Emergency Management Policy

Hamilton By Design – Emergency Management Policy

Hamilton By Design is committed to protecting the health and safety of employees, contractors, clients, and visitors by ensuring effective planning, preparedness, and response to emergency situations.

This Emergency Management Policy outlines the framework for identifying potential emergency situations and responding in a timely, coordinated, and effective manner to minimise harm to people, property, and the environment.


Scope

This policy applies to all Hamilton By Design activities, including:

  • Office-based engineering and design work
  • 3D LiDAR scanning and site data capture
  • Engineering inspections and site visits
  • Work performed at client, construction, industrial, and mining sites
  • Interaction with clients, contractors, and visitors

Emergency Preparedness

Hamilton By Design will:

  • Identify potential emergency situations relevant to its activities, including but not limited to:
    • Fire and smoke
    • Medical emergencies
    • Chemical exposure or spills
    • Electrical incidents
    • Structural instability or collapse
    • Vehicle incidents
    • Extreme weather events
  • Maintain emergency response procedures appropriate to the nature of work being undertaken
  • Ensure access to emergency contact information and first aid resources
  • Comply with client and site-specific emergency management requirements when working off-site

Emergency Response

In the event of an emergency, Hamilton By Design will:

  • Prioritise the safety of people above all other considerations
  • Follow established emergency response procedures and site-specific emergency plans
  • Evacuate or isolate areas as required
  • Notify emergency services and relevant authorities when required
  • Communicate clearly with affected personnel, clients, and contractors

Roles and Responsibilities

Management

Management is responsible for:

  • Ensuring emergency management procedures are in place and maintained
  • Providing appropriate resources, training, and support
  • Coordinating emergency response where reasonably practicable

Employees and Contractors

Employees and contractors are responsible for:

  • Familiarising themselves with emergency procedures relevant to their work
  • Following emergency instructions and site rules
  • Reporting emergencies, hazards, or near misses immediately

Training and Awareness

Hamilton By Design ensures that:

  • Personnel are informed of emergency procedures applicable to their workplace or site
  • Site-specific emergency inductions are completed where required
  • Emergency awareness is maintained through ongoing communication

Incident Reporting and Review

All emergency incidents, near misses, and significant events must be reported. Hamilton By Design will investigate incidents to identify causes and implement corrective actions to prevent recurrence.


Business Continuity Considerations

Where appropriate, Hamilton By Design will take reasonable steps to:

  • Protect critical data and digital assets
  • Maintain continuity of engineering services following an emergency
  • Support recovery and return-to-work activities

Review and Continuous Improvement

This Emergency Management Policy is reviewed periodically to ensure it remains current, effective, and aligned with legislative requirements, operational changes, and industry best practice.


Approved by:
Hamilton By Design Management

Effective Date: 06/12/2006

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Fatigue Management Policy

Hamilton By Design – Fatigue Management Policy

1. Purpose

Hamilton By Design is committed to providing a safe, healthy, and productive work environment.
The purpose of this Fatigue Management Policy is to identify, assess, and manage fatigue-related risks to ensure work is performed safely and effectively.

Fatigue can impair judgement, reaction time, decision-making, and situational awareness. In engineering and site-based environments, unmanaged fatigue presents a significant safety risk.


2. Scope

This policy applies to:

  • Employees
  • Directors and officers
  • Contractors and consultants
  • Subcontractors
  • Any person performing work on behalf of Hamilton By Design

This policy applies to office work, remote work, travel, and site-based activities, including shutdowns and extended work periods.


3. Definition of Fatigue

Fatigue is a state of physical and/or mental exhaustion that reduces a personโ€™s ability to perform work safely and effectively.

Fatigue may result from:

  • Long work hours
  • Insufficient sleep or rest
  • Extended travel or commuting
  • High mental workload or sustained concentration
  • Night work or early starts
  • Poor work-life balance

4. Responsibilities

4.1 Hamilton By Design

Hamilton By Design will:

  • Plan work to minimise fatigue risk
  • Monitor working hours, travel demands, and workload
  • Avoid scheduling excessive hours where practicable
  • Ensure fatigue risks are considered when planning site work and shutdown activities
  • Encourage open communication regarding fatigue concerns
  • Take reasonable action where fatigue risk is identified

4.2 Workers

All workers are responsible for:

  • Presenting fit for work and adequately rested
  • Managing personal fatigue and wellbeing
  • Not performing work when fatigued to the point it may affect safety
  • Reporting fatigue concerns to management as soon as practicable
  • Following client and site-specific fatigue management requirements

5. Working Hours and Rest

To manage fatigue, Hamilton By Design will, where reasonably practicable:

  • Plan work schedules to allow adequate rest between shifts
  • Consider cumulative fatigue during extended or consecutive workdays
  • Manage travel to avoid excessive driving hours, particularly after long workdays
  • Allow rest breaks during prolonged periods of work or travel

Workers must take reasonable steps to ensure they obtain sufficient sleep and rest prior to performing work.


6. Travel and Remote Work

Hamilton By Design recognises that travel and remote work can significantly contribute to fatigue.

  • Travel time will be considered when planning work schedules
  • Workers must not drive or operate vehicles when fatigued
  • Alternative arrangements (rest breaks, overnight accommodation, or schedule changes) will be implemented where practicable
  • Remote and isolated work will be planned to minimise fatigue risk

7. High-Risk and Safety-Critical Work

Additional fatigue controls may be implemented for:

  • Shutdowns and time-critical work
  • Work requiring high levels of concentration or judgement
  • Site activities with elevated safety risk

Where fatigue is identified as a risk, work may be modified, delayed, or suspended.


8. Reporting Fatigue

Workers are encouraged to report fatigue without fear of reprisal.

  • Fatigue reports will be treated seriously and confidentially
  • Reporting fatigue will not result in disciplinary action when raised in good faith
  • Early reporting helps prevent incidents and injuries

9. Non-Compliance

Failure to comply with this policy may result in:

  • Removal from work duties or site
  • Review of work arrangements
  • Disciplinary action where applicable
  • Termination of engagement in serious or repeated cases

10. Policy Review

This policy will be reviewed periodically to ensure alignment with:

  • Australian WHS legislation
  • Client and site requirements
  • Industry best practice

11. Commitment

Hamilton By Design is committed to managing fatigue proactively to protect the safety, wellbeing, and performance of all people engaged in our work.


Approved by:
Hamilton By Design Management

Effective Date: 06/12/2006

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Fitness for Work Policy

Hamilton By Design – Fitness for Work Policy

1. Purpose

Hamilton By Design is committed to providing a safe, healthy, and productive working environment for employees, contractors, clients, and visitors.
The purpose of this Fitness for Work Policy is to ensure that all persons performing work on behalf of Hamilton By Design are physically and mentally capable of safely carrying out their duties, without risk to themselves or others.

Fitness for work is critical to maintaining high standards of safety, engineering judgement, and professional performanceโ€”particularly when working on industrial sites, construction environments, and shutdown-critical projects.


2. Scope

This policy applies to:

  • Employees
  • Directors and officers
  • Contractors and consultants
  • Subcontractors
  • Any person performing work on behalf of Hamilton By Design

This policy applies to office-based work, remote work, and site-based activities, including travel to and from work sites where required as part of duties.


3. Definition of Fitness for Work

A person is considered fit for work when they are in a physical and mental condition that enables them to perform assigned tasks competently and safely.

Factors that may affect fitness for work include, but are not limited to:

  • Fatigue
  • Alcohol or drug use
  • Medical conditions or injuries
  • Stress or mental health concerns
  • Medication that may impair performance
  • Illness
  • Excessive working hours or insufficient rest

4. Responsibilities

4.1 Hamilton By Design

Hamilton By Design will:

  • Take reasonable steps to ensure workers are fit for work
  • Manage work hours, travel, and workload to reduce fatigue risk
  • Comply with client site fitness-for-work and drug & alcohol requirements
  • Provide a supportive environment where fitness-for-work concerns can be raised without fear of reprisal
  • Take appropriate action where fitness for work may be compromised

4.2 Workers

All workers are responsible for:

  • Presenting fit for work at all times
  • Managing personal health and fatigue
  • Not attending work while impaired by alcohol, drugs, fatigue, or illness
  • Complying with client and site-specific fitness-for-work requirements
  • Promptly reporting any condition that may affect their ability to work safely

5. Fatigue Management

Hamilton By Design recognises fatigue as a significant safety risk.

To manage fatigue:

  • Work hours and travel will be planned to allow adequate rest
  • Extended hours and high-risk activities will be assessed and managed
  • Workers must advise management if they believe fatigue may affect their safety or performance
  • Workers must not perform safety-critical tasks when fatigued

6. Alcohol and Drugs

Workers must not attend work while under the influence of alcohol or drugs that may impair judgement, coordination, or reaction time.

  • Zero tolerance applies where required by client or site rules
  • Workers must comply with client drug and alcohol testing requirements
  • Prescription and over-the-counter medications that may affect performance must be managed responsibly

Any concerns regarding impairment will be addressed immediately and may result in removal from work duties.


7. Medical Conditions and Medication

Workers must ensure that any medical condition, injury, or medication does not compromise their ability to work safely.

Where required:

  • Workers should inform management of any condition that may affect safety
  • Reasonable adjustments may be implemented where practicable
  • Medical clearance may be required for specific site or task requirements

All medical information will be treated confidentially.


8. Mental Health and Wellbeing

Hamilton By Design recognises that mental health is an important component of fitness for work.

  • Workers are encouraged to speak up if experiencing stress, anxiety, or other mental health concerns
  • Supportive and practical solutions will be considered where possible
  • No worker will be disadvantaged for raising genuine fitness-for-work concerns

9. Non-Compliance

Failure to comply with this policy may result in:

  • Removal from work duties or site
  • Further assessment of fitness for work
  • Disciplinary action, where applicable
  • Termination of engagement in serious cases

10. Review and Continuous Improvement

This policy will be reviewed periodically to ensure it remains current with legislative requirements, client expectations, and industry best practice.


11. Commitment

Hamilton By Design is committed to ensuring that all work is carried out by people who are fit for work, capable of exercising sound engineering judgement, and able to perform their duties safely and professionally.

Approved by:
Hamilton By Design Management

Effective Date: 06/12/2006

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

ndustrial machine guarding solutions showing a conveyor system, a robotic cell, and a belt drive with fixed guards designed to prevent access to hazardous moving parts.

Machine guarding examples showing a guarded conveyor, enclosed robotic cell, and belt drive with safety covers

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Machine guarding remains one of the most persistent and preventable safety risks across Australian industry.
Despite improvements in automation, safety culture, and regulatory oversight, serious injuries and fatalities involving machinery continue to occur every year, particularly in manufacturing, mining, food processing, and materials handling.

Over the past decade, regulators, courts, and insurers have consistently reinforced one message:
machine guarding is not optional, not administrative, and not a โ€œfit-laterโ€ activity โ€” it is a core engineering and governance responsibility.

This article examines:

  • The international and Australian standards framework for machine guarding
  • Accident and injury trends over the past ten years
  • Legal and enforcement signals emerging from prosecutions
  • Why machine guarding must be treated as a strategic asset-risk issue, not just a safety task

The Global Framework: International Standards for Machine Guarding

Machine guarding is governed globally through standards developed by the International Organization for Standardization (ISO).


ISO standards portal
Core International Standards

ISO 12100 Risk assessment

ISO 14120 Guard design

ISO 13857 Safety distances

ISO 13849-1 Interlocks & control systems

These standards establish a risk-based engineering approach, requiring hazards to be:

  1. Identified
  2. Eliminated where possible
  3. Engineered out through guards and control systems
  4. Verified through geometry, distances, and fail-safe logic

This methodology underpins CE marking, global OEM compliance, and multinational EPC project delivery.


The Australian Context: AS 4024 and WHS Expectations

Australia adopts and localises ISO principles through AS 4024 โ€“ Safety of Machinery, referenced extensively by regulators under Work Health and Safety (WHS) legislation.

Standards Australia โ€“ AS 4024 Series
Key Australian Standards

AS 4024.1201 Risk assessment

AS 4024.1601 Guards

AS 4024.1602 Interlocks

AS 4024.1801 Safety distances

AS 4024.1501 Safety control systems

While standards themselves are not legislation, courts and regulators consistently use AS 4024 as the benchmark for determining whether risks have been managed so far as is reasonably practicable.


A Decade of Data: What the Accident Trends Tell Us

Australia does not publish a dedicated โ€œmachine guarding accidentโ€ metric. However, national data from Safe Work Australia clearly shows machinery remains a leading cause of serious harm.

Safe Work Australia โ€“ Key WHS statistics:
National Trends (Approximate โ€“ Last 10 Years)

MetricEvidence Source
~1,850+ traumatic work fatalitiesSafework Australia
~180โ€“200 fatalities per yearSafework Australia
Highest fatality rateMachinery operators & drivers
~130,000โ€“140,000 serious injury claims annuallyAustralian Institute of health and welfare
Common mechanismsTrapped by machinery, struck by moving objects

Machinery operators consistently record:

  • The highest fatality rates of all occupation groups
  • Disproportionate representation in serious injury claims
  • Higher exposure to entanglement, crush, shear, and impact hazards

These mechanisms are directly linked to guarding effectiveness, not worker behaviour alone.


What Hasnโ€™t Changed โ€” and Why It Matters

1. Legacy Plant Remains a Key Risk

Many incidents involve:

  • Older machinery
  • Brownfield modifications
  • Equipment altered without re-engineering guarding

Australian WHS law does not grandfather unsafe plant.


2. Guarding Is Still Added Too Late

Common failures include:

  • Guards designed post-fabrication
  • Inadequate reach distances
  • Interlocks added without validated performance levels

This often leads to bypassing, removal, or unsafe maintenance practices.


3. Lack of Engineering Documentation

Post-incident investigations frequently identify:

  • No formal risk assessment
  • No justification against AS 4024 or ISO standards
  • No evidence that guarding was engineered, tested, or validated

In legal proceedings, absence of documentation is treated as absence of control.


Legal and Enforcement Signals

Australian regulators (WorkSafe NSW, WorkSafe VIC, SafeWork QLD, SafeWork SA) have consistently prosecuted machine-guarding failures, particularly where:

  • Hazards were known
  • Improvement notices were ignored
  • Guards were removed or ineffective

Regulator portals:

Courts have reinforced that:

  • Training does not replace guarding
  • PPE does not replace guarding
  • Signage does not replace guarding

Guarding as a Governance Issue

For executives and boards, machine guarding intersects with:

  • Officer due diligence obligations
  • Asset lifecycle risk
  • Insurance and liability exposure
  • Business continuity and ESG performance

Well-designed guarding:

  • Reduces downtime
  • Enables safer automation
  • Improves workforce confidence
  • Creates defensible compliance positions

The Engineering Reality: Geometry Drives Compliance

Modern compliance relies on:

  • Verified reach distances
  • Measured openings and clearances
  • Validated interlock logic

This is why accurate:

  • As-built capture
  • 3D modelling
  • Engineering-grade spatial data

are increasingly essential for brownfield and high-risk plant.


Looking Ahead: The Next Decade

Trends indicate:

  • Greater scrutiny of legacy machinery
  • Stronger linkage between standards and prosecutions
  • Higher expectations for engineering evidence
  • Increased use of digital engineering to prove compliance

Organisations that integrate guarding early into engineering workflows will be better protected legally, operationally, and reputationally.


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Final Thought

Machine guarding is not about mesh and fences.
It is about engineering intent, risk ownership, and accountability.

The last decade of Australian data, prosecutions, and standards alignment is clear:
when guarding fails, the outcomes are predictable โ€” and preventable.

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Maximising Uptime at Transfer Points: How Hamilton By Design Optimises Chutes, Hoppers, and Conveyors for the Mining Industry

In the mining industry, system uptime isnโ€™t just a goalโ€”itโ€™s a necessity. Transfer points such as chutes, hoppers, and conveyors are often the most failure-prone components in processing plants, especially in high-wear environments like HPGR (High Pressure Grinding Rolls) circuits. Abrasive ores, heavy impact, fines accumulation, and moisture can all combine to reduce flow efficiency, damage components, and drive up maintenance costs.

At Hamilton By Design, we help mining clients minimise downtime and extend the life of their material handling systems by applying advanced 3D scanning, DEM simulation, smart material selection, and modular design strategies. This ensures that transfer points operate at peak efficiencyโ€”day in, day out.

Hereโ€™s how we do it:

Optimised Flow with DEM-Based Chute & Hopper Design

Flow blockages and misaligned velocities are among the biggest contributors to transfer point failure in the mining industry. Thatโ€™s why we use Discrete Element Method (DEM) simulations to model bulk material flow through chutes, hoppers, and transfer transitions.

Through DEM, we can simulate how different oresโ€”ranging from dry coarse rock to sticky finesโ€”move, compact, and impact structures. This allows us to tailor chute geometry, outlet angles, and flow paths in advance, helping:

  • Prevent material buildup or arching inside hoppers and chutes
  • Align material velocity with the conveyor belt speed using hood & spoon or trumpet-shaped designs
  • Reduce wear by managing trajectory and impact points

Optimised flow equals fewer shutdowns, longer equipment life, and better plant throughput.

Wear-Resistant Liners & Material Engineering

Not all wear is the sameโ€”and neither are the materials we use to combat it. By studying the abrasion and impact zones in your chute and hopper systems, we strategically apply wear liners suited to each application.

Our engineering team selects from:

  • AR (Abrasion-Resistant) steels for high-wear areas
  • Ceramic liners in fines-rich or ultra-abrasive streams
  • Rubber liners to absorb shock and reduce noise

This approach reduces liner replacement frequency, improves operational safety, and lowers the risk of unplanned shutdowns at key transfer points.

Dust and Spillage Control: Cleaner, Safer Operation

Dust and spillage around conveyors and transfer chutes can lead to extensive cleanup time, increased maintenance, and health hazards. At Hamilton By Design, we treat this as a core design challenge.

We design chutes and hoppers with:

  • Tight flange seals at interface points
  • Enclosed transitions that contain dust at the source
  • Controlled discharge points to reduce turbulent material drops

This reduces environmental risk and contributes to more consistent plant performanceโ€”especially in confined or enclosed processing facilities in the mining industry.

Modular & Accessible Designs for Faster Maintenance

When liners or components need replacement, every minute counts. That’s why our chute and hopper systems are built with modular sectionsโ€”each engineered for fast removal and reinstallation.

Key maintenance-driven design features include:

  • Bolt-on panels or slide-in liner segments
  • Accessible inspection doors for safe visual checks
  • Lightweight modular components for easy handling

These details reduce labour time, enhance safety, and keep your plant online longerโ€”especially critical in HPGR zones where throughput is non-stop.

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Precision 3D Scanning & 3D Modelling for Retrofit Accuracy

One of the most powerful tools we use is 3D scanning. In retrofit or brownfield projects, physical measurements can be inaccurate or outdated. We solve this by conducting detailed laser scans that generate accurate point cloud dataโ€”a precise digital twin of your plant environment.

That data is then transformed into clean 3D CAD models, which we use to:

  • Design retrofits that precisely match existing structure
  • Identify interferences or fit-up clashes before fabrication
  • Reduce install time by ensuring right-first-time fits

This scan-to-CAD workflow dramatically reduces rework and error margins during installation, saving time and cost during shutdown windows.

Real-World Application: HPGR & Minerals Transfer Systems

In HPGR-based circuits, transfer points between crushers, screens, and conveyors experience high rates of wear, dust generation, and blockagesโ€”particularly where moisture-rich fines are present.

Hereโ€™s how Hamilton By Designโ€™s methodology addresses these pain points:

  • DEM-based flow modelling ensures the HPGR discharge flows cleanly into chutes and onto conveyors without buildup.
  • Hood/spoon geometries help track material to belt velocityโ€”minimising belt wear and reducing misalignment.
  • Strategic liner selection extends life in critical wear zones under extreme abrasion.
  • Modular chute designs allow for fast liner swap-outs without major disassembly.
  • 3D scanning & CAD design ensures new chute sections fit seamlessly into existing HPGR and conveyor frameworks.

By designing smarter transfer systems with these technologies, we enable operators to reduce downtime, increase liner life, and protect critical assets in high-throughput mining applications.

Uptime Benefits at a Glance

Performance AreaImpact on Mining Operations
Smooth bulk material flowFewer clogs, improved throughput, longer operating cycles
Velocity-matched dischargeLower conveyor belt wear and downtime
Robust wear protectionLonger life, fewer liner replacements
Modular designFaster maintenance turnarounds during scheduled shutdowns
3D scanning & CAD integrationPrecise fit, reduced installation time, fewer errors during retrofit

Final Word: Engineering That Keeps the Mining Industry Moving

At Hamilton By Design, we combine mechanical engineering expertise with 3D modelling, material flow simulation, and smart fabrication practices to deliver high-performance chute, hopper, and transfer point systems tailored for the mining industry.

Whether youโ€™re dealing with a problematic HPGR discharge, spillage issues, or planning a brownfield upgrade, our integrated design process delivers results that improve reliability, extend service life, and protect uptime where it matters most.

Looking to retrofit or upgrade transfer systems at your site?
Letโ€™s talk. We bring together 3D scanning, DEM modelling, practical engineering, and proven reliability to deliver systems that workโ€”from concept through to install.

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