Mining & Mineral Processing

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We support mining and mineral processing operations with engineering-grade LiDAR scanning and mechanical design for CHPPs, conveyors, transfer stations, plant upgrades, and brownfield modifications. Our experience in live operating environments helps reduce shutdown risk, rework, and costly fabrication errors.

Mining & Mineral Processing Engineering Services

Hamilton By Design supports mining and mineral processing operations with engineering-grade LiDAR scanning, mechanical engineering, and design support for complex, live operating environments.
Our work focuses on delivering accurate existing-condition data and engineering outcomes that reduce shutdown risk, minimise rework, and support safe, efficient plant upgrades.

We work across the full project lifecycle โ€” from early site capture and feasibility through to detailed design, fabrication support, and construction verification โ€” with a strong emphasis on brownfield and retrofit projects where getting the geometry right is critical.


Mining Engineering Services

Our mining engineering services are built around a clear principle: engineering decisions must be based on accurate site data. We combine reality capture with mechanical engineering to support informed design, modification, and execution of mining projects.

These services support:

  • Existing asset validation
  • Upgrade and modification planning
  • Engineering design development
  • Risk reduction in live operating plants

By integrating scanning and engineering under one workflow, we provide mining teams with confidence that designs reflect real-world conditions.


Mining & Industrial Engineering

Mining operations rely on complex industrial systems that must perform reliably under demanding conditions. Hamilton By Design works at the interface between mining infrastructure and industrial plant systems, supporting projects where mechanical, structural, and operational requirements overlap.

Our experience includes:

  • Mineral processing facilities and CHPPs
  • Materials handling systems
  • Industrial plant equipment within mining sites
  • Brownfield integration and asset upgrades

This cross-disciplinary approach allows us to support mining clients with solutions that are practical, buildable, and aligned with operational constraints.


Mining Services

Our mining services focus on practical project delivery support. We work alongside site teams, engineers, and contractors to capture existing conditions, verify designs, and support construction and shutdown activities.

Typical services include:

  • Engineering-grade LiDAR and as-built capture
  • Existing condition verification
  • Design coordination support
  • Construction and installation validation

These services help reduce uncertainty on site and provide a reliable digital foundation for engineering and fabrication activities.


Mechanical Engineering in Mining

Mechanical engineering is central to the safe and efficient operation of mining assets. Hamilton By Design provides mechanical engineering support informed directly by site-captured data, ensuring designs are suitable for real operating environments.

Our mechanical engineering capabilities support:

  • Conveyors, chutes, and transfer stations
  • Plant upgrades and modifications
  • Structural and mechanical interfaces
  • Fabrication-ready design documentation

Where required, our work can be supported by engineering verification and analysis to provide additional confidence in design outcomes.


Engineering-Led, Fit-for-Purpose Outcomes

Hamilton By Design operates with a strong focus on:

  • Accuracy over assumption
  • Engineering accountability
  • Fit-first-time outcomes
  • Reduced risk in brownfield environments

By combining reality capture with mechanical engineering, we help mining and mineral processing clients move from uncertain existing conditions to confident engineering decisions.


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If you are planning a mining or mineral processing upgrade, modification, or verification project, Hamilton By Design can support your team with engineering-grade scanning and mechanical design services tailored to live operating environments.


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3D Laser Scanning

3D LiDAR Scanning โ€“ Digital Quality Assurance

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3D LiDAR Scanning and 3D Modelling – Hamilton By Design

From Scan to Shutdown

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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 Australiaโ€™s coal production engine. This is not a region defined by conceptual studies or theoretical designโ€”it is defined by tonnes per hour, shutdown windows, safety performance, and whether plant modifications fit first time.

For mining companies operating in this regionโ€”including major operators such as BHP Mitsubishi Alliance, Anglo American, Glencore, Whitehaven Coal, QCoal Group, Yancoal Australia, Coronado Global Resources, and Bowen Coking Coalโ€”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 Basinโ€”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 truthโ€”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 correctโ€”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.


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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 pragmaticallyโ€”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 assetโ€”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 Designโ€™s workflow aligns with how mining actually operates in Moranbahโ€”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 thisโ€”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 engineeringโ€”from scan to shut down.

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Mining Engineering Services Australia

Mining Engineering Services Australia

Hamilton By Design provides specialist mining engineering services supporting brownfield upgrades, plant modifications, and asset life-extension projects across Australia.

Our mining services combine engineer-led 3D LiDAR scanning, SolidWorks-based mechanical design, finite element analysis (FEA), and fabrication-ready documentation to reduce site risk, rework, and downtime. We work closely with mine owners, EPCMs, and fabricators to deliver practical, buildable engineering solutions for operating sites.


Engineering Services for Mining Operations

Mining assets operate in demanding environments where legacy drawings are often incomplete or unreliable. Hamilton By Design specialises in engineering services that start with accurate as-built capture and finish with constructible design documentation.

We support:

  • Operating mines and CHPP facilities
  • Brownfield plant upgrades and retrofits
  • Shutdown and maintenance projects
  • Safety, access, and compliance upgrades
  • Life-of-asset improvement programs

Our approach is tailored to live operational sites, minimising disruption while delivering reliable engineering outcomes.


Engineer-Led 3D LiDAR Scanning for Mining Sites

Accurate site data is the foundation of effective mining engineering. Hamilton By Design delivers engineer-led 3D laser scanning, ensuring the person responsible for the design understands site constraints from the outset.

Our scanning services support:

  • CHPPs and materials handling facilities
  • Conveyors, transfer chutes, and hoppers
  • Structural steel, platforms, and walkways
  • Pipework, mechanical services, and plant rooms

๐Ÿ‘‰ Learn more about our scanning capability:
3D Laser Scanning Services


Scan-to-CAD & As-Built Modelling for Mining Projects

Hamilton By Design converts mining site scans into accurate SolidWorks 3D models, forming the basis for design development, clash detection, and fabrication planning.

Our Scan-to-CAD services enable:

  • Confident retrofit design in brownfield environments
  • Reduced rework during fabrication and installation
  • Improved coordination between disciplines
  • Digital QA against real-world geometry

View our CAD modelling services:
3D CAD Modelling Australia


Mechanical Engineering for Mining Infrastructure

We deliver mechanical engineering services tailored to mining and heavy industry, with a strong focus on constructability, safety, and compliance.

Services include:

  • Mechanical design and equipment integration
  • Structural and load assessments
  • Retrofit and upgrade engineering
  • Design verification and peer review
  • Compliance with relevant Australian Standards

Learn more about our mining-focused engineering capability:
Mechanical Engineering โ€“ Mining Industry


Finite Element Analysis (FEA) & Engineering Verification

Where required, Hamilton By Design applies Finite Element Analysis (FEA) to verify structural performance, fatigue risk, and load paths for mining assets.

FEA is commonly applied to:

  • Modified steel structures and platforms
  • Equipment supports and frames
  • Conveyor and chute modifications
  • Brownfield load changes

Explore our FEA services:
FEA Capabilities


Fabrication-Ready Drawings & Digital QA

In mining projects, fabrication errors can lead to costly delays and extended shutdowns. Hamilton By Design delivers fabrication-ready drawings developed directly from verified 3D models and scan data.

Our drafting services include:

  • General arrangement drawings
  • Fabrication and assembly drawings
  • BOMs and part schedules
  • Digital QA against point-cloud data

View drafting services:
Drafting & Documentation Services


Supporting Mining Projects in a Skills-Constrained Market

Across Australia, skilled engineering and construction resources are increasingly limited. Hamilton By Design helps mining clients reduce reliance on site-based engineering, streamline design workflows, and progress projects with greater certainty.

Our integrated scan-to-engineering delivery model:

  • Reduces site visits and re-measurement
  • Minimises RFIs and design revisions
  • Improves coordination with fabricators
  • Accelerates design-to-installation timelines

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Speak With a Mining Engineer

If youโ€™re planning a mining upgrade, shutdown scope, or brownfield modification, speak directly with an engineer who understands site realities and fabrication requirements.

Our clients:

Contact Hamilton By Design:
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E-mail : info@hamiltonbydesign.com.au

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Structural Engineers

Structural Engineers for Industrial and Mining Projects

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Hamilton By Design provides structural engineering support for industrial facilities, mining operations, and heavy infrastructure across Australia. We work in complex, high-risk environments where accuracy matters โ€” brownfield sites, operating plants, shutdown windows, and projects that must be buildable the first time.

Our approach combines practical structural engineering with digital capture and modelling workflows to reduce uncertainty, minimise rework, and help projects move from site conditions to fabrication-ready outcomes with confidence.


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Structural Engineering Services

We support asset owners, EPCs, maintenance teams, and fabricators with structural engineering services including:

  • Structural design and upgrade packages for plant modifications, support steelwork, access platforms, and equipment foundations
  • Structural assessments and verification for existing assets, including fit-for-purpose checks and load capacity reviews
  • Brownfield integration and retrofit design, accounting for existing geometry, constraints, and constructability
  • Connection detailing and design intent, supporting practical fabrication and installation sequencing
  • Compliance-aligned engineering documentation, suitable for procurement, fabrication, and site installation
  • Engineering support for shutdowns, upgrades, and maintenance-driven scope where time and accuracy are critical

If you need broader capability beyond structural work, view our full service offering here:
https://www.hamiltonbydesign.com.au/engineering-services/


Where Structural Engineers Add Value in Industrial Sites

Industrial and mining environments create structural challenges that differ from greenfield construction. Common drivers include:

  • Uncertain existing conditions (missing drawings, undocumented changes, deformation over time)
  • High operational loads, vibration exposure, and fatigue risk
  • Space constraints and access limitations in operating plants
  • Safety and compliance obligations for access systems, platforms, and guarding interfaces
  • Tight installation windows during shutdowns โ€” where rework is not an option

Hamilton By Design supports these conditions with structural design methods that are grounded in constructability and site realities, not just theoretical models.


Scan-to-Engineering Workflows for Structural Accuracy

Structural engineering outcomes improve dramatically when design is based on accurate existing conditions. Where appropriate, we integrate engineering-grade 3D scanning and modelling so that structural solutions fit first time.

This workflow supports:

  • Accurate member locations and interface checks
  • Clearance verification for equipment and access structures
  • Retrofit designs that align with existing steelwork and foundations
  • Reduced site clashes and fewer fabrication changes

Learn more about our scanning capability here:
https://www.hamiltonbydesign.com.au/home/3d-lidar-scanning-digital-quality-assurance/3d-laser-scanning/


Drafting and Fabrication-Ready Documentation

Structural work only delivers value when it can be fabricated and installed cleanly. Hamilton By Design produces documentation that supports workshop and site teams, including:

  • GA drawings and layout plans
  • Fabrication drawings and installation details
  • BOM support (where required)
  • As-built updates based on verified site data

Explore drafting support here:
https://www.hamiltonbydesign.com.au/engineering-services/services-drafting-lidar-scanning/


Structural Analysis and Verification

For projects involving modification, unusual loads, vibration concerns, or uncertainty around existing asset performance, we can support analysis and verification pathways to reduce risk and improve decision-making.

Our capability includes engineering checks that align with mechanical and structural project needs. If analysis is part of your scope, you can also review our assessment services here:
https://www.hamiltonbydesign.com.au/finite-element-analysis-fea-mechanical-assessment/


Typical Structural Engineering Applications

Hamilton By Design frequently supports structural engineering across:

  • Mining and process plants (CHPPs, conveyors, transfer stations, access systems)
  • Industrial facilities and workshops (equipment supports, platforms, structural modifications)
  • Brownfield upgrades where new equipment must integrate with existing structures
  • Safety improvements such as walkways, stairs, handrails, guarding supports, and maintenance access
  • Foundation and support modifications for mechanical equipment upgrades and plant change-outs

For mining-specific engineering support, see:
https://www.hamiltonbydesign.com.au/mechanical-engineering-mining-industry-australia/


Why Work With Hamilton By Design

Clients engage Hamilton By Design when they need structural engineering that is:

  • Practical and buildable โ€” designed for fabrication and installation reality
  • Accurate โ€” supported by digital site capture where needed
  • Integrated โ€” structural work aligned with mechanical interfaces and plant constraints
  • Responsive โ€” suited to shutdown-driven and time-critical scopes
  • Single-source accountable โ€” engineering, modelling, and drafting in one workflow

See examples of outcomes delivered across real projects here:
https://www.hamiltonbydesign.com.au/case-studies-hamilton-by-design/


Talk to a Structural Engineer

If you are planning a plant upgrade, safety improvement, retrofit, or structural assessment, Hamilton By Design can support your project from site conditions through to fabrication-ready documentation.

Visit our Engineering Services hub to get started:
https://www.hamiltonbydesign.com.au/engineering-services/

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Case Studies | Hamilton By Design

Proven Engineering. Real Results.
Every project starts with a challenge โ€” tight shutdowns, outdated drawings, structural fatigue, or a need to innovate fast.
At Hamilton By Design, we bring practical design engineering, LiDAR scanning, and SolidWorks expertise together to deliver reliable, measurable outcomes for clients across mining, manufacturing, and data-centre infrastructure.

Explore some of our featured case studies below.

CHPP Chute & Launder Replacement โ€“ Hunter Valley

Scope: Redesign and replacement of a primary discharge chute and launder system within a coal wash plant shutdown.
Challenge: The original chute geometry caused material hang-ups, high wear, and unplanned downtime.
Our Approach:

  • 3D laser scan of as-built geometry to capture alignment constraints
  • SolidWorks 3D modelling and flow verification
  • FEA structural validation to AS 3990 and AS 4100
  • Prefabrication validation and bolt-access checks

Outcome:
Reduced install time by 38 %, eliminated flow bottlenecks, and improved liner change-out safety.

3D LiDAR Scan-to-Model Retrofit โ€“ Central Coast

Scope: Full as-built capture of process plant and mechanical upgrade integration.
Challenge: No reliable drawings existed; site shutdown window limited to 24 hours.
Our Approach:

  • High-accuracy terrestrial LiDAR scanning
  • Point-cloud registration and SolidWorks conversion
  • Clash detection and layout optimisation
  • Deliverables in STEP and DWG formats

Outcome:
Delivered verified as-built model within 48 hours, enabling prefabrication of pipe spools with zero site rework.

Structural Frame Validation โ€“ Manufacturing Facility

Scope: Lifting and access frame redesign for production line maintenance.
Challenge: Existing frame lacked design documentation and had unknown load paths.
Our Approach:

  • Reverse-engineered frame geometry using scanning
  • Conducted FEA load analysis to AS 4991 (Lifting Devices)
  • Updated design and certification drawings

Outcome:
Achieved compliance, extended equipment life, and avoided costly frame replacement.

Our clients:

Modular Data-Centre Rack Design โ€“ Sydney

Scope: Design and verification of modular rack and cooling infrastructure.
Challenge: High-density data-centre upgrade required prefabricated mechanical assemblies with tight tolerances.
Our Approach:

  • Parametric SolidWorks models with integrated cable-tray routing
  • CFD and FEA integration for airflow and load validation
  • Fabrication drawings optimised for CNC manufacture

Outcome:
Cut installation time by 60 %, achieving on-site plug-and-play assembly.


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Pump Box & Pipe Spool Replacement โ€“ Bowen Basin

Scope: Replace corroded steel pump boxes and spools under constrained shutdown.
Challenge: Limited access and poor documentation of existing plant.
Our Approach:

  • Laser scanning and model overlay with prefabrication QA
  • SolidWorks modelling of new spools and supports
  • On-site installation alignment checks

Outcome:
Zero interference fits and a fully verified installation delivered on schedule.

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