Scan to BIM Gold Coast | Hotels & Commercial Buildings

Scan to BIM Gold Coast for hotels, resorts and commercial buildings using 3D laser scanning, point cloud data and BIM modelling.

Scan to BIM Gold Coast | 3D Laser Scanning for Hotels, Commercial Buildings & Redevelopment

Gold Coast hotels, resorts and commercial buildings are continually being refurbished, upgraded and redeveloped. However, many projects begin with the same fundamental problem: the available drawings no longer accurately represent what exists on site.

Walls may have been relocated, hotel rooms reconfigured, building services rerouted, plant replaced and structural modifications completed without every change being incorporated into the original drawing set.

For architects, engineers, project managers and contractors preparing a refurbishment, that creates uncertainty before design work even begins.

Hamilton By Design provides Scan to BIM Gold Coast services, combining engineering-led 3D laser scanning, LiDAR point-cloud processing and digital modelling to establish an accurate representation of existing building conditions.

Rather than designing around assumptions, project teams can begin with measured information captured directly from the existing building.

Our broader Scan to BIM services across Queensland support commercial, industrial, infrastructure and redevelopment projects where accurate existing-condition information is required before engineering or design work proceeds.

When the Drawings Don’t Match the Building

Existing drawings remain valuable, but buildings change throughout their operating life.

This is particularly relevant to hotels and commercial properties that may have undergone numerous refurbishments, tenancy changes, services upgrades and modifications.

A hotel constructed decades ago may have subsequently experienced:

guest-room refurbishments
bathroom alterations
restaurant upgrades
commercial kitchen modifications
lobby renovations
conference-area changes
mechanical plant replacement
air-conditioning upgrades
electrical modifications
fire-system changes
façade upgrades
accessibility improvements
structural modifications.

Even relatively minor projects can gradually create significant differences between the original drawings and the physical building.

The problem appears when another refurbishment begins.

Designers may initially rely on existing PDFs, CAD drawings or archived plans, only to discover during construction that columns, walls, ceilings, pipework or services are not where the documentation indicated.

This can lead to additional site visits, design revisions, clashes, fabrication changes and construction delays.

The objective of Scan to BIM is simple:

Capture the building that actually exists today.

What Is Scan to BIM?

Scan to BIM combines reality capture with digital modelling.

A terrestrial 3D laser scanner records millions of individual measurements from the visible surfaces around the building. These measurements form a three-dimensional point cloud representing the existing geometry.

The point cloud can then become the dimensional reference for developing BIM, CAD and engineering models.

Hamilton By Design’s broader 3D laser scanning services support projects where accurate spatial information is needed for design, engineering, verification and existing-condition documentation.

Instead of manually measuring individual walls, columns, rooms or plant items one dimension at a time, laser scanning captures extensive spatial information across the surveyed area.

The result is a measurable digital record that can be reviewed after the site visit.

Scan to BIM for Gold Coast Hotels and Resorts

Hotels and resorts represent a particularly useful application for Scan to BIM.

A refurbishment may involve only a group of rooms, one floor or a restaurant area. Alternatively, the project may involve major redevelopment across multiple levels of an operating property.

Before new work begins, designers need to understand the geometry they are connecting into.

Hamilton By Design provides 3D laser scanning for hospitality projects including hotels, resorts, restaurants, clubs and other hospitality facilities.

Areas that can potentially be captured include:

guest rooms
bathrooms
corridors
foyers and lobbies
restaurants
bars
function rooms
commercial kitchens
back-of-house areas
plant rooms
service corridors
stairways
façades
rooftop plant
loading and service areas.

The scan scope should be determined by what information the refurbishment team actually needs.

A hotel room refurbishment may require accurate wall, door, window and bathroom geometry.

A mechanical upgrade may instead require detailed capture of plant rooms, ceiling spaces, services and equipment interfaces.

The scanner is therefore only one part of the process.

The important question is:

What does the project team need to know before design begins?

Commercial Buildings and Gold Coast Redevelopment

The same approach can be applied to offices, retail properties, shopping centres, entertainment facilities, mixed-use developments and other commercial buildings.

Redevelopment projects can become particularly challenging when new construction needs to connect into retained portions of an existing structure.

The project team needs to know the position of existing walls, floors, structural elements and services with enough confidence to develop the new design.

Hamilton By Design’s 3D laser scanning for engineering projects connects reality capture with engineering and design workflows, helping establish reliable existing-condition information before modifications proceed.

This can be particularly valuable where conventional measurement is difficult because the building contains complex geometry, restricted areas or congested plant and services.

From Gold Coast Site to BIM Model

A Scan to BIM project typically follows a structured workflow.

1. Define the Project Requirement

Before scanning begins, the required outcome should be understood.

Does the architect require an architectural Revit model?

Does an engineer require structural geometry?

Does the mechanical contractor need an accurate plant-room model?

Does the developer simply need a reliable existing-condition point cloud?

The required deliverable influences both the scanning strategy and modelling scope.

2. Capture Existing Conditions

The relevant areas of the property are captured using terrestrial or mobile 3D laser scanning technology.

Multiple scanner positions can be used to capture rooms, corridors, external areas and complex building geometry.

3. Register the Point Cloud

Individual scans are aligned into a coordinated point-cloud dataset.

The resulting point cloud creates a measurable three-dimensional reference representing the building at the time it was captured.

For projects extending into the wider South East Queensland region, Hamilton By Design also provides 3D scanning services in Brisbane supporting construction, commercial, infrastructure and engineering projects.

4. Develop the Required BIM or CAD Model

Not everything visible in the point cloud necessarily needs to be modelled.

The modelling scope should reflect the purpose of the project.

Depending on the requirement, this may include:

walls
floors
ceilings
columns
beams
doors
windows
stairs
façade geometry
plant
equipment
pipework
structural steel
building-service interfaces.

For conventional building projects, BIM environments such as Revit may be appropriate.

For mechanical equipment or fabricated components within plant rooms, mechanical CAD may also form part of the workflow.

What Tools Can Assist?

Scan to BIM is not based around one software package or one piece of equipment.

A project may use several technologies throughout the workflow.

These can include:

3D LiDAR scanners for capturing existing geometry.

FARO SCENE for scan registration and processing.

Autodesk ReCap for point-cloud management and CAD integration.

Autodesk Revit for BIM-oriented building models.

AutoCAD for existing-condition plans, sections, elevations and engineering documentation.

Navisworks for coordination and model review.

SolidWorks where detailed mechanical components, equipment or fabricated assemblies need to be developed.

The appropriate combination should be determined by the intended outcome rather than forcing every project into the same modelling environment.

Hamilton By Design’s wider engineering services connect reality capture with mechanical engineering, modelling, drafting and practical project outcomes.

Scan Once – Use the Information Throughout the Project

One of the major benefits of a well-planned scanning exercise is that the captured information can potentially support several project stages.

The point cloud may assist with:

existing-condition verification
feasibility studies
architectural design
mechanical design
structural coordination
services coordination
floor plans
sections and elevations
plant-room modelling
clash reviews
construction planning
contractor coordination
future maintenance projects.

Additional dimensions can also be inspected digitally where the required geometry has been captured clearly.

This can reduce dependence on repeated site measurement visits as the project progresses.

For an operating hotel, this can be particularly valuable because repeated access to guest areas, plant rooms and back-of-house spaces may be disruptive.

Potential Scan to BIM Deliverables

Every project does not need the same deliverables.

Depending on the agreed scope, Hamilton By Design can develop information suitable for a range of downstream engineering and design workflows.

Potential deliverables may include:

registered point-cloud datasets
E57 files
RCP and RCS point clouds
Revit models
CAD geometry
DWG files
DXF files
STEP or SAT models
SolidWorks parts and assemblies
floor plans
elevations
sections
general arrangement drawings
measurable 3D models
PDF engineering drawings.

Hamilton By Design’s national Scan to BIM Australia capability provides the broader framework for converting existing physical assets into usable digital information for engineering, construction and asset-management decisions.

Scan to BIM Across the Gold Coast

Hamilton By Design can support suitable projects throughout the Gold Coast, including areas such as:

Surfers Paradise, Broadbeach, Southport, Main Beach, Mermaid Beach, Burleigh Heads, Miami, Palm Beach, Coolangatta, Robina, Varsity Lakes, Bundall, Nerang, Hope Island and surrounding areas.

For organisations with projects extending north into Brisbane, our dedicated Scan to BIM Brisbane service provides the same fundamental workflow of site capture, point-cloud processing and digital modelling for existing buildings and infrastructure.

This creates an opportunity for developers, asset owners and engineering teams managing multiple properties across South East Queensland to establish a consistent reality-capture methodology.

Why an Engineering-Led Approach Matters

Capturing millions of measurements does not automatically produce useful engineering information.

A successful Scan to BIM project starts by understanding why the information is being captured.

The scan strategy for a general architectural model may differ significantly from a project involving mechanical equipment replacement or structural modification.

Hamilton By Design approaches reality capture from an engineering perspective.

The objective is not simply to create a visually impressive point cloud.

The objective is to produce information that assists the project team in answering practical questions:

What actually exists?

Where is it located?

What will the new design need to connect to?

What geometry needs to be modelled?

What information will designers, engineers and contractors need later?

Establishing those answers early can provide a more reliable basis for refurbishment and redevelopment decisions.

Frequently Asked Questions – Scan to BIM Gold Coast

What is Scan to BIM?

Scan to BIM is the process of capturing an existing building or facility using 3D laser scanning and using the resulting point cloud as a dimensional reference for creating BIM, CAD or engineering models.

Why use Scan to BIM for a hotel refurbishment?

Hotels frequently undergo multiple renovations and services upgrades during their operating life. Existing drawings may therefore no longer represent current conditions. Laser scanning provides a way to capture the property as it exists before the next refurbishment begins.

Can individual hotel rooms be scanned?

Yes. Depending on the project scope, scanning can focus on selected guest rooms, bathrooms, corridors or specific refurbishment areas rather than necessarily capturing the entire building.

Can you scan plant rooms and building services?

Yes. Plant rooms are well suited to 3D reality capture because they often contain congested mechanical equipment, pipework, structural elements and building services that can be difficult to document using conventional measurement techniques.

Do we need a Revit model?

Not necessarily. The appropriate deliverable depends on what the information will be used for. Some projects require Revit, while others may only require a registered point cloud, AutoCAD drawings, mechanical CAD models or specific sections and elevations.

Can the point cloud be supplied?

Depending on the agreed scope, registered point-cloud data can be supplied in formats suitable for downstream review and modelling, including common formats such as E57, RCP and RCS.

Can Scan to BIM help before redevelopment?

Yes. Reality capture is particularly useful where new construction needs to interface with an existing building. Accurately capturing retained areas provides designers with a more reliable dimensional basis for developing the proposed works.

Does laser scanning eliminate the need for all site verification?

No. Critical design, structural, fabrication or construction information should still be verified in accordance with the requirements of the project. Scan to BIM provides a highly valuable existing-condition reference, but the required accuracy, scope and verification process should always be established for the intended application.

Do you provide Scan to BIM outside the Gold Coast?

Yes. Hamilton By Design provides Scan to BIM and 3D laser scanning support across Queensland and other Australian locations for commercial, industrial, infrastructure, mining and engineering projects.

What information is useful when requesting a quotation?

Useful information includes the project location, approximate building or scan area, number of levels, access requirements, available drawings, intended use of the captured data, required file formats and the type of BIM, CAD or engineering deliverable required.

Discuss Your Gold Coast Scan to BIM Project

If unreliable drawings or uncertain existing conditions are affecting a hotel refurbishment, commercial development or redevelopment project, establishing the actual building geometry can provide a stronger starting point.

Hamilton By Design combines 3D laser scanning, point-cloud processing, BIM and engineering-led modelling to help project teams work from measured existing conditions.

Start with what actually exists. Design the refurbishment from measured information.

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Scan to BIM Services Queensland | 3D Laser Scanning & BIM

Scan to BIM services Queensland using 3D laser scanning, LiDAR point clouds and engineering-led BIM modelling for industrial, mining and infrastructure projects.

Scan to BIM Services Queensland | 3D Laser Scanning & BIM Modelling

Across Queensland, asset owners, engineering teams and project managers are increasingly working with facilities where the available drawings no longer accurately represent what exists on site.

Industrial plants are modified. Structural steel is added or removed. Pipework routes change. Equipment is replaced. Buildings are refurbished. Mining infrastructure develops over decades.

For organisations responsible for multiple facilities, the problem becomes even greater: how do you establish a consistent and reliable digital record of existing conditions across assets located throughout Queensland?

Hamilton By Design provides Scan to BIM services across Queensland, combining engineering-grade 3D laser scanning, LiDAR point-cloud processing and engineering-led 3D modelling to convert existing physical assets into accurate digital information that can support future engineering, construction and asset-management decisions.

Our broader Scan to BIM Australia capability supports projects where existing buildings, industrial plants and infrastructure need to be accurately captured before design work begins.

What Is Scan to BIM?

Scan to BIM is the process of capturing an existing physical environment using 3D laser scanning or LiDAR technology and using that measured information to develop an accurate digital model.

Rather than relying entirely on historical drawings, tape measurements or assumptions about existing construction, a 3D laser scanner captures millions of spatial measurements from the actual asset.

These measurements form a 3D point cloud representing the existing geometry.

The point cloud can then be processed and used as the dimensional reference for developing BIM, CAD and engineering models.

Hamilton By Design approaches this process from an engineering perspective. The objective is not simply to produce an attractive three-dimensional model. The objective is to capture and model the information needed to support the next engineering, construction or asset-management decision.

Our broader 3D laser scanning services support engineering projects throughout Australia, including Queensland and regional industrial centres.

The Queensland Scan to BIM Problem

Queensland presents a particular challenge for organisations managing geographically distributed assets.

A business may have its engineering or project-management team based in Brisbane while operating facilities hundreds or thousands of kilometres away.

Assets may be located across:

Brisbane and South East Queensland, Gladstone, Rockhampton, Emerald, Mackay, the Bowen Basin, Townsville, Mount Isa and other regional or remote areas.

The documentation available for these facilities can also vary significantly.

One site may have relatively current CAD information, while another may rely on drawings produced decades earlier. Modifications undertaken during shutdowns or maintenance campaigns may never have been incorporated into the original drawings.

This creates uncertainty.

When a new conveyor, pipe route, platform, piece of machinery, building service or structural modification needs to be designed, the engineering team first needs to establish:

What is actually there?

Scan to BIM provides a method of answering that question consistently.

One Reality-Capture Workflow Across Queensland

For multi-site asset owners, one of the major advantages of Scan to BIM is the ability to establish a repeatable process.

Instead of every project beginning with a different measurement method, Hamilton By Design can use a common workflow:

Site capture → scan registration → point-cloud processing → engineering interpretation → BIM/CAD modelling → verification → project deliverables.

In Brisbane and South East Queensland, our LiDAR scanning Brisbane services support industrial facilities, infrastructure, manufacturing plants and other engineering environments requiring accurate point-cloud data.

The same fundamental process can then be applied to regional facilities, providing organisations with greater consistency between projects and sites.

Step 1 – Define What the Model Needs to Achieve

A successful Scan to BIM project should begin before the scanner is switched on.

The first question should be:

What will the captured information ultimately be used for?

The answer affects both the scan strategy and the modelling requirements.

Potential applications include:

brownfield plant modifications
equipment replacement
structural upgrades
refurbishment projects
construction planning
shutdown engineering
clash detection
fabrication
pipework modifications
building refurbishment
asset documentation
digital engineering
development of digital twins.

A model intended to document the general arrangement of a facility does not necessarily require the same information as one being used to design fabrication interfaces.

This is why engineering involvement at the beginning of the scanning process can be important.

Hamilton By Design’s wider engineering services integrate LiDAR capture with modelling, engineering and fabrication-oriented outcomes rather than treating reality capture as an isolated survey activity.

Step 2 – Capture Existing Conditions with 3D LiDAR

Once the required outcome is understood, the existing facility can be captured.

Terrestrial 3D laser scanning can rapidly record complex geometry that would otherwise require extensive manual measurement.

Depending on the project, this may include:

structural columns and beams
buildings
floor levels
equipment
conveyors
transfer stations
chutes
tanks
pipework
access platforms
stairs
handrails
machinery
surrounding infrastructure.

This is particularly valuable in congested industrial environments where conventional measurement can become difficult.

The scanner records the physical geometry visible from each scan position. Multiple scan positions are subsequently combined to create a coordinated representation of the facility.

For projects specifically located in the Queensland capital, our existing Scan to BIM Brisbane service provides a dedicated Brisbane-focused pathway from LiDAR capture through point-cloud modelling and engineering-led documentation.

Step 3 – Register and Process the Point Cloud

Individual scanner positions need to be aligned or registered into a common coordinate system.

The result is a measurable three-dimensional point-cloud dataset.

Depending on project requirements, processing may include:

scan registration
removal of unnecessary data
coordinate alignment
establishing project datums
checking scan coverage
segmentation of areas
preparation for CAD or BIM modelling.

Point clouds may subsequently be supplied in formats such as E57, RCP or RCS depending on the client’s required workflow.

This registered dataset becomes the measured reference against which the digital model can be developed.

Step 4 – Convert Required Geometry into BIM or CAD

The next stage is where Scan to BIM becomes more than reality capture.

Not everything visible in a point cloud necessarily needs to be modelled.

The question should instead be:

What information does the project team actually need?

For a commercial building, Revit may provide the appropriate BIM environment.

For an industrial plant, however, the solution may involve a combination of BIM and mechanical CAD.

Hamilton By Design’s SolidWorks Brisbane capability, for example, allows LiDAR information to feed into detailed mechanical modelling, reverse engineering and fabrication-oriented workflows.

This can be particularly important for Queensland mining, mineral-processing and industrial facilities where the existing environment contains significant mechanical equipment rather than conventional building elements alone.

Revit Is Not Always the Whole Answer

Scan to BIM is frequently associated with Autodesk Revit, but industrial facilities can require several modelling environments.

A useful Queensland industrial workflow might include:

Revit for buildings and BIM-oriented structural information.

SolidWorks for mechanical equipment, machinery and fabricated assemblies.

AutoCAD for 2D engineering documentation.

Navisworks for coordination and model review.

FARO SCENE and Autodesk ReCap for point-cloud registration, management and preparation.

The final deliverable should therefore be selected according to the project requirement rather than forcing every captured asset into a single software environment.

Supporting Brownfield and Shutdown Projects

One of the strongest applications for Scan to BIM is brownfield engineering.

Unlike greenfield projects, existing facilities contain constraints that cannot simply be moved because they conflict with a new design.

Existing steelwork, conveyors, services, pipework and operating equipment all need to be considered.

Accurate reality capture therefore gives designers an opportunity to identify potential conflicts before fabrication or construction begins.

This becomes particularly important where access to the plant is restricted or site attendance must occur during limited shutdown windows.

Hamilton By Design also provides 3D scanning for mining shutdown projects, where captured site information can support mechanical upgrades, structural verification, Scan-to-CAD modelling and plant-layout assessment.

Scan Once – Use the Data for Multiple Engineering Tasks

A well-planned scan can support more than one immediate project.

The point cloud may provide a reference for:

existing-condition verification
concept development
mechanical design
structural drafting
fabrication planning
clash checking
accessibility reviews
equipment replacement
future maintenance planning.

This is particularly valuable for remote Queensland assets.

Returning to a regional or remote site simply because one critical dimension was missed can be expensive and disruptive.

The scan strategy should therefore consider not only what is immediately obvious but also what information the engineering team may reasonably need later in the project.

Hamilton By Design applies this approach to SMP project delivery using 3D laser scanning, where reality capture establishes a reliable baseline of structural, mechanical and piping conditions for subsequent engineering activities.

Scan to BIM Deliverables

Deliverables can be configured around the needs of the client’s software environment and project team.

These may include:

registered point clouds
E57 files
RCP/RCS datasets
Revit models
IFC models
SolidWorks parts and assemblies
STEP or SAT geometry
DWG and DXF files
general arrangement drawings
sections and elevations
PDF engineering drawings
measurable digital models.

The objective is to deliver information that the engineering, construction or asset-management team can actually use.

Scan to BIM Services Across Queensland

Hamilton By Design supports Queensland projects where reliable existing-condition information is required before engineering work proceeds.

Projects may range from commercial and infrastructure facilities in Brisbane through to industrial, mining and processing assets in regional Queensland.

The common objective remains the same:

Capture the existing condition accurately, convert the required information into usable digital geometry, and provide the project team with a more reliable basis for engineering decisions.

For multi-site organisations, that also creates an opportunity to establish a consistent reality-capture and modelling methodology across facilities rather than beginning every project with a different approach.

Frequently Asked Questions – Scan to BIM Queensland

What is Scan to BIM?

Scan to BIM combines 3D laser scanning with digital modelling. Existing buildings, structures, plant and equipment are captured as a point cloud, which is then used as the dimensional reference for developing BIM or CAD models.

Does Scan to BIM always mean Revit?

No. Revit is commonly used for BIM, particularly for buildings and building services, but industrial projects may also require SolidWorks, AutoCAD, IFC, STEP or other CAD formats. The appropriate deliverable depends on how the information will ultimately be used.

Can Scan to BIM be used for mining and industrial facilities?

Yes. Reality capture can be particularly valuable for brownfield mining and industrial environments containing structural steel, conveyors, machinery, pipework, platforms and other complex existing infrastructure.

Can you provide the point cloud as well as the model?

Yes. Depending on the agreed project scope, deliverables can include registered point-cloud datasets as well as CAD, BIM and engineering documentation.

Why use laser scanning instead of existing drawings?

Existing drawings can be incomplete, outdated or may not include modifications made during the operating life of an asset. Laser scanning captures the physical conditions present at the time of the survey, providing the design team with a current dimensional reference.

Can Scan to BIM help reduce site revisits?

Yes. A properly planned scan captures extensive dimensional information during the initial site visit. This can allow engineers and designers to take additional measurements digitally from the point cloud later, although critical project dimensions and coverage requirements should always be identified before scanning.

Can the same process be used across several Queensland facilities?

Yes. This is one of the strongest applications for multi-site asset owners. A consistent scanning, registration and modelling methodology can be applied across metropolitan, regional and remote facilities, helping standardise the digital information available to engineering teams.

What Queensland projects are suitable for Scan to BIM?

Suitable projects can include industrial facilities, mining infrastructure, mineral-processing plants, manufacturing facilities, commercial buildings, utilities, transport infrastructure, brownfield upgrades and major refurbishment projects.

What should we determine before requesting a Scan to BIM quotation?

The most useful starting point is to establish what the final information will be used for. Providing the site location, approximate area, required model format, intended engineering application and expected level of modelling detail helps determine the appropriate scanning and modelling scope.

Talk to Hamilton By Design

If outdated drawings, inaccessible dimensions or inconsistent site information are creating uncertainty for an engineering project, Scan to BIM can provide a reliable starting point.

Hamilton By Design provides engineering-led Scan to BIM services across Queensland, connecting 3D LiDAR reality capture with point-cloud processing, CAD modelling, BIM and engineering documentation for industrial, mining, infrastructure and brownfield projects.

Start with the existing condition. Build the engineering from measured information.

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Mine Process Plant Asset Capture Mudgee NSW | Hamilton By Design

Mine process plant asset capture in Mudgee NSW using engineer-led LiDAR scanning and point-cloud modelling

Mine Process Plant Asset Capture Mudgee NSW

Existing mine process plants are complex engineering environments. Mechanical equipment, pipework, structural steel, conveyors, chutes, access platforms, guarding and services are frequently installed within constrained spaces and across multiple elevations.

Over the operating life of a mine, these assets may also be modified, replaced or extended during maintenance programs, shutdowns and plant-expansion projects. As a result, the physical plant can progressively differ from the engineering drawings and models originally produced for the facility.

For engineers planning brownfield modifications, this creates a practical challenge:

How can existing process equipment be captured accurately when direct manual measurement is difficult, restricted or potentially exposes personnel to unnecessary plant hazards?

Hamilton By Design provides engineer-led mine process plant asset capture in Mudgee NSW and surrounding Central West mining areas, using terrestrial LiDAR scanning, registered point clouds and engineering CAD workflows to establish reliable existing-condition information.

The purpose is not simply to generate a visually impressive point cloud. The objective is to produce measurable engineering information that can support plant modifications, equipment replacement, shutdown preparation, fabrication and future asset management.

The Engineering Problem: Existing Plant Can Be Difficult to Measure Safely

Traditional field measurement remains valuable for many engineering activities. However, process plants often contain areas where comprehensive manual measurement becomes inefficient or difficult to undertake safely.

Existing equipment may be:

elevated above operating plant;
located behind guarding;
surrounded by pipework and services;
installed within congested structural framing;
positioned close to moving equipment;
accessible only during limited shutdown periods;
surrounded by hot or process-sensitive surfaces;
located beneath conveyors or transfer structures; or
difficult to view from conventional measuring positions.

A mechanical engineer may need the location of a flange, equipment centreline, shaft position or support interface but find that direct physical access is restricted.

The engineering problem becomes more significant when the project requires an understanding of the complete three-dimensional relationship between several assets, rather than a single isolated dimension.

Hamilton By Design’s approach to engineering 3D scanning for mining and process plants uses reality capture as part of the engineering process, allowing structures, mechanical equipment, piping and surrounding plant to be recorded as measurable spatial data.

Why Engineer-Led Asset Capture Matters

Reality capture should ideally begin with an understanding of the engineering problem.

A scanning technician may ask:

Where can the scanner obtain coverage?

An engineer must also ask:

What information will be required to design the modification?

That distinction influences the quality and usefulness of the final dataset.

An engineer considering an equipment replacement may recognise the importance of capturing:

equipment mounting interfaces;
flange faces;
pipework connections;
shaft or pulley centres;
equipment removal routes;
surrounding structural steel;
maintenance clearances;
access platforms; and
nearby services that could interfere with installation.

Hamilton By Design’s engineer-led approach is therefore intended to connect site capture directly with downstream engineering requirements.

The workflow can extend beyond point-cloud delivery into CAD modelling, equipment design, structural interfaces, drawings and fabrication-support information.

The value is not merely obtaining more scan data. It is capturing the right engineering information for the project.

What Mine Process Plant Assets Can Be Captured?

Engineering-grade reality capture can be applied to a broad range of mining and processing infrastructure.

Typical assets may include:

crushers and screens;
pumps and pump skids;
tanks and vessels;
bins and hoppers;
chutes and transfer points;
conveyors;
pipework and valves;
flanges and nozzles;
structural steel;
equipment supports;
platforms and walkways;
stairs and handrails;
machine guarding;
ducts;
cable trays;
concrete plinths;
foundations; and
interfaces between existing and proposed equipment.

The ability to capture surrounding context is particularly important.

A replacement pump, for example, does not exist independently. Its position may be constrained by foundations, pipework, structural members, walkways, lifting access and surrounding equipment.

A point cloud provides a digital reference to these relationships.

How Does LiDAR Asset Capture Reduce Personnel Exposure?

The objective of LiDAR scanning is not to replace site safety controls.

Plant isolations, permits, exclusion zones, working-at-height controls and client procedures remain essential.

However, terrestrial LiDAR can reduce the amount of close-contact manual measuring required in some plant environments.

A scanner can record a large volume of dimensional information from an appropriate stand-off position.

This may reduce the need for personnel to repeatedly:

approach machinery;
climb structures to obtain individual dimensions;
work behind guards;
access difficult corners of plant; or
return to the same area for missing measurements.

Hamilton By Design’s work on engineering-grade 3D laser scanning for mining plant upgrades demonstrates how reality capture can establish existing-condition information before brownfield plant modifications are developed.

The key benefit is therefore not that scanning makes a mine site inherently safe.

It is that well-planned reality capture can reduce unnecessary exposure while improving the quantity of usable dimensional information collected during site access.

Capture Once, Measure as the Engineering Develops

One of the limitations of conventional field measurement is that engineers must anticipate every dimension required before detailed design begins.

This is not always practical.

A project engineer may collect the dimensions believed to be necessary, return to the office and commence modelling. During design, another interface may become important.

This creates the familiar cycle:

Measure → model → identify missing information → return to site → remeasure → revise

A registered LiDAR point cloud provides a different approach.

The site environment is captured comprehensively, allowing many additional dimensions to be obtained from the digital dataset after leaving site.

A useful principle is:

Capture comprehensively during the available site access, then measure selectively as the engineering develops.

This can be particularly valuable for Mudgee-region projects where engineering teams, specialist contractors or fabricators may be located considerable distances from the mine site.

Registering the Point Cloud

Terrestrial LiDAR projects generally involve multiple scanner locations.

Each scanner position records a portion of the plant from a different viewpoint.

These individual scans are subsequently processed and registered into a coordinated point-cloud dataset.

The resulting point cloud can provide measurable information including:

equipment centres;
flange positions;
nozzle locations;
structural member locations;
elevations;
equipment footprints;
pipe routes;
clearances;
support geometry;
floor levels; and
maintenance envelopes.

The point cloud becomes a digital record of the visible plant condition at the time of scanning.

It should not, however, automatically be regarded as the final engineering deliverable.

The point cloud is often the evidence base from which further engineering information is developed.

Verifying Legacy Drawings Against Existing Conditions

Mining process plants may operate for several decades.

During this period, equipment replacement, shutdown repairs and production modifications can progressively alter the plant configuration.

Changes may include:

relocated equipment;
replacement pumps or motors;
rerouted pipework;
new supports;
modified steelwork;
added platforms;
additional services; and
changed equipment interfaces.

Existing drawings remain important engineering records, but critical dimensions should not necessarily be assumed to represent current conditions without verification.

The point cloud allows project teams to compare historical information with the physical plant.

This can help identify discrepancies before new equipment is designed or fabricated.

From Point Cloud to Engineering CAD

Some projects require only a measurable point-cloud dataset.

Others require selected assets to be reconstructed into CAD geometry.

Hamilton By Design’s Scan to BIM services for mining and industrial facilities provide one pathway for converting existing-condition LiDAR data into usable digital engineering information.

Depending on the project, modelling may include:

mechanical equipment;
tanks and vessels;
structural steel;
pipework;
platforms;
conveyors;
chutes;
equipment interfaces; and
surrounding clearance envelopes.

The modelling strategy should be fit for purpose.

A project involving pump replacement may require detailed flange and support interfaces but only simplified representations of surrounding plant.

A structural modification may require accurate steel geometry while nearby equipment remains within the point cloud.

This avoids unnecessary modelling effort while maintaining the information required for engineering decisions.

Reducing Fabrication and Installation Risk

One of the most important applications of process-plant asset capture is verifying proposed modifications against existing conditions before fabrication.

A component can be manufactured accurately to a drawing and still fail to fit the plant if the original existing-condition information was incorrect.

Potential consequences include:

fabrication rework;
cutting or welding on site;
revised pipe spools;
altered structural connections;
additional crane time;
installation delays; and
extended shutdown duration.

By developing the proposed design against registered scan data, engineers can identify many interface problems earlier.

The objective is simple:

Identify the dimensional conflict digitally before discovering it during installation.

Supporting Shutdown Planning

Process-plant modifications are frequently completed during scheduled mine shutdowns.

Shutdown periods may provide only limited access to equipment that cannot otherwise be approached while operating.

This makes preparation particularly important.

Hamilton By Design’s CHPP 3D scanning and shutdown engineering workflows demonstrate how captured site geometry can progress through point-cloud processing, engineering modelling and fabrication documentation before shutdown execution.

Reality capture can assist shutdown preparation by improving:

understanding of existing conditions;
fabrication confidence;
installation planning;
interface verification;
equipment-removal planning;
clash identification; and
engineering readiness before the shutdown begins.

Scanning cannot eliminate every shutdown risk.

It can, however, improve the quality of the engineering information available when those risks are assessed and managed.

Mine Process Plant Asset Capture in Mudgee NSW

Mudgee is positioned within an established Central West NSW mining region, with major mining and processing activity around Mudgee, Ulan, Gulgong and Wollar.

Hamilton By Design can provide engineer-led reality capture for mining and industrial projects throughout:

Mudgee;
Ulan;
Gulgong;
Wollar; and
surrounding Central West NSW mining areas.

The service is particularly relevant for existing brownfield facilities where equipment has been progressively modified, access is restricted or accurate engineering information is required before new plant is designed.

Tools Supporting the Asset-Capture Workflow

Depending on project requirements, Hamilton By Design can combine several technologies.

FARO Focus S70 can provide detailed terrestrial LiDAR capture of process equipment and surrounding infrastructure.

FARO Orbis may provide supplementary mobile capture where appropriate to the project.

FARO SCENE supports scan registration and point-cloud processing.

Autodesk ReCap can prepare point-cloud data for engineering workflows.

SolidWorks supports mechanical equipment modelling, reverse engineering and fabrication-focused design.

Autodesk Inventor and AutoCAD can support plant layouts, mechanical modelling and technical drawings.

Navisworks can assist with large-model coordination and clash review.

Revit may be appropriate where structured BIM information is required.

Potential deliverables can include E57, RCP, RCS and LAS point clouds together with SolidWorks, STEP, SAT, Parasolid, DWG, DXF, eDrawings and PDF engineering information.

The tools are important, but they remain secondary to the engineering purpose.

The principal deliverable is reliable information about the existing plant.

Frequently Asked Questions

What is mine process plant asset capture?

Mine process plant asset capture uses technologies such as terrestrial LiDAR scanning to record the three-dimensional geometry of existing equipment, structures, pipework and surrounding plant.

Why use LiDAR instead of manual measurements?

Manual measurement remains useful, but complex process plants may require hundreds of spatial relationships to be documented. LiDAR can capture much broader existing-condition information from suitable scanner positions.

Can scanning reduce the need to access difficult plant areas?

In some circumstances, yes. LiDAR can capture visible geometry from stand-off positions, potentially reducing the amount of close-contact measurement required. Normal mine-site safety procedures and access controls still apply.

Can measurements be obtained after the scanning is complete?

Yes. Once correctly registered, point-cloud datasets can be measured during later engineering stages, subject to the geometry being visible and adequately captured.

Can old engineering drawings be checked against the scan?

Yes. Point-cloud information can be compared with drawings and models to help identify differences between documented and installed conditions.

Can the point cloud be converted into CAD?

Yes. Selected equipment, structures and interfaces can be reconstructed as CAD or BIM geometry according to the engineering purpose of the project.

Can asset capture help with equipment replacement?

Yes. Existing mounting points, pipe connections, structural interfaces and surrounding clearances can be captured before replacement equipment is designed or selected.

Can LiDAR scanning support shutdown projects?

Yes. Reality capture can improve existing-condition information before or during shutdown access and support subsequent engineering, fabrication and installation planning.

What file formats can Hamilton By Design provide?

Depending on the agreed project scope, deliverables may include E57, RCP, RCS and LAS point clouds, CAD models, STEP, SAT, Parasolid, DWG, DXF, eDrawings and PDF documentation.

What areas around Mudgee can Hamilton By Design support?

Hamilton By Design can support mine and industrial projects throughout Mudgee, Ulan, Gulgong, Wollar and surrounding Central West NSW mining regions.

Mine Process Plant Asset Capture Mudgee NSW

Existing process plants can be difficult to measure comprehensively when equipment is operating, access is constrained or engineering teams have only limited opportunities to enter particular plant areas.

Engineer-led terrestrial LiDAR provides a practical method of capturing equipment, structures and surrounding interfaces as a measurable existing-condition dataset.

Hamilton By Design combines reality capture with point-cloud processing, CAD modelling and mechanical engineering to help project teams progress from site condition to engineering information.

For mine operators and project teams in Mudgee and Central West NSW, the principle is straightforward:

Capture safely where practical. Verify the installed condition. Engineer from measurable reality. Reduce uncertainty before fabrication and shutdown execution.

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3D Laser Scanning

Mining NSW – 3D LiDAR Scanning, Scan to CAD, Reverse Engineering and Brownfield Engineering Support

Scan for Conveyor Transfers

Why Conveyor Transfer Chute Design Matters

7 August 20266 September 2026

Mine Conveyor Gallery Scanning Hunter Valley NSW | Hamilton By Design

Mine conveyor gallery scanning in the Hunter Valley NSW using engineering-grade LiDAR and point-cloud modelling

Mine Conveyor Gallery Scanning Hunter Valley NSW

Engineering-Grade LiDAR Scanning for Existing Conveyor Structures, Brownfield Upgrades and Shutdown Planning

Mine conveyor galleries are long-life assets that are frequently modified as operating requirements change. Over time, additional bracing may be installed, structural members may be strengthened, walkways altered, guarding replaced, services added and conveyor equipment upgraded.

The challenge is that these modifications are not always fully incorporated into the original engineering drawings.

For project, maintenance and structural engineering teams, this creates a significant source of uncertainty:

Does the available drawing represent the conveyor gallery that is actually installed on site?

Hamilton By Design provides mine conveyor gallery scanning services throughout the Hunter Valley NSW, using engineering-grade terrestrial LiDAR scanning, registered point clouds and CAD modelling to capture the actual existing condition of conveyor galleries and associated mining infrastructure.

The objective is not simply to create a 3D image of the conveyor.

It is to provide reliable engineering information that can be used to verify existing conditions, support structural modifications, reduce fabrication risk and improve shutdown planning.

The Problem: Undocumented Structural Changes

Mine conveyor galleries may operate for decades.

During their service life, structural and mechanical modifications can accumulate through maintenance projects, production upgrades, shutdown work and equipment replacement.

Examples may include:

additional structural bracing;
replacement beams or columns;
strengthened connections;
modified conveyor support frames;
altered walkways;
new access platforms;
replacement handrails;
additional equipment supports;
pipework and service additions;
relocated cable trays;
modified guarding;
changes to conveyor drives or pulleys; and
local repairs following corrosion or damage.

The original drawings may remain useful, but they cannot always be assumed to represent the final installed arrangement.

Hamilton By Design’s work with 3D laser scanning for conveyor transfer towers addresses a closely related brownfield problem: conveyors, chutes, steelwork and access structures often evolve over time, creating differences between the physical plant and legacy drawings. (Hamilton By Design Co.)

For conveyor gallery upgrades, those differences can affect every stage from conceptual design through fabrication and installation.

What Risk Does Incorrect Existing Information Create?

The engineering risk is not simply that a drawing contains an incorrect dimension.

The larger issue is that a project may be developed around an incorrect understanding of the existing structure.

Structural Interface Risk

A proposed beam, support or platform may be designed around an assumed connection point that differs from the installed arrangement.

This can result in late redesign or unplanned field modifications.

Fabrication Fit-Up Risk

New steelwork may be fabricated accurately to the design model but still fail to fit because an undocumented brace, support or service occupies the required space.

Shutdown Risk

Unexpected existing conditions may only become apparent once the plant is isolated and installation work begins.

During a short shutdown window, even relatively minor fit-up problems can consume valuable time.

Access Risk

New equipment or structural modifications may interfere with walkways, platforms, guarding or maintenance access.

Scope and Cost Risk

Additional structural work may be discovered after detailed engineering has commenced, potentially affecting project scope, programme and cost.

The purpose of LiDAR scanning is therefore broader than dimensional measurement.

It is a method of reducing uncertainty before design decisions become expensive to change.

Who Can Benefit from Conveyor Gallery Scanning?

Mine conveyor gallery scanning can support:

mine owners and operators;
engineering managers;
project engineers;
structural engineers;
mechanical engineers;
maintenance teams;
reliability engineers;
shutdown planners;
CHPP personnel;
conveyor contractors;
EPCM organisations;
structural steel fabricators; and
drafting and modelling teams.

The strongest use case is generally a brownfield project where new work must interface accurately with existing infrastructure.

A structural engineer may need to know the actual position of existing steel before developing strengthening details.

A mechanical engineer may need the conveyor centreline, drive arrangement or equipment envelope.

A fabricator may need confidence that a prefabricated assembly will fit when delivered to site.

All of these requirements depend on reliable existing-condition information.

Capture the Existing Conveyor Gallery

Terrestrial LiDAR scanning allows conveyor galleries and their surrounding structures to be captured from multiple positions.

The scanner records millions of spatial measurements that collectively describe the visible geometry of the structure.

Typical items captured may include:

conveyor trusses;
gallery steelwork;
trestles and columns;
structural bracing;
conveyor stringers;
idler frames;
pulley arrangements;
access platforms;
stairs and walkways;
handrails;
guarding;
equipment supports;
pipework;
cable trays;
services; and
interfaces with transfer towers.

The advantage over isolated field measurements is context.

Rather than measuring only the component thought to be important at the beginning of the project, the scan captures the broader physical relationship between the structure, conveyor equipment and surrounding plant.

Hamilton By Design’s broader 3D laser scanning services specifically address the limitations of outdated as-built drawings and manual measurement in complex industrial environments, where undocumented changes and difficult access can undermine design accuracy. (Hamilton By Design Co.)

Register the Point Cloud

Individual scans are processed and aligned into a registered point-cloud dataset.

This produces a measurable digital representation of the conveyor gallery at the time of capture.

Engineering teams can then inspect and measure the gallery away from site.

Potential measurements include:

structural member positions;
elevations;
conveyor centrelines;
beam spacing;
column locations;
bracing geometry;
clearances;
walkway widths;
platform elevations;
equipment offsets; and
service locations.

This can substantially reduce the need to return to site every time an additional dimension becomes important during detailed design.

A useful project principle is:

Capture comprehensively on site, then measure selectively during engineering.

Compare Drawings with the Installed Structure

Where legacy drawings are available, LiDAR provides an opportunity to compare documented geometry with actual site conditions.

This may identify:

additional structural members;
removed members;
relocated components;
modified platforms;
undocumented services;
altered support arrangements; and
differences in equipment position.

This is particularly important when historical drawings are labelled as-built but have not been comprehensively updated following later modifications.

Hamilton By Design also uses LiDAR for as-built drawings derived from registered point clouds, allowing structural, mechanical and service information to be documented from the physical installed condition rather than relying solely on historic mark-ups. (Hamilton By Design Co.)

For conveyor-gallery projects, the principle is straightforward:

Use the drawing as engineering information, but verify critical interfaces against reality.

From Point Cloud to CAD or BIM

A registered point cloud can often provide sufficient information for measurement and spatial review.

However, some projects benefit from converting selected elements into CAD or BIM geometry.

Depending on the engineering scope, modelling may include:

primary structural steel;
conveyor centreline;
trestles;
bracing;
walkways;
platforms;
equipment supports;
conveyor equipment; and
interfaces with adjacent structures.

The appropriate level of modelling should be determined by the engineering purpose.

There is little value in modelling every nut, bolt and cable if those details do not influence the proposed modification.

For larger engineering and asset-information workflows, Hamilton By Design’s Scan to BIM services for Newcastle and the Hunter support conveyor upgrades, structural modifications, mining assets and brownfield projects using LiDAR capture, point clouds and digital modelling. (Hamilton By Design Co.)

The purpose is to create usable engineering information rather than digital complexity for its own sake.

Design Against the Actual Installed Condition

Once the existing conveyor gallery has been captured, proposed structural or mechanical modifications can be reviewed against the point cloud.

This allows engineers to assess:

structural connection points;
equipment clearances;
conveyor alignment;
new support locations;
platform interfaces;
access requirements;
guarding;
service clashes; and
installation space.

A proposed steel assembly can be positioned within the existing scan before fabrication.

This provides an opportunity to identify clashes or incorrect assumptions while changes are still relatively inexpensive.

A useful engineering objective is:

Find the clash in the digital model rather than during the shutdown.

Improving Shutdown Preparation

Mine conveyor modifications are frequently undertaken during planned shutdowns.

The available installation period may be limited, while multiple trades and work fronts compete for access.

Unexpected structural conditions during these periods can create significant disruption.

Accurate LiDAR information can support shutdown planning by allowing engineering teams to investigate the existing gallery before the shutdown begins.

Potential benefits include:

improved fabrication confidence;
better identification of interface conditions;
reduced field measuring;
earlier clash detection;
improved installation planning;
better understanding of access limitations; and
fewer unplanned modifications during installation.

This does not eliminate every project risk, but it can substantially improve the quality of information used to manage those risks.

Mine Conveyor Gallery Scanning Across the Hunter Valley

The Hunter Valley contains extensive mining, coal-processing and bulk-material-handling infrastructure.

Hamilton By Design supports engineering and 3D scanning projects throughout the region, including areas around:

Singleton;
Muswellbrook;
Ravensworth;
Mount Thorley;
Warkworth;
Lemington;
the Upper Hunter; and
the wider Hunter Region.

The Hunter region includes substantial mining, industrial, coal-handling and materials-handling infrastructure, making accurate existing-condition information particularly relevant for brownfield upgrades and ongoing asset maintenance. Hamilton By Design’s regional services include LiDAR scanning, point-cloud modelling, reverse engineering and scan-to-fabrication workflows. (Hamilton By Design Co.)

Tools Supporting Conveyor Gallery Scanning

A conveyor-gallery project may use several complementary technologies.

FARO Focus S70 can provide high-density terrestrial LiDAR capture of conveyor and structural infrastructure.

FARO Orbis may assist with supplementary mobile capture where appropriate to the required accuracy and site conditions.

FARO SCENE supports scan registration and point-cloud processing.

Autodesk ReCap assists with point-cloud preparation and use within CAD workflows.

SolidWorks can support mechanical modelling, equipment interfaces and fabrication-oriented design.

Autodesk Inventor and AutoCAD can support plant modelling, structural layouts and engineering documentation.

Navisworks can assist with model coordination and clash review.

Revit may be used where a structured BIM model is required.

Depending on the project, deliverables may include:

E57 point clouds;
RCP and RCS files;
LAS datasets;
measurable point clouds;
CAD models;
SolidWorks models;
STEP or Parasolid files;
DWG and DXF drawings;
general arrangement drawings;
sections and elevations;
existing-versus-proposed models;
clash-review models; and
PDF engineering documentation.

The software is not the principal product.

The principal product is improved confidence in the existing-condition information used for engineering.

Frequently Asked Questions

What is mine conveyor gallery scanning?

Mine conveyor gallery scanning uses terrestrial LiDAR to capture the three-dimensional geometry of conveyor structures, structural steel, access systems, equipment and surrounding services.

Why scan a conveyor gallery if drawings already exist?

Existing drawings can remain valuable, but conveyor galleries may have undergone structural or mechanical modifications that are not fully documented. LiDAR allows critical existing conditions to be checked against the physical structure.

Can LiDAR identify undocumented structural changes?

LiDAR captures visible installed geometry. When compared with existing drawings or models, it can help identify differences such as additional bracing, relocated members, altered platforms and changed equipment positions.

Can additional measurements be taken after leaving site?

Yes. Once the scans are correctly registered, engineers can obtain many additional dimensions from the point cloud as the project develops.

Can the scan support structural upgrades?

Yes. Point-cloud information can support structural engineering by documenting existing member positions, connections, clearances and interfaces required for modification work.

Can the point cloud be converted into CAD?

Yes. Relevant portions of the gallery can be converted into fit-for-purpose CAD or BIM geometry depending on the project requirements.

Can conveyor gallery scanning reduce shutdown risk?

It can reduce uncertainty by improving knowledge of existing conditions before fabrication and installation. This may help identify clashes and interface issues before the shutdown begins.

What areas does Hamilton By Design service in the Hunter Valley?

Hamilton By Design can support projects throughout the Hunter Valley, including Singleton, Muswellbrook, the Upper Hunter and surrounding mining and industrial areas.

Mine Conveyor Gallery Scanning Hunter Valley NSW

For brownfield conveyor projects, one of the greatest risks is designing against an existing-condition record that no longer reflects the physical plant.

Engineering-grade LiDAR scanning provides a practical method of capturing conveyor galleries, structural steel, access systems and surrounding infrastructure before modification work begins.

The resulting point cloud can support verification, measurement, CAD modelling, structural design, fabrication and shutdown planning.

For mine operators and engineering teams throughout the Hunter Valley NSW, the principle is simple:

Verify what is installed. Design from measured reality. Reduce uncertainty before fabrication and shutdown execution.

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Scan for Conveyor Transfers

Why Conveyor Transfer Chute Design Matters

Engineering Preparation for Coal Plant Shutdowns

Reducing Shutdown Risk Using Digital Engineering Models

Detailing Transfer Stations in the Age of Digital Engineering

AS 1755 Conveyor Safety

Mining NSW – 3D LiDAR Scanning, Scan to CAD, Reverse Engineering and Brownfield Engineering Support

3D Laser Scanning

Structural Engineers

AS 1755 Conveyor Safety

AS 1657 Access Compliance | Fixed Platforms, Walkways, Stairs & Ladders

Bulk Material Handling in Mining: Engineering the Movement of Raw Materials from ROM to Plant

7 August 202611 September 2026

Mine Transfer Station Scanning Muswellbrook NSW | Hamilton By Design

Mine transfer station scanning in Muswellbrook NSW using engineering-grade 3D LiDAR and point-cloud modelling

Mine Transfer Station Scanning Muswellbrook NSW

Engineering-Grade 3D Laser Scanning for Congested Transfer Stations, Chutes and Conveyor Upgrades

Mine transfer stations are among the most spatially complex areas within coal-handling and bulk-material-handling infrastructure.

Within a relatively small footprint, a transfer station may contain conveyors, head pulleys, transfer chutes, structural steel, access platforms, walkways, guarding, dust extraction ducting, pipework, electrical services and maintenance zones. These systems must operate together while remaining accessible for inspection, maintenance and future modification.

For engineering teams, this creates a practical problem:

Transfer stations are highly congested and can be difficult to measure accurately using conventional methods.

Hamilton By Design provides mine transfer station scanning services in Muswellbrook NSW and throughout the Upper Hunter, using engineering-grade terrestrial LiDAR scanning, registered point clouds and CAD modelling to capture the actual installed condition of existing mining infrastructure.

The objective is not simply to create a visual 3D representation. It is to establish a reliable, measurable engineering dataset that can support conveyor modifications, chute replacements, structural upgrades, shutdown planning and brownfield plant development.

Why Transfer Stations Are Difficult to Measure

Transfer stations are different from relatively open conveyor galleries. They are typically vertical, congested structures in which multiple mechanical and structural systems intersect.

An existing transfer station may include:

incoming and outgoing conveyors;
head and discharge pulleys;
transfer chutes;
hoppers;
structural columns and beams;
maintenance platforms;
stairs and ladders;
handrails;
conveyor guarding;
pipework;
dust extraction systems;
cable trays;
concrete floors and plinths; and
surrounding plant interfaces.

As mining infrastructure is progressively modified, the installed arrangement may also diverge from original drawings.

A chute may have been replaced during a previous shutdown. Steelwork may have been strengthened. Platforms may have been modified. Additional services may have been installed around the original plant.

Hamilton By Design’s work with 3D laser scanning for conveyor transfer towers addresses this problem by capturing the true geometry of conveyors, chutes, structural steel and surrounding plant before engineering modifications are developed.

The Cost of Incomplete Site Information

Traditional field measurement remains useful, but it becomes increasingly difficult when an engineering project depends on hundreds of spatial relationships.

An engineer may visit site, obtain the dimensions considered necessary at the time and then return to the office to begin design.

Once modelling progresses, another critical dimension may be identified.

This can produce a repeated cycle:

Site measure → design → discover missing dimension → return to site → remeasure → revise design

For mine sites, repeated access can be costly because site visits may involve inductions, travel, permits, shutdown access and coordination with operations.

The engineering issue is therefore not merely the time required to measure one dimension. It is the uncertainty created when the wider installed environment has not been comprehensively captured.

Terrestrial LiDAR scanning changes that approach by recording millions of spatial measurements throughout the transfer station.

The resulting point cloud can subsequently be interrogated as the engineering develops.

A simple value proposition is:

Capture the transfer station once and continue measuring digitally from the registered point cloud.

Who Can Benefit from Transfer Station Scanning?

Mine transfer station scanning can support a wide range of technical stakeholders, including:

mine owners and operators;
engineering managers;
project engineers;
mechanical engineers;
structural engineers;
maintenance superintendents;
reliability teams;
shutdown planners;
CHPP personnel;
conveyor contractors;
chute specialists;
EPCM organisations;
fabrication contractors; and
drafting teams.

The important consideration is not who wants a 3D model.

The real question is:

Who requires reliable information about the existing transfer station to make an engineering decision?

For example, a project engineer may need accurate pulley centres before designing a replacement chute. A structural engineer may need existing beam locations before modifying supporting steel. A shutdown planner may need to understand removal paths and maintenance access before work begins.

Each discipline may use the same captured dataset differently.

Define the Engineering Requirement

Before scanning begins, the purpose of the project should be established.

Typical transfer-station projects may involve:

new transfer chute installation;
chute replacement;
conveyor modification;
pulley replacement;
structural strengthening;
new platforms or walkways;
guarding upgrades;
dust extraction modifications;
equipment replacement; or
plant expansion.

Understanding the engineering requirement determines the required scan coverage.

The objective is not to collect unnecessary data. It is to ensure that all critical interfaces are captured before the project moves into detailed design.

Capture the Existing Transfer Station

Terrestrial LiDAR scanners are positioned at multiple levels and viewpoints throughout the transfer station.

Each scan records the three-dimensional relationship between visible surfaces.

Because the scanner captures a broad field of view, the resulting dataset can include much more than the component initially being modified.

For example, a scan undertaken for a chute replacement may also capture surrounding beams, existing platforms, maintenance access, adjacent pipework, guarding, floor levels and nearby equipment.

This contextual information may become important later in the project.

For mining transfer points specifically, Hamilton By Design combines scanning with engineering analysis through its work on 3D scanning of chutes, hoppers and mining transfer points, where captured geometry can support retrofit accuracy, chute design and material-flow improvements.

Register the Point Cloud

Individual scans are processed and registered into a coordinated point-cloud dataset.

This creates a measurable digital representation of the transfer station at the time of capture.

Engineering personnel can then review dimensions away from site.

Typical information may include:

conveyor centrelines;
pulley locations;
chute flange positions;
structural member coordinates;
equipment offsets;
platform elevations;
available clearances;
service locations; and
maintenance access envelopes.

This is particularly useful where project teams are geographically separated or where physical access to the transfer station is restricted.

Convert the Scan into Engineering CAD

Point-cloud data may be sufficient for some projects.

For others, selected infrastructure can be reconstructed as engineering CAD geometry.

Depending on the project, the model may include:

conveyor centrelines;
pulleys;
transfer chute geometry;
structural steel;
platforms;
equipment envelopes;
maintenance clearances; and
surrounding plant interfaces.

The appropriate modelling philosophy is fit for purpose.

It is rarely necessary to model every nut, bolt, bracket and cable tray.

The objective is to represent the geometry required to answer the engineering question accurately.

For brownfield work, Hamilton By Design applies this type of reality-capture workflow through its engineering-led 3D scanning for brownfield industrial upgrades, where existing plant conditions are used as the basis for practical retrofit and shutdown engineering.

Design Against the Actual Installed Condition

Once the existing transfer station has been captured, the proposed modification can be developed directly against the point cloud or CAD model.

This can help engineers assess:

equipment clearances;
structural interfaces;
conveyor alignment;
chute fit-up;
installation pathways;
maintenance access;
guarding requirements; and
potential clashes.

The objective is straightforward:

Identify the interference during design rather than during the shutdown.

This is particularly important in brownfield mining environments where fabrication may occur off site and components must arrive ready to install.

Unexpected site modifications during a shutdown can affect labour, crane planning, production and overall project schedule.

Transfer Chutes and Material-Flow Problems

Not every transfer-station problem is dimensional.

Some are operational.

Examples include:

chute blockages;
material buildup;
excessive wear;
poor trajectory;
spillage;
dust generation;
impact damage; and
belt loading problems.

In these cases, scanning provides the actual installed geometry, while engineering analysis can investigate why the transfer point is not performing as intended.

Where appropriate, discrete element modelling can also be used to analyse material behaviour through the chute.

Hamilton By Design’s broader mining engineering services combine LiDAR capture, mechanical design and fabrication-focused engineering for brownfield mining and asset modification projects.

Conveyor Transfer Chute Design

Transfer chute performance is closely connected to conveyor reliability.

Poor chute geometry can contribute to material buildup, excessive wear, impact loading, spillage and belt-tracking problems.

Where the existing transfer point is being modified, the point cloud can be used to establish the installed geometry before a replacement or upgraded chute is developed.

Hamilton By Design provides conveyor transfer chute design for mining, combining practical mechanical engineering with existing-condition capture to support retrofit and brownfield projects.

Coal Chute Design

Coal transfer systems require consideration of more than dimensional fit.

Flow direction, material properties, liner arrangement, wear zones, impact velocity and maintenance access can influence chute performance.

For coal-handling applications, Hamilton By Design’s coal chute design services provide an additional engineering pathway where captured transfer-station geometry can be combined with chute redesign and materials-handling analysis.

Conveyor Reliability and Failure Reduction

Transfer stations are often closely associated with conveyor reliability problems.

Misalignment, wear, spillage, poor transfer geometry and structural movement can all contribute to operational issues.

Hamilton By Design’s technical resource on common conveyor failures in mining plants provides further context on how engineering, inspection and digital modelling can support more reliable conveyor systems.

Bulk Material Handling Engineering

Transfer stations should not always be considered in isolation.

They form part of a wider bulk-material-handling system connecting ROM infrastructure, conveyors, stockpiles, processing plant and product handling systems.

Hamilton By Design’s bulk material handling engineering for mining considers the wider relationship between conveyors, chutes, transfer stations and supporting mine infrastructure.

This broader systems view can be particularly useful when a transfer-station modification affects upstream or downstream equipment.

Mine Transfer Station Scanning in Muswellbrook NSW

Muswellbrook is strategically located within the Upper Hunter mining region and is surrounded by substantial coal-mining and materials-handling infrastructure.

This makes the area particularly relevant for services associated with:

conveyor upgrades;
CHPP modifications;
transfer-station refurbishments;
structural upgrades;
chute replacement;
shutdown engineering; and
mine plant life-extension projects.

Hamilton By Design can support projects throughout Muswellbrook, Denman, the Upper Hunter and the wider Hunter Valley region.

The service is particularly valuable where existing infrastructure is ageing, heavily modified or difficult to access.

Tools Supporting the Workflow

A practical mine transfer-station scanning workflow may incorporate several tools.

FARO Focus S70 can provide detailed terrestrial LiDAR capture of transfer towers and surrounding infrastructure.

FARO Orbis may support supplementary mobile capture where appropriate.

FARO SCENE can be used to register individual scans into a coordinated point cloud.

Autodesk ReCap can assist with point-cloud preparation and CAD interoperability.

SolidWorks can support mechanical components, chute geometry and fabrication models.

Autodesk Inventor and AutoCAD can support broader plant modelling, layouts and drafting.

Navisworks can assist with coordination and clash review between existing-condition data and proposed models.

Where material-flow performance is part of the engineering problem, Rocky DEM may assist with analysing particle trajectories, impact locations, wear zones and transfer behaviour.

The technology should, however, remain secondary to the engineering objective.

The primary deliverable is reliable information that supports better engineering decisions.

Typical Project Deliverables

Depending on client requirements, deliverables may include:

registered E57 point clouds;
RCP and RCS datasets;
LAS files;
measurable point-cloud data;
existing-condition CAD models;
SolidWorks models;
STEP or Parasolid files;
DWG and DXF drawings;
general arrangement drawings;
sections and elevations;
proposed-versus-existing models;
clash-review models;
eDrawings; and
PDF engineering documentation.

Some projects may require only scan data.

Others may progress through:

Scan → Register → Model → Engineer → Detail → Fabricate

Frequently Asked Questions

What is mine transfer station scanning?

Mine transfer station scanning uses terrestrial LiDAR to capture the three-dimensional geometry of conveyors, chutes, structural steel, platforms, services and surrounding plant within a transfer station.

Why are transfer stations difficult to measure manually?

Transfer stations are typically congested and multi-level structures. Conveyor systems, chute geometry, steelwork, access platforms, guarding and services can occupy the same restricted space, making comprehensive manual measurement difficult.

Can additional dimensions be obtained after leaving site?

Yes. Once scans are registered into a measurable point cloud, engineering teams can obtain many additional dimensions digitally without necessarily returning to site.

Can transfer station scanning support chute replacement?

Yes. LiDAR can capture existing pulley positions, chute interfaces, structural steel, surrounding equipment and maintenance clearances before a replacement chute is designed.

Can the point cloud be converted into CAD?

Yes. Relevant infrastructure can be reconstructed as CAD geometry according to the engineering requirement. The appropriate level of modelling depends on how the information will ultimately be used.

Can scanning assist with structural modifications?

Yes. Existing structural members, columns, beams, platforms and equipment interfaces can be captured to support brownfield structural modifications and strengthening projects.

Is DEM required for every transfer station project?

No. DEM is most relevant where material-flow behaviour, trajectory, wear, blockage or impact is part of the problem. For dimensional fit-up and structural modifications, LiDAR and CAD may be sufficient.

What areas do you service around Muswellbrook?

Hamilton By Design can support mine and industrial projects throughout Muswellbrook, Denman, the Upper Hunter and the wider Hunter Valley NSW region.

Mine Transfer Station Scanning Muswellbrook NSW

For transfer-station upgrades, reliable knowledge of the existing plant can significantly reduce engineering uncertainty.

Terrestrial LiDAR scanning provides a practical way to capture congested conveyors, chutes, structural steel, platforms and surrounding services as a measurable digital dataset.

That dataset can then support engineering modelling, structural upgrades, conveyor modifications, shutdown planning and fabrication.

For brownfield mine projects in Muswellbrook and the Upper Hunter, the principle is simple:

Capture the congested transfer station accurately. Develop the engineering from measured reality. Verify the modification before it reaches site.

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Surface Mine 3D LiDAR Scanning for Hunter Valley, Singleton, Muswellbrook & Upper Hunter NSW

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Explore related Hamilton By Design services supporting mine transfer stations, CHPPs, conveyors, bulk materials handling, shutdown engineering, LiDAR scanning and Scan-to-CAD projects across Muswellbrook, Singleton, the Upper Hunter, Hunter Valley and mining operations throughout NSW.

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7 August 20268 September 2026

Mine Conveyor 3D Scanning Singleton NSW | Hamilton By Design

Mine conveyor 3D scanning in Singleton NSW using engineering-grade LiDAR, point-cloud modelling and CAD design

Mine Conveyor 3D Scanning Singleton NSW

Engineering-Grade LiDAR Scanning for Conveyor Upgrades, Maintenance and Plant Expansion

Mine conveyor systems are rarely static assets. Over their operating life, conveyors may be extended, shortened, re-aligned, reinforced or modified to suit changing production requirements. Transfer chutes are replaced, drives are upgraded, supporting structures are altered and access platforms are added around existing plant.

As these modifications accumulate, the physical conveyor system can progressively differ from the original engineering drawings.

This creates a practical problem for project and maintenance teams:

Conveyor upgrades can require repeated field measurements because available drawings do not always represent the installed condition accurately.

Hamilton By Design provides mine conveyor 3D scanning services in Singleton NSW and throughout the Hunter Valley, using engineering-grade terrestrial LiDAR scanning, registered point clouds and CAD modelling to capture existing conveyor systems and surrounding mine infrastructure.

The objective is to reduce repeated site measuring and provide engineers with a measurable digital representation of the actual installed plant before modification work begins.

For broader open-cut mining environments, Hamilton By Design also provides surface mine 3D LiDAR scanning across the Hunter Valley NSW, supporting existing-condition capture of mining, processing and materials-handling infrastructure.

The Problem: Repeated Field Measurements During Conveyor Upgrades

Brownfield conveyor projects frequently begin with incomplete information.

Existing drawings may show the original plant layout, but subsequent modifications may not have been fully incorporated into the available engineering documentation.

Typical discrepancies can include:

altered chute geometry;
modified structural steel;
replacement pulleys;
relocated equipment;
additional pipework and services;
changes to access platforms;
revised guarding;
undocumented shutdown modifications; and
differences between nominal and installed dimensions.

A project engineer may initially visit site to measure a conveyor upgrade area, return to the office and begin modelling, only to discover that another dimension is required.

This can produce an inefficient cycle:

Measure → design → identify missing information → return to site → remeasure → revise design.

Engineering-grade LiDAR scanning changes this process by capturing the wider plant environment rather than relying solely on isolated manual measurements.

The resulting registered point cloud allows additional measurements to be obtained digitally as the design develops.

A simple way to express the value is:

Capture once on site. Measure repeatedly from the point cloud.

What Mine Conveyor Infrastructure Can Be Scanned?

A conveyor scanning project can include much more than the belt itself.

Depending on the scope, terrestrial LiDAR can capture:

conveyor gantries;
stringers;
head pulleys;
tail pulleys;
take-up systems;
drive stations;
transfer towers;
chutes;
hoppers;
feeders;
idler arrangements;
structural steel;
walkways;
platforms;
stairs;
guards;
pipework;
cable trays;
concrete structures; and
adjacent equipment.

This wider capture is important because conveyor modification projects depend on the spatial relationship between multiple assets.

For example, a replacement chute must fit between the conveyor discharge point, receiving equipment, supporting steel and surrounding maintenance access.

The engineering problem is therefore not simply measuring one component.

It is understanding the complete installed environment around the component being modified.

Who Can Benefit from Mine Conveyor 3D Scanning?

Mine conveyor 3D scanning can assist:

mine owners and operators;
engineering managers;
project engineers;
mechanical engineers;
maintenance superintendents;
reliability teams;
shutdown planners;
CHPP engineers;
conveyor maintenance contractors;
EPCM organisations;
structural engineers;
fabricators; and
drafting teams.

For companies working across NSW coal operations, Hamilton By Design’s wider mining engineering and 3D scanning services in NSW can support projects beyond individual conveyor systems, including processing plant, structural and mechanical infrastructure.

The common requirement is reliable information about the existing plant before engineering decisions are made.

From Conveyor to Registered Point Cloud

1. Define the Engineering Requirement

Before scanning begins, the project team should establish the intended modification.

This may include:

chute replacement;
conveyor extension;
drive upgrade;
pulley replacement;
conveyor re-alignment;
transfer-station modification;
structural strengthening;
walkway modification; or
installation of new conveyor equipment.

Understanding the engineering requirement determines the scan coverage and level of detail required.

2. Capture the Existing Conveyor System

Terrestrial LiDAR scanners are positioned around the conveyor and surrounding infrastructure.

Each scan records a large number of three-dimensional spatial measurements.

Multiple scan positions allow equipment to be captured from different viewpoints and reduce areas hidden by surrounding structures.

This approach is particularly useful in complex brownfield environments where manual measurement would require numerous individual dimensions.

3. Register the Scan Data

Individual scans are processed and combined into a coordinated point-cloud dataset.

The resulting point cloud becomes a measurable record of the plant condition at the time of scanning.

Engineering personnel can then interrogate the dataset away from site and obtain additional dimensions as required.

This is particularly valuable where physical access is limited or where repeated measuring trips would interrupt engineering progress.

From Point Cloud to Engineering CAD

The point cloud may be sufficient for some projects, but other conveyor upgrades require selected infrastructure to be converted into CAD geometry.

Hamilton By Design provides surface mine Scan-to-CAD services throughout the Hunter Valley NSW to convert captured existing conditions into practical engineering models for brownfield design and plant modification.

Depending on the project, CAD geometry may include:

conveyor centreline;
pulley centres;
belt path;
structural steel;
chute geometry;
equipment interfaces;
support frames;
floor levels;
access structures; and
surrounding plant envelopes.

The objective is not to model every visible component unnecessarily.

Instead, the digital model should contain the information required to solve the engineering problem.

Designing Conveyor Upgrades Against Existing Conditions

Once the conveyor environment has been captured, proposed equipment can be developed directly against the existing point-cloud or CAD geometry.

This can support:

clearance assessment;
clash detection;
structural interfaces;
installation planning;
equipment positioning;
maintenance access;
conveyor alignment;
chute fit-up;
fabrication interfaces; and
shutdown preparation.

This allows potential problems to be identified before fabrication.

A strong engineering objective is therefore:

Find the interference digitally before finding it during installation.

This becomes increasingly important during mine shutdowns where installation windows may be short and delays can affect plant availability.

Conveyor and CHPP Projects in Singleton NSW

Singleton is located within one of Australia’s most significant coal-mining regions, with extensive materials-handling and coal-processing infrastructure throughout the surrounding Hunter Valley.

Conveyors form critical connections between mining, ROM handling, crushing, stockpiling and coal preparation systems.

Hamilton By Design’s CHPP 3D scanning services in Singleton NSW provide a closely related application where conveyor systems, transfer stations, chutes, structural steel and surrounding processing infrastructure can be captured to support shutdowns and brownfield modifications.

This makes conveyor scanning particularly relevant for:

CHPP upgrades;
transfer-station modifications;
new chute installations;
conveyor extensions;
structural changes;
equipment replacement; and
plant-expansion projects.

Reverse Engineering Existing Conveyor and Mining Equipment

Mining operations can also contain equipment for which reliable manufacturing information is no longer available.

Components may have been modified during previous shutdowns, suppliers may no longer support older equipment, or drawings may not reflect current configurations.

In these cases, reality capture can provide the starting geometry for reverse engineering.

Hamilton By Design’s open-cut mine machinery reverse-engineering services in Muswellbrook NSW demonstrate how LiDAR and engineering modelling can support legacy mining equipment and replacement-component development.

For conveyor projects, this approach may be useful for:

guards;
frames;
supports;
chute components;
equipment interfaces;
access structures; and
other existing mechanical assemblies.

The objective is not necessarily to copy an existing component exactly. Captured geometry can also provide the basis for a modified or improved replacement.

Practical Tools for Conveyor 3D Scanning

A mine conveyor 3D scanning project may involve several complementary technologies.

FARO Focus S70

Terrestrial LiDAR scanning can provide dense spatial capture of conveyor systems, transfer stations and surrounding infrastructure.

FARO Orbis

Mobile scanning may provide supplementary capture where rapid coverage is beneficial and appropriate to the engineering requirement.

FARO SCENE

Scan data can be processed and registered into coordinated point-cloud datasets.

Autodesk ReCap

Point clouds can be prepared for use within CAD and engineering software.

SolidWorks

Mechanical components, chute systems, equipment and fabrication models can be developed from captured geometry.

Autodesk Inventor and AutoCAD

These tools can support plant modelling, layouts, engineering drawings and mechanical design.

Navisworks

Large point clouds and proposed design models can be reviewed together for coordination and clash checking.

Rocky DEM

Where a project involves chute or transfer-point performance, discrete element modelling can assist with analysing material flow, trajectories, wear zones and impact behaviour.

Rocky DEM is not required for every conveyor project, but it can become valuable when the engineering problem extends beyond dimensional fit-up into bulk-material behaviour.

Typical Deliverables

Depending on the scope, mine conveyor scanning deliverables may include:

registered E57 point clouds;
RCP and RCS datasets;
LAS files;
measurable point-cloud datasets;
existing-condition CAD models;
SolidWorks models;
STEP files;
Parasolid files;
DWG and DXF drawings;
general arrangement drawings;
sections and elevations;
existing-versus-proposed models;
clash-review models;
eDrawings; and
PDF engineering documentation.

Some projects may require only a registered point cloud.

Others may extend through:

Scan → Register → Model → Engineer → Draw → Fabricate.

Mine Conveyor 3D Scanning Singleton NSW

For conveyor upgrades, one of the greatest sources of engineering uncertainty is incomplete knowledge of the existing plant.

Repeated site visits may provide additional dimensions, but they can also interrupt design progress, increase travel requirements and still leave important spatial relationships undocumented.

Engineering-grade terrestrial LiDAR provides an alternative approach.

By capturing the conveyor and surrounding infrastructure as a registered point cloud, project teams can obtain a reusable digital record of the installed condition.

This information can then support CAD modelling, brownfield engineering, fabrication planning, shutdown preparation and future plant modifications.

For mine operators and contractors working throughout Singleton and the Hunter Valley NSW, the principle is straightforward:

Capture the conveyor once. Measure digitally as the engineering develops. Design against what is actually installed.

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1. Define the Project Requirement

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3. Register the Point Cloud

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Why use Scan to BIM for a hotel refurbishment?

Can individual hotel rooms be scanned?

Can you scan plant rooms and building services?

Do we need a Revit model?

Can the point cloud be supplied?

Can Scan to BIM help before redevelopment?

Does laser scanning eliminate the need for all site verification?

Do you provide Scan to BIM outside the Gold Coast?

What information is useful when requesting a quotation?

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One Reality-Capture Workflow Across Queensland

Step 1 – Define What the Model Needs to Achieve

Step 2 – Capture Existing Conditions with 3D LiDAR

Step 3 – Register and Process the Point Cloud

Step 4 – Convert Required Geometry into BIM or CAD

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Scan to BIM Services Across Queensland

Frequently Asked Questions – Scan to BIM Queensland

What is Scan to BIM?

Does Scan to BIM always mean Revit?

Can Scan to BIM be used for mining and industrial facilities?

Can you provide the point cloud as well as the model?

Why use laser scanning instead of existing drawings?

Can Scan to BIM help reduce site revisits?

Can the same process be used across several Queensland facilities?

What Queensland projects are suitable for Scan to BIM?

What should we determine before requesting a Scan to BIM quotation?

Talk to Hamilton By Design

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Capture Once, Measure as the Engineering Develops

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From Point Cloud to Engineering CAD