Bowen Coking Coal—engineering success is measured by outcomes, not promises.

Hamilton By Design exists specifically for environments like Moranbah: brownfield, high-risk, shutdown-driven, and unforgiving of design errors. This article explains why our engineer-led, scan-to-fabrication workflow aligns so closely with the realities of mechanical engineering in the Bowen Basin—and how it delivers value across CHPPs, materials-handling plants, and mine infrastructure.

Moranbah: a convergence of mining, mechanics, and margin

Mechanical engineering in Moranbah is unique because it operates at the intersection of:

Live production assets
Harsh environmental conditions
Compressed shutdown schedules
Zero tolerance for rework

Almost every mine in the region is supported by a CHPP, conveyors, crushers, stackers, reclaimers, and complex transfer stations. These assets are often decades old, modified many times, and poorly documented.

For operators, this creates constant engineering risk:

Unknown as-built conditions
Dimensional uncertainty
Legacy structural fatigue
Congested plant layouts
Safety constraints during access and installation

Hamilton By Design was formed to remove this uncertainty.

The core problem: brownfield uncertainty

Most engineering failures in the Bowen Basin are not caused by poor calculations. They are caused by poor information.

Traditional workflows often rely on:

Outdated drawings
Manual tape measurements
Partial site access
Assumptions made under time pressure

In Moranbah, these assumptions are expensive.

A single clash during a CHPP shutdown can cascade into:

Lost production
Extended outages
Emergency site modifications
Safety exposure
Cost overruns

Hamilton By Design addresses this problem at its source: accurate, engineer-owned site data.

Engineer-led 3D laser scanning: data you can trust

Hamilton By Design delivers engineering-grade 3D LiDAR scanning, not generic survey capture. This distinction matters.

Our scans are:

Planned by mechanical engineers
Captured with fabrication tolerances in mind
Registered and verified for design use
Interpreted by the same engineers who model and draft the solution

For Bowen Basin operators, this means:

Confidence in clearances
Reliable tie-in locations
Accurate centre-lines and datum references
Reduced site revisits
Fewer RFIs during fabrication and installation

This approach underpins everything that follows.

From scan to CAD: turning reality into buildable models

Point clouds are only valuable if they are converted into usable engineering models.

Hamilton By Design specialises in:

SolidWorks-based mechanical modelling
CHPP equipment modelling
Conveyor and chute systems
Structural steel and platforms
Pipework, transfer chutes, and guards

Unlike generic drafting services, our models are:

Built for fabrication
Aligned to Australian Standards
Structured for downstream FEA where required
Designed with maintenance and installation in mind

For Moranbah projects, this means the model becomes a single source of truth—shared between engineering, fabrication, and site teams.

Shutdown-driven design: engineering to the clock

Shutdowns in the Bowen Basin are short, expensive, and unforgiving.

Hamilton By Design engineers design specifically for shutdown execution by:

Preferring modular assemblies
Designing for pre-fabrication and trial-fit
Minimising hot work on site
Reducing installation complexity
Embedding lift and access considerations early

Our experience working with fabricators and site crews ensures that drawings are not just correct—they are buildable under shutdown conditions.

Fabrication-ready drawings that reduce risk

In Moranbah, fabrication errors propagate directly to site risk.

Hamilton By Design produces:

Detailed fabrication drawings
Clear GA and assembly drawings
Accurate BOMs
Weld-ready detailing
Clear tolerances and notes

Fabricators value our drawings because they:

Reduce shop-floor guesswork
Minimise RFIs
Support first-time assembly
Align with real-world workshop practices

For mining companies, this translates to smoother shutdowns and fewer surprises.

A 3D laser scanner on a tripod capturing an industrial plant structure, with a colourful point cloud and blue CAD wireframe overlay illustrating engineering-grade 3D laser scanning accuracy.

Structural verification and FEA where it counts

Many Bowen Basin assets were not designed for their current duty cycles. Increased throughput, equipment upgrades, and extended asset life introduce structural risk.

Hamilton By Design integrates:

Structural checks
Load-path verification
Fatigue considerations
Finite Element Analysis (where appropriate)

FEA is applied pragmatically—not as an academic exercise, but as a decision-support tool to:

Validate modifications
Avoid over-design
Reduce unnecessary steel
Confirm safety margins

This approach supports compliance while respecting cost and schedule constraints.

Digital QA and as-built confidence

One of the most overlooked advantages of scan-based engineering is digital quality assurance.

Hamilton By Design can:

Validate fabricated components against the model
Confirm installed geometry post-shutdown
Provide updated as-built documentation
Support future modifications with confidence

For asset owners, this builds a cumulative digital asset—each project improving the next.

Why this matters to Bowen Basin operators

For companies operating multiple sites across the region, the benefits compound:

Consistency across projects and sites
Reduced engineering rework
Improved shutdown reliability
Better collaboration with fabricators
Lower total project risk

Hamilton By Design’s workflow aligns with how mining actually operates in Moranbah—not how it is described in textbooks.

A partner, not just a consultant

Hamilton By Design does not operate as a detached design office. We work alongside:

Maintenance teams
Shutdown planners
Fabricators
Site supervisors

Our value lies in understanding why a design is needed, how it will be built, and when it must be installed.

This mindset resonates strongly in the Bowen Basin, where credibility is earned through delivery.

Why Moranbah companies choose Hamilton By Design

In summary, Hamilton By Design helps mining companies in Moranbah and the Bowen Basin because we:

Specialise in brownfield mining environments
Deliver engineer-led 3D scanning
Convert data into fabrication-ready models
Design for shutdown execution
Reduce risk across engineering, fabrication, and installation
Speak the language of site, not just design offices

Engineered for Moranbah

Moranbah is not a place for generic solutions. It demands engineering that is accurate, practical, and accountable.

Hamilton By Design was built for regions like this—where engineering decisions have immediate operational consequences and where doing it right the first time matters.

For mining companies across the Bowen Basin, we provide more than drawings.
We provide clarity, confidence, and constructable engineering—from scan to shut down.