Mechanical Engineering | 3D Scanning | 3D Modelling
Tag: Structural Engineer
Structural engineering support services for industrial, mining, commercial, and residential projects.
This tag covers structural engineering activities including structural drafting, connection detailing, as-built documentation, design support, and coordination with registered structural engineers, informed by engineering-led LiDAR scanning and accurate existing-conditions capture.
Structural Engineering: Turning Structural Concepts into Buildable, Compliant Outcomes
Structural engineering plays a critical role in ensuring that structures are safe, stable, and fit for purpose—not just on paper, but in the real world.
Across industrial facilities, mining sites, power infrastructure, and building projects, structural engineering is what turns concepts into buildable, verifiable outcomes. It requires more than calculations alone; it depends on accurate information, sound judgement, and clear documentation that can be understood and constructed on site.
At Hamilton By Design, structural engineering is delivered with a strong focus on existing conditions, constructability, and compliance, particularly for brownfield and live environments.
What structural engineering actually delivers
Structural engineering involves the assessment, design, and verification of structures that support loads safely over their intended life.
Typical applications include:
Structural steelwork and framing
Platforms, walkways, stairs, and access systems
Equipment support structures and foundations
Modifications to existing buildings and industrial assets
Strengthening, repair, and upgrade works
In many projects, especially upgrades and refurbishments, the challenge is not designing something new—but understanding what already exists and how it behaves.
Our clients:
Structural engineering on existing and brownfield sites
Many industrial and construction projects rely on incomplete or outdated drawings. Over time, assets are modified, reinforced, or repaired without full documentation, increasing risk when new works are planned.
Structural engineering in these environments often involves:
Verifying existing steel sizes and connections
Assessing capacity against current load requirements
Identifying undocumented changes or deterioration
Designing upgrades that integrate with existing structures
Accurate engineering input at this stage reduces rework, improves safety, and avoids costly site changes during construction.
The role of structural drafting in successful outcomes
Even the best structural design can fail if it is not clearly documented.
Structural drafting is the critical link between engineering intent and construction reality. It translates structural engineering decisions into clear, coordinated drawings that fabricators and builders can rely on.
Well-executed structural drafting ensures:
Load paths and connections are clearly communicated
Member sizes, levels, and interfaces are unambiguous
Drawings reflect actual site conditions
Fabrication and installation can proceed with confidence
3D Scanning Bathurst | Engineering-Grade LiDAR & Scan-to-CAD
Bathurst and the Central West region support a diverse mix of manufacturing facilities, mining operations, quarries, infrastructure assets, utilities, and heritage structures. These environments demand more than survey-grade outputs.
Hamilton By Design combines LiDAR scanning with mechanical engineering expertise, ensuring that:
Scan coverage targets critical interfaces and load paths
Accuracy supports fabrication-ready design
Models reflect real-world constraints, not assumptions
This significantly reduces rework, clashes, and site uncertainty during upgrades or expansions.
Our 3D Scanning Services in Bathurst
We provide a complete scan-to-engineering workflow, including:
High-resolution terrestrial LiDAR scanning
Registered point clouds (colourised and structured)
Support for mechanical, structural, and fabrication design
All deliverables are tailored to your project scope — from concept planning through to construction and installation.
Typical Bathurst Applications
Our 3D scanning services are commonly used for:
Industrial plant upgrades and brownfield modifications
Mining and quarry infrastructure
Conveyors, chutes, hoppers, and bulk materials handling systems
Mechanical equipment replacement and tie-ins
Structural steel verification and retrofits
Asset documentation and digital twins
Risk reduction for shutdown and live-site works
Where required, scanning data is integrated directly into engineering calculations, FEA models, and fabrication drawings.
Why Hamilton By Design
Engineer-Led Scanning
Your scan is planned and executed by engineers who understand loads, tolerances, constructability, and compliance, not just data capture.
Fit-for-Purpose Accuracy
We capture only the data that matters — at the accuracy required for design, fabrication, and installation.
Single-Source Accountability
One team responsible for scanning, modelling, and engineering, eliminating scope gaps between consultants.
Regional & Mobile Delivery
We regularly support projects across Bathurst, Orange, Lithgow, Dubbo, Mudgee, and the broader Central West NSW, mobilising to site as required.
Deliverables You Can Build From
Depending on your project, we can supply:
Registered point clouds (E57 / RCP / compatible formats)
3D CAD models aligned to engineering workflows
GA drawings and interface layouts
Fabrication-ready references
Digital records for asset management and future upgrades
Our clients:
3D Scanning Bathurst – Get Started
If you are planning a retrofit, upgrade, or new installation in Bathurst or Central West NSW, early 3D scanning can significantly reduce risk and cost.
Talk to an engineer about your site Request a Bathurst 3D scanning proposal On-site scanning available across the Central West
AS 3774 – Loads on Bulk Solids Containers | Safety & Compliance
AS 3774 Loads on Bulk Solids Containers exists for a simple reason: bulk solids do not behave like fluids, and incorrect load assumptions can create serious structural and safety risks.
For asset owners, engineers, and project teams involved in mining, mineral processing, manufacturing, and bulk materials handling, AS 3774 provides the framework for understanding how loads actually develop in silos, bins, hoppers, chutes, transfer stations, and surge bins.
Yet despite its long-standing availability, many new installations are still being delivered without full consideration of AS 3774 load cases.
The risks created by this gap are often not immediately visible — but they are very real.
What AS 3774 Is Designed to Address
AS 3774 recognises that bulk solids behave in complex and sometimes counter-intuitive ways. Unlike liquids, bulk materials:
Develop non-uniform wall pressures
Apply eccentric and asymmetric loads
Change load paths depending on flow behaviour
Generate dynamic and cyclic forces during filling and discharge
The standard provides guidance for determining realistic design loads based on how material actually flows and interacts with container geometry.
This applies across all bulk solids containers, including:
Silos
Bins and surge bins
Hoppers
Chutes and transfer stations
Rail and ship loading structures
Feeders integrated with bins
Why Safety and Compliance Depend on AS 3774
The purpose of AS 3774 is not academic. It exists to prevent outcomes such as:
Progressive wall deformation
Fatigue cracking and bolt failure
Local buckling or plate tearing
Uncontrolled discharge or blockage release
Unexpected load transfer into supporting structures
What makes these issues particularly dangerous is that they often develop over time, not at commissioning.
A structure can appear “fine” on day one — while accumulating damage due to:
Cyclic loading
Eccentric discharge patterns
Inaccurate assumptions about material properties
Mixed construction materials behaving differently over time
Common Design Assumptions That Create Hidden Risk
In practice, many bulk solids containers are still designed using simplified or incorrect assumptions, including:
1. Treating Bulk Solids Like Fluids
Uniform hydrostatic pressure assumptions do not reflect real wall loading patterns and can significantly under-predict peak stresses.
2. Ignoring Eccentric Discharge
Off-centre outlets, partial blockages, or asymmetric flow paths can introduce large bending and torsional effects that are not obvious from geometry alone.
3. Incorrect or Assumed Material Properties
Bulk density, cohesion, moisture content, and flow behaviour are often assumed rather than verified — yet small changes can have large load implications.
4. Mixed Materials Without Long-Term Consideration
It is not uncommon to see hoppers fabricated from a combination of stainless steel and mild steel, without adequate consideration of:
Differential stiffness
Fatigue behaviour
Corrosion mechanisms
Galvanic interaction
These issues may not present as immediate failures, but they can significantly reduce structural life and reliability.
Why the Risk Is Often Not Evident Today
One of the most concerning aspects of non-compliance with AS 3774 is that failure is rarely immediate.
Instead, risk accumulates quietly through:
Repeated filling and discharge cycles
Minor operational changes
Variations in material condition
Small geometric imperfections
By the time visible cracking, deformation, or operational issues appear, the structure may already be compromised.
The Role of Modern Engineering Tools (Briefly)
While AS 3774 is fundamentally about load determination, modern engineering tools can support compliance by helping teams:
Verify as-built geometry against design assumptions
Identify eccentric discharge paths and flow constraints
Review interfaces, wall angles, and structural continuity
Support independent engineering assessment without extended shutdowns
These tools do not replace the standard — but they can help reveal whether its principles have been properly applied.
What Asset Owners and Project Managers Should Ask For
To demonstrate that AS 3774 has been adequately considered, asset owners and project managers should expect to see clear answers to questions such as:
What load cases were considered under AS 3774?
How were discharge conditions defined and assessed?
What assumptions were made about material properties?
How were eccentric and asymmetric loads addressed?
Was fatigue or cyclic loading considered?
How were mixed materials and interfaces assessed?
Has an independent engineering review been undertaken?
If this information cannot be clearly provided, compliance is difficult to demonstrate, regardless of how new the installation is.
Why This Matters for New Installations
AS 3774 compliance is not about legacy assets or historical practices. It is about ensuring that new installations are fit for purpose, safe, and defensible.
Where bulk solids containers are being delivered today without adequate consideration of realistic load behaviour, the risk is being transferred downstream — to operators, maintainers, and asset owners.
Our clients
A Practical Closing Thought
If you are unsure whether AS 3774 has been properly applied to a bulk solids container, an independent engineering review can provide clarity.
The cost of verifying load assumptions and structural adequacy is typically minor compared to the consequences of discovering load-related issues after commissioning.
Hamilton By Design supports asset owners and project teams with engineering review, verification, and redesign of bulk solids containers, helping ensure that safety and compliance are addressed before problems develop.
Mobile equipment for the continuous handling of bulk materials—such as stackers, reclaimers, and ship loaders—forms the backbone of Australia’s mining and export infrastructure. Many of these assets operate continuously in demanding environments, often well beyond their original design life.
Australian Standard AS 4324.1 provides essential guidance for the design and safe operation of this class of equipment. However, on many Australian mine sites, the practical application of the standard is misunderstood or only partially implemented, particularly when dealing with legacy machines and brownfield upgrades.
For asset owners and engineering managers, the challenge is rarely about greenfield compliance. It is about managing risk, extending asset life, and implementing upgrades without unplanned downtime.
Understanding AS 4324.1 in a Brownfield Context
AS 4324.1 addresses mobile equipment used for continuous bulk handling, including:
Yard stackers and reclaimers
Bucket wheel reclaimers
Slewing and travelling machines
Ship loaders at export terminals
While the standard establishes a strong baseline for design and safety, many operating machines:
Pre-date the current revision of the standard
Have undergone multiple undocumented modifications
Operate under loading conditions that differ from original assumptions
In these situations, engineering judgement is required. Compliance becomes less about box-ticking and more about demonstrating that risks are understood, controlled, and managed over the asset lifecycle.
Common Challenges on Operating Mine Sites
Across coal handling plants, iron ore operations, and port facilities, several recurring issues emerge:
1. Incomplete or Outdated As-Built Information
Accurate geometry, slew limits, clearances, and structural interfaces are often unknown. This creates risk during upgrades and maintenance planning.
2. Fatigue and Structural Degradation
Large mobile machines experience cyclic loading across slewing, luffing, and travel motions. Fatigue cracking and unexpected failures require ongoing monitoring, not one-off assessments.
3. Access, Guarding, and Maintenance Compliance
Requirements evolve over time. Older machines may not meet current expectations for access systems, guarding, or safe maintenance practices.
4. Downtime Sensitivity
Stackers, reclaimers, and ship loaders are often production-critical assets. Upgrade windows are limited, and poor fit-up or rework can have significant commercial consequences.
Technology Supporting Modern Risk Management
While AS 4324.1 remains the foundation, modern technology allows asset owners to manage risk more effectively—particularly on brownfield equipment.
GPS Positioning and Controlled Operating Zones
Where GPS positioning is enabled, defined operating zones can be established to:
Prevent interaction with stockpiles during rapid translation
Automatically reduce slew or travel speed in high-risk zones
Limit impact loads on critical components such as slew rings and fluffing gears
These systems are primarily productivity-driven, but they also reduce the likelihood of high-energy impacts that contribute to mechanical damage.
LiDAR Scanning as an Emerging Risk Layer
LiDAR scanning is not a replacement for traditional controls, and it is still evolving in this application. However, it can provide:
Accurate spatial awareness of surrounding structures
Verification of clearances and exclusion envelopes
A secondary risk-management layer supporting operator decision-making
When combined with engineering-led interpretation, LiDAR contributes to a layered risk approach rather than acting as a standalone safety system.
Condition Monitoring and Real Load Understanding
Accelerometers installed across a range of frequencies can deliver valuable insight into:
Actual operating loads
Dynamic response during slewing, reclaiming, and travel
Early indicators of fatigue-related issues
This data supports more informed maintenance decisions and provides evidence of how a machine is truly being used—often revealing load cases not considered in original designs.
Engineering-Led Compliance and Asset Life Extension
For brownfield assets, compliance with AS 4324.1 is best approached as a continuous engineering process, not a single milestone. This includes:
Accurate reality capture and digital models
Verification of clearances, interfaces, and structural geometry
Informed upgrade design that fits the first time
Risk-based decision-making supported by real operating data
This approach helps asset owners extend the life of critical machines while managing risk, performance, and availability.
How Hamilton By Design Supports Bulk Handling Assets
Hamilton By Design works with asset owners and engineering teams to support:
Brownfield upgrades of stackers, reclaimers, and ship loaders
Engineering-grade LiDAR scanning and as-built documentation
Fit-for-purpose mechanical design for modifications and life-extension
Independent engineering insight across OEM and site interfaces
Our focus is on engineering clarity, practical risk reduction, and minimising disruption to operations.
Talk to an Engineer About Your Asset
If you are planning a brownfield upgrade, life-extension, or risk review of mobile bulk-handling equipment, talk to an engineer at Hamilton By Design about how accurate data and practical engineering can support your next decision.
Melbourne has long been recognised as one of Australia’s most advanced engineering and manufacturing centres, and inner-city hubs such as South Yarra sit at the intersection of design, industry, infrastructure, and innovation. As projects become more complex and timelines more compressed, engineering teams are increasingly seeking partners who can reduce uncertainty, improve accuracy, and provide reliable technical insight from day one.
This is where Hamilton By Design delivers genuine value.
Hamilton By Design operates as an engineer-led consultancy focused on precision, constructability, and real-world outcomes. Rather than working from assumptions or incomplete information, the business is built around capturing existing conditions accurately and transforming that data into practical engineering deliverables that support confident decision-making.
Moving Beyond Assumptions in Modern Engineering
Many engineering challenges in metropolitan Melbourne are not greenfield projects. They involve existing buildings, operating facilities, constrained spaces, legacy assets, or staged upgrades that must integrate seamlessly with what is already in place. In these environments, relying on outdated drawings or manual measurements introduces risk — misalignment, clashes, rework, and delays that can quickly erode budgets and schedules.
Hamilton By Design addresses this challenge by placing reality capture and engineering validation at the front end of projects. This ensures that every downstream decision is based on what truly exists on site, not what is assumed to exist.
For engineering teams working in and around South Yarra — whether supporting manufacturing, infrastructure, plant upgrades, or specialist facilities — this approach significantly reduces technical risk and increases confidence across all stakeholders.
LiDAR Scanning as a Foundation for Accuracy
A key capability that differentiates Hamilton By Design is its use of engineering-grade LiDAR scanning. Unlike traditional surveys that capture selective points, LiDAR scanning records millions of measurements across an entire environment, producing a high-resolution digital representation of buildings, plant, structures, and surrounding context.
This data becomes a reliable reference point for engineers, designers, fabricators, and project managers alike.
LiDAR scanning enables:
Accurate capture of complex geometries and tight spaces
Clear identification of spatial constraints and interfaces
Early detection of clashes and access issues
Reduced need for repeat site visits
Improved coordination between disciplines
By converting physical assets into precise digital data, Hamilton By Design helps teams eliminate ambiguity and work from a single source of truth.
From Scan Data to Engineering Outcomes
Importantly, Hamilton By Design does not operate as a scanning-only service. The real value lies in how scan data is interpreted, validated, and converted into engineering outputs that directly support delivery.
Scan information is used to develop structured models, layouts, and documentation that reflect real-world conditions. This supports engineering activities such as:
Mechanical and structural modifications
Plant upgrades and equipment integration
Space planning and layout optimisation
Fabrication and installation planning
Asset documentation and as-built records
Because the work is led by experienced engineers, the focus is always on what needs to be built, installed, or modified, not just on creating visually impressive models.
Supporting Engineering Teams and Decision-Makers
In a business and engineering environment like South Yarra — where projects are often time-sensitive and commercially driven — external engineering support must be reliable, efficient, and technically sound.
Hamilton By Design integrates smoothly with internal teams, consultants, and contractors, providing additional technical depth without adding unnecessary complexity. The consultancy model is deliberately structured to support decision-makers who need clarity, not noise.
This means:
Clear communication of constraints and risks
Practical recommendations grounded in real site data
Deliverables aligned with fabrication and construction needs
Engineering documentation that supports approval and execution
The result is fewer surprises downstream and a smoother path from concept through to implementation.
Engineering for Brownfield and Live Environments
One of the most challenging aspects of modern engineering is working within live or brownfield environments — facilities that cannot simply shut down for measurement, redesign, or rework. In these settings, accuracy and planning are critical.
Hamilton By Design’s LiDAR-driven workflows are particularly well suited to these conditions. Rapid data capture minimises disruption on site, while the detailed digital record allows engineering work to continue remotely with confidence.
This approach supports safer planning, better coordination, and reduced exposure to operational risk — outcomes that are highly valued by engineering leaders and project managers alike.
A Practical, Engineer-Led Philosophy
At its core, Hamilton By Design operates on a simple but powerful principle: engineering should be grounded in reality. By combining high-accuracy site data with deep engineering experience, the consultancy helps organisations make informed decisions, avoid costly mistakes, and deliver projects that work the first time.
For organisations operating in South Yarra and the broader Melbourne region, this means access to an engineering partner who understands both the technical and commercial pressures of modern project delivery.
Engineering Certainty in a Complex World
As engineering projects continue to increase in complexity, the margin for error continues to shrink. Those who invest early in accurate data and sound engineering judgement gain a clear advantage — fewer delays, lower risk, and better outcomes.
Hamilton By Design provides that advantage by bridging the gap between the physical site and the engineering office. Through precise LiDAR scanning, practical engineering insight, and a strong focus on constructability, the consultancy supports confident, efficient, and reliable project delivery across Melbourne’s most demanding environments.
Why Hamilton By Design Is the Engineering Partner of Choice in Moranbah and the Bowen Basin – Engineering where it matters most
Moranbah and the surrounding Bowen Basin sit at the centre of Australia’s coal production engine. This is not a region defined by conceptual studies or theoretical design—it is defined by tonnes per hour, shutdown windows, safety performance, and whether plant modifications fit first time.
For mining companies operating in this region—including major operators such as BHP Mitsubishi Alliance, Anglo American, Glencore, Whitehaven Coal, QCoal Group, Yancoal Australia, Coronado Global Resources, and Bowen Coking Coal—engineering success is measured by outcomes, not promises.
Hamilton By Design exists specifically for environments like Moranbah: brownfield, high-risk, shutdown-driven, and unforgiving of design errors. This article explains why our engineer-led, scan-to-fabrication workflow aligns so closely with the realities of mechanical engineering in the Bowen Basin—and how it delivers value across CHPPs, materials-handling plants, and mine infrastructure.
Moranbah: a convergence of mining, mechanics, and margin
Mechanical engineering in Moranbah is unique because it operates at the intersection of:
Live production assets
Harsh environmental conditions
Compressed shutdown schedules
Zero tolerance for rework
Almost every mine in the region is supported by a CHPP, conveyors, crushers, stackers, reclaimers, and complex transfer stations. These assets are often decades old, modified many times, and poorly documented.
For operators, this creates constant engineering risk:
Unknown as-built conditions
Dimensional uncertainty
Legacy structural fatigue
Congested plant layouts
Safety constraints during access and installation
Hamilton By Design was formed to remove this uncertainty.
The core problem: brownfield uncertainty
Most engineering failures in the Bowen Basin are not caused by poor calculations. They are caused by poor information.
Traditional workflows often rely on:
Outdated drawings
Manual tape measurements
Partial site access
Assumptions made under time pressure
In Moranbah, these assumptions are expensive.
A single clash during a CHPP shutdown can cascade into:
Lost production
Extended outages
Emergency site modifications
Safety exposure
Cost overruns
Hamilton By Design addresses this problem at its source: accurate, engineer-owned site data.
Engineer-led 3D laser scanning: data you can trust
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Hamilton By Design delivers engineering-grade 3D LiDAR scanning, not generic survey capture. This distinction matters.
Our scans are:
Planned by mechanical engineers
Captured with fabrication tolerances in mind
Registered and verified for design use
Interpreted by the same engineers who model and draft the solution
For Bowen Basin operators, this means:
Confidence in clearances
Reliable tie-in locations
Accurate centre-lines and datum references
Reduced site revisits
Fewer RFIs during fabrication and installation
This approach underpins everything that follows.
From scan to CAD: turning reality into buildable models
Point clouds are only valuable if they are converted into usable engineering models.
Hamilton By Design specialises in:
SolidWorks-based mechanical modelling
CHPP equipment modelling
Conveyor and chute systems
Structural steel and platforms
Pipework, transfer chutes, and guards
Unlike generic drafting services, our models are:
Built for fabrication
Aligned to Australian Standards
Structured for downstream FEA where required
Designed with maintenance and installation in mind
For Moranbah projects, this means the model becomes a single source of truth—shared between engineering, fabrication, and site teams.
Shutdown-driven design: engineering to the clock
Shutdowns in the Bowen Basin are short, expensive, and unforgiving.
Hamilton By Design engineers design specifically for shutdown execution by:
Preferring modular assemblies
Designing for pre-fabrication and trial-fit
Minimising hot work on site
Reducing installation complexity
Embedding lift and access considerations early
Our experience working with fabricators and site crews ensures that drawings are not just correct—they are buildable under shutdown conditions.
Fabrication-ready drawings that reduce risk
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In Moranbah, fabrication errors propagate directly to site risk.
Hamilton By Design produces:
Detailed fabrication drawings
Clear GA and assembly drawings
Accurate BOMs
Weld-ready detailing
Clear tolerances and notes
Fabricators value our drawings because they:
Reduce shop-floor guesswork
Minimise RFIs
Support first-time assembly
Align with real-world workshop practices
For mining companies, this translates to smoother shutdowns and fewer surprises.
Structural verification and FEA where it counts
Many Bowen Basin assets were not designed for their current duty cycles. Increased throughput, equipment upgrades, and extended asset life introduce structural risk.
Hamilton By Design integrates:
Structural checks
Load-path verification
Fatigue considerations
Finite Element Analysis (where appropriate)
FEA is applied pragmatically—not as an academic exercise, but as a decision-support tool to:
Validate modifications
Avoid over-design
Reduce unnecessary steel
Confirm safety margins
This approach supports compliance while respecting cost and schedule constraints.
Digital QA and as-built confidence
One of the most overlooked advantages of scan-based engineering is digital quality assurance.
Hamilton By Design can:
Validate fabricated components against the model
Confirm installed geometry post-shutdown
Provide updated as-built documentation
Support future modifications with confidence
For asset owners, this builds a cumulative digital asset—each project improving the next.
Why this matters to Bowen Basin operators
For companies operating multiple sites across the region, the benefits compound:
Consistency across projects and sites
Reduced engineering rework
Improved shutdown reliability
Better collaboration with fabricators
Lower total project risk
Hamilton By Design’s workflow aligns with how mining actually operates in Moranbah—not how it is described in textbooks.
A partner, not just a consultant
Hamilton By Design does not operate as a detached design office. We work alongside:
Maintenance teams
Shutdown planners
Fabricators
Site supervisors
Our value lies in understanding why a design is needed, how it will be built, and when it must be installed.
This mindset resonates strongly in the Bowen Basin, where credibility is earned through delivery.
Why Moranbah companies choose Hamilton By Design
In summary, Hamilton By Design helps mining companies in Moranbah and the Bowen Basin because we:
Specialise in brownfield mining environments
Deliver engineer-led 3D scanning
Convert data into fabrication-ready models
Design for shutdown execution
Reduce risk across engineering, fabrication, and installation
Speak the language of site, not just design offices
Engineered for Moranbah
Moranbah is not a place for generic solutions. It demands engineering that is accurate, practical, and accountable.
Hamilton By Design was built for regions like this—where engineering decisions have immediate operational consequences and where doing it right the first time matters.
For mining companies across the Bowen Basin, we provide more than drawings. We provide clarity, confidence, and constructable engineering—from scan to shut down.
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