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

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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

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

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.

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Mechanical Engineering – The Mining Industry

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CHPP Engineering, 3D Scanning & Upgrade Services

16 December 202514 January 2026

3D Scanning Engineering in Orange

Orange is one of Australia’s most distinctive regional cities. Set high on the Central Tablelands, it combines a cool-climate environment with major health, education, agriculture, infrastructure, and mining-services activity. Engineering in Orange is shaped by altitude, frost, diverse industries, and a mix of modern and legacy assets—making accuracy, coordination, and practical design essential.

Hamilton By Design supports projects in and around Orange by combining 3D LiDAR laser scanning, mechanical and structural engineering, 3D CAD modelling, FEA, and fabrication-ready drafting. Our approach focuses on capturing real site conditions and turning them into buildable, engineering-approved outcomes.

Engineering challenges in a high-altitude regional city

Unlike many inland centres, Orange’s elevation brings colder temperatures, frost, and greater thermal movement. At the same time, the city supports critical assets such as hospitals, utilities, agricultural processing facilities, and infrastructure that must remain operational.

Engineering teams commonly deal with:

Brownfield sites with assets added over decades
Incomplete or outdated drawings
Tight staging requirements around live facilities
A need for conservative, reliable design

In this environment, assumptions introduce risk. Accurate as-built data is the foundation of successful projects.

3D Laser Scanning for Orange projects

Hamilton By Design uses high-accuracy 3D Laser Scanning to capture the true as-built condition of sites across Orange and the Central Tablelands. Laser scanning records millions of precise measurements, creating a detailed digital record of buildings, plant, structures, and surrounding interfaces.

3D laser scanning is particularly valuable in Orange for:

Health, education, and public infrastructure upgrades
Industrial and agricultural processing facilities
Mining-support and utilities assets
Sites where drawings no longer reflect reality

Scanning is typically completed during short, controlled site visits, minimising disruption while delivering data that can be relied on throughout the project.

Turning scan data into accurate 3D models

Once scanning is complete, the data is processed and converted into detailed 3D CAD Modelling. These models represent what actually exists on site—not what historic documentation suggests.

For Orange projects, scan-based 3D modelling supports:

Mechanical upgrades and equipment replacements
Structural additions such as platforms, supports, and access ways
Integration of new assets into existing facilities
Long-term digital records for future maintenance and expansion

Accurate models reduce uncertainty and allow design decisions to be made early and with confidence.

Mechanical and structural engineering built on real conditions

Engineering in Orange often involves coordinating multiple disciplines across constrained or operational sites. Working from scan-derived models allows engineers to:

Understand existing load paths and constraints
Check clearances and access early in the design
Coordinate mechanical and structural elements in a single environment

This leads to designs that are practical, buildable, and aligned with how assets are actually used—particularly important in a climate-affected region.

FEA to support performance and compliance

Where performance, safety, or compliance is critical, Hamilton By Design applies FEA Capabilities to support engineering decisions.

Finite Element Analysis is commonly used to:

Check structural capacity under operational and environmental loads
Assess modifications to existing steel and concrete
Review fatigue, vibration, and deflection
Support engineering approval and sign-off

Using FEA on scan-based geometry provides confidence that designs will perform as intended in real operating conditions.

Easy-to-build fabrication drawings with engineering approval

Clear documentation is essential for efficient construction—particularly in regional locations where rework can be costly. Hamilton By Design produces fabrication-ready Drafting directly from coordinated 3D models.

Typical deliverables include:

General arrangement and detail drawings
Fabrication and installation drawings
Engineering-reviewed and approval-ready documentation

This focus on clarity and constructability helps fabricators and contractors build accurately the first time.

Reducing risk through digital engineering

By capturing site conditions once and completing the majority of engineering off site, projects in Orange benefit from:

Reduced site visits and travel costs
Improved safety outcomes
Better coordination before fabrication
Fewer surprises during installation

This approach aligns well with Orange’s role as a regional hub supporting diverse industries across central NSW.

Supporting Orange with practical, buildable engineering

Orange’s strength lies in its balance—health, agriculture, infrastructure, mining services, and community all intersect here. Hamilton By Design’s integrated scanning and engineering workflow supports this complexity by delivering accurate data, sound engineering judgement, and clear documentation.

3D Scanning Engineering in Orange is about turning real-world site conditions into clear, buildable engineering outcomes that support growth, reliability, and long-term performance across the region.

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12 December 202514 January 2026

3D Scanning Engineering in Mount Gambier

3D Scanning in Mount Gambier

Mount Gambier is one of South Australia’s most geologically and environmentally distinctive engineering locations. Built on volcanic ground and surrounded by limestone karst systems and abundant groundwater, it is also the heart of the Limestone Coast forestry and timber-processing industry. Engineering in Mount Gambier must carefully balance ground conditions, water sensitivity, and heavy industrial operations.

Hamilton By Design supports projects across Mount Gambier and the wider Limestone Coast with 3D LiDAR laser scanning, engineering, 3D modelling, FEA, and easy-to-build fabrication drawings, helping clients plan, upgrade, and maintain assets with confidence.

Engineering in Mount Gambier: Where Ground and Water Matter

Unlike many regional centres, engineering in Mount Gambier is heavily influenced by what lies beneath the surface.

Projects here often involve:

Volcanic soils and variable ground conditions
Limestone bedrock with potential voids and groundwater interaction
Forestry, timber processing, and associated heavy plant
Industrial facilities operating close to environmentally sensitive areas

These factors make accurate site data and conservative, well-verified engineering essential.

3D Laser Scanning for Mount Gambier Projects

High-accuracy 3D LiDAR laser scanning provides a reliable foundation for engineering in Mount Gambier.

Hamilton By Design captures precise as-built data for:

Sawmills and timber-processing facilities
Conveyors, handling systems, and heavy machinery
Industrial buildings, platforms, and access structures
Infrastructure located on variable or sensitive ground

3D scanning records the true geometry of existing assets, including misalignment, settlement, and undocumented modifications — all common in older industrial sites and facilities built over complex geology.

This allows projects to move forward with reduced risk, fewer site visits, and greater confidence during construction.

Learn more about our scanning services:
3D Laser Scanning

3D Modelling Built from Real As-Built Conditions

From the point cloud, Hamilton By Design develops accurate 3D CAD models that reflect actual site conditions.

Our 3D modelling services support:

Brownfield plant upgrades
Modifications to timber-processing equipment
Spatial coordination in tight industrial layouts
Clash detection and constructability reviews
Long-term digital asset records

In Mount Gambier, modelling from real data is especially valuable where ground movement, legacy plant, or limited documentation exists.

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3D CAD Modelling

FEA for Structural and Mechanical Confidence

Many Mount Gambier assets operate continuously and must perform reliably under changing loads and environmental conditions. Finite Element Analysis (FEA) is used to validate designs and extend asset life.

Hamilton By Design applies FEA to:

Assess structural capacity and stiffness
Check modifications to existing steelwork
Evaluate deflection, fatigue, and buckling
Support strengthening or life-extension decisions

By analysing as-built geometry, FEA provides results that better represent real behaviour — particularly important where foundations and ground conditions influence structural performance.

Learn more about our analysis services:
FEA Capabilities

Easy-to-Build Fabrication and Installation Drawings

Clear, practical documentation is essential for regional projects where fabrication and installation teams rely on drawings to get the job done efficiently.

Hamilton By Design produces easy-to-build fabrication drawings, including:

General arrangement drawings
Fabrication and workshop details
Installation and modification layouts
As-built documentation

Because drawings are generated directly from scanned data and validated 3D models, they align closely with site conditions, reducing ambiguity and rework.

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Drafting Services

Why Hamilton By Design in Mount Gambier?

Hamilton By Design delivers an integrated, engineering-led workflow — from site capture through to modelling, analysis, and construction documentation.

For Mount Gambier clients, this means:

Better understanding of complex ground and plant conditions
Reduced risk when upgrading existing assets
Designs that support forestry and industrial operations
Fabrication-ready drawings that are practical to build

Whether you are working within timber processing, industrial facilities, or regional infrastructure, Hamilton By Design provides accurate, practical, and build-ready engineering solutions tailored to Mount Gambier’s unique conditions.

If you’re planning a project in Mount Gambier or across the Limestone Coast, we’re ready to help — starting with accurate data and carrying it through to buildable outcomes.

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11 December 202514 January 2026

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.

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3D Laser Scanning

Benefits for Kalgoorlie–Boulder include:

Reduced downtime during shutdowns
No need for repeat site visits
Accurate tie-in points for brownfield modifications
Clear visibility of alignment issues, deflections and wear
Safe data capture in challenging environments

Intelligent 3D CAD Modelling for Mining & Industrial Assets

Once scanned, we convert the point cloud into accurate 3D CAD models suitable for engineering analysis, fabrication and layout planning.

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3D CAD Modelling

This enables:

Clash detection before fabrication
Reverse-engineering of components
Visualisation of complex plant areas
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.

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FEA Capabilities

Our analysis supports:

Structural steelwork validation
Chute, tank and vessel assessments
Conveyor and machinery load cases
Fatigue and vibration studies
Repair strategy development

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.

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Drafting Services

We provide: