AS 3774 – Why Loads on Bulk Solids Containers Matter More Than You Think
In mining, mineral processing, manufacturing, and bulk materials handling, silos, bins, hoppers, chutes, and transfer stations are critical pieces of infrastructure. Yet the way loads develop in these structures is often misunderstood — or worse, oversimplified.
This is exactly why AS 3774 – Loads on Bulk Solids Containers exists.
Unlike liquids, bulk solids do not apply uniform pressures. Their behaviour changes depending on material properties, geometry, flow patterns, and discharge conditions. When these factors are not properly considered, structures may appear adequate at commissioning but develop latent safety, reliability, and compliance risks over time.
Why AS 3774 Is So Important
AS 3774 provides guidance on:
Non-uniform wall pressures
Eccentric and asymmetric discharge loads
Dynamic and cyclic loading during operation
The influence of material flow behaviour
These factors apply to all bulk solids containers, including silos, bins, hoppers, surge bins, chutes, and transfer stations.
Despite this, many new installations are still being delivered without clear evidence that AS 3774 load cases have been fully considered.
The Risk Isn’t Always Obvious
One of the most challenging aspects of bulk solids design is that problems often do not present immediately. Instead, issues can develop gradually through:
Cyclic loading and fatigue
Small changes in operating conditions
Inaccurate material assumptions
Mixed construction materials behaving differently over time
By the time cracking, deformation, or operational issues become visible, the underlying structural risk may already be well established.
What Asset Owners and Project Teams Should Ask
To demonstrate compliance with AS 3774, asset owners and project managers should expect clear answers to questions such as:
What load cases were considered?
How were discharge conditions defined?
What assumptions were made about material properties?
How were asymmetric and eccentric loads addressed?
Was fatigue or cyclic loading considered?
If this information cannot be clearly demonstrated, compliance — and long-term safety — is difficult to defend.
Read the Full Engineering Insight
Hamilton By Design has published a detailed engineering article explaining:
This article is written for asset owners, mechanical engineers, structural engineers, and project managers who want a clearer understanding of safety and compliance in bulk solids infrastructure.
AS 4324.1 and the Reality of Brownfield Bulk Handling Assets
Across Australian mine sites, stackers, reclaimers, and ship loaders are some of the most critical—and most complex—pieces of mobile equipment in operation.
While Australian Standard AS 4324.1 provides guidance for mobile equipment used in continuous bulk materials handling, many operating assets:
Pre-date the current version of the standard
Have undergone undocumented upgrades
Operate under loading conditions very different to their original design intent
For asset owners and engineering managers, compliance is rarely a simple checklist exercise. The real challenge is managing risk, fatigue, access, and upgrade work on machines that cannot afford extended downtime.
Modern engineering approaches are now playing a growing role in how these risks are managed. Technologies such as GPS positioning, engineering-grade LiDAR scanning, and condition monitoring using accelerometers are being used to better understand real operating loads, reduce impact risks, and support informed engineering decisions—particularly on brownfield assets.
Hamilton By Design has published a detailed engineering article exploring how AS 4324.1 applies in practice across coal handling plants, iron ore operations, and port infrastructure, with a focus on:
Brownfield upgrades and life-extension projects
Legacy equipment and partial compliance realities
The role of modern digital engineering tools in risk management
Why Engineering-Grade 3D Scanning Delivers Superior Accuracy
In bulk materials handling systems, chutes and transfer stations represent some of the most geometrically complex and operationally critical areas of any plant. They sit at the intersection of conveyors, structures, liners, skirts, and access systems — often in live, highly constrained environments.
In these conditions, accuracy is not optional.
Hamilton By Design approaches chute and transfer station projects from the position that engineering-grade 3D laser scanning provides a level of accuracy and reliability that traditional measurement and legacy drawings cannot achieve. This accuracy underpins every downstream decision, from modelling and detailing through to fabrication and installation.
Chutes & Transfer Stations: Geometry Matters
Chutes and transfer stations manage changes in:
Direction
Velocity
Material flow behaviour
Structural load paths
Small geometric deviations can result in:
Material spillage
Accelerated wear
Blockages
Misalignment with conveyors
Installation clashes during shutdowns
Because of this, chute and transfer station projects are highly sensitive to dimensional accuracy.
The Limitations of Traditional Measurement and Legacy Drawings
Many existing facilities rely on:
Outdated design drawings
Manual tape or handheld measurements
Assumptions carried forward from previous projects
These approaches introduce compounding risk, particularly in brownfield environments where:
Assets have been modified over time
Wear has altered geometry
Documentation no longer reflects reality
Access is limited or unsafe
In practice, these methods rarely capture:
True spatial relationships
Non-orthogonal geometry
Deformation or misalignment
Complex interfaces between systems
Engineering-Grade 3D Laser Scanning: A Higher Standard of Accuracy
Engineering-grade 3D laser scanning fundamentally changes how chute and transfer station geometry is captured.
Using high-precision LiDAR scanners, millions of data points are collected across all visible surfaces, producing a dense, registered point cloud that represents the asset exactly as it exists.
This approach delivers:
Millimetre-level geometric accuracy
Complete spatial context
Objective, measurable data
Global coordinate alignment
Unlike manual methods, scanning captures everything, not just what can be reached or measured easily.
Why Higher Accuracy Matters for Chutes & Transfer Stations
For chute and transfer station projects, the increased accuracy provided by 3D scanning enables:
Reliable interface modelling with existing conveyors and structures
Early identification of clashes and clearance issues
Confident liner and wear plate detailing
Accurate assessment of support steel geometry
Reduced fabrication and installation risk
In short, higher input accuracy leads directly to better project outcomes.
Point Cloud Modelling Built on Accurate Data
Once captured, LiDAR scan data is processed into a registered point cloud, which becomes the foundation for all modelling and detailing.
Because the point cloud is derived from high-accuracy scan data:
Modelling reflects real-world geometry
Assumptions are minimised
Tolerances are understood early
Engineering decisions are data-driven
For chute and transfer stations, this is particularly valuable where geometry is irregular, access is constrained, or existing assets must be retained.
Accurate As-Built Drawings from LiDAR Data
Where projects require formal documentation, point cloud data can be converted into as-built CAD models and drawings that accurately represent existing conditions.
These deliverables support:
Upgrade and refurbishment design
Fabrication planning
Installation sequencing
Compliance and documentation requirements
Importantly, as-built drawings generated from LiDAR scans carry a higher level of confidence than those derived from legacy information or manual surveys.
High-accuracy scanning and modelling is particularly beneficial for:
Chute refurbishments and replacements
Transfer station upgrades
Integration of new conveyors into existing systems
Documentation of legacy assets prior to shutdown
Planning wear mitigation and liner strategies
In each case, accuracy reduces uncertainty, and reduced uncertainty leads to better decisions.
Conclusion: Accuracy Is the Foundation of Reliable Design
For chutes and transfer stations, geometry governs performance. When geometry is wrong, problems follow.
By using engineering-grade 3D laser scanning as the foundation for point cloud modelling and as-built documentation, Hamilton By Design delivers a higher level of accuracy — and with it, greater confidence — for complex bulk materials handling projects.
Discuss Your Chute or Transfer Station Project
If you’re planning a chute or transfer station upgrade and need accurate, engineering-grade data, Hamilton By Design can support your project from site capture through to detailed modelling and documentation.
Melbourne’s built environment is complex, layered, and constantly evolving. From heritage structures and transport infrastructure to live industrial facilities and construction sites, understanding what actually exists on site is critical before any engineering or construction decision is made.
This is where 3D point cloud modelling plays a pivotal role.
At Hamilton By Design, we support Melbourne projects by converting engineering-grade LiDAR scan data into accurate, usable 3D point cloud models that engineers, designers, and project teams can rely on.
Why point cloud modelling matters on Melbourne projects
Many projects across Melbourne face common challenges:
Outdated or incomplete as-built drawings
Limited access to live or operational sites
Complex interfaces between new and existing assets
Tight construction tolerances and compliance requirements
Point cloud modelling provides a reliable foundation by capturing existing conditions in high detail and translating them into models that reflect real-world geometry, not assumptions.
From LiDAR scanning to usable engineering models
Point cloud modelling begins with high-accuracy 3D laser scanning, capturing millions of data points that define the true shape, position, and alignment of structures, plant, and services.
These point clouds are then processed and modelled to support:
Engineering design and verification
As-built documentation
Constructability reviews
Retrofit and upgrade planning
Interface coordination
Rather than being used only for visualisation, point cloud models become a single source of truth that reduces risk and uncertainty across the project lifecycle.
Engineering-led workflows, not just data capture
A key difference in engineering-grade point cloud modelling is how the data is used.
Hamilton By Design’s workflows are developed with engineering outcomes in mind. Models are created to support real decisions — fabrication, installation, safety, and compliance — not just presentation.
This approach is particularly valuable on Melbourne projects involving:
Live industrial or manufacturing facilities
Brownfield construction environments
Infrastructure upgrades and asset life-extension
Heritage or complex civic structures
Learn more: 3D Point Cloud Modelling Melbourne
If you’re planning a project in Melbourne and need accurate, engineering-led 3D point cloud modelling, we’ve published a detailed overview explaining how these workflows support better project outcomes.
The page explains how LiDAR data is captured, processed, and converted into usable engineering models — and why this matters for industrial, construction, and infrastructure projects across Melbourne.
About Hamilton By Design
Hamilton By Design provides engineering-led reality capture, point cloud modelling, and design support for complex projects across Australia. Our services are focused on accuracy, constructability, and accountability — helping project teams reduce risk before work begins on site.
Transfer stations and chutes remain some of the most critical — and most failure-prone — components in bulk materials handling systems. While the fundamentals of chute and transfer station detailing have been understood for decades, the way engineers now capture, validate, and deliver these details has changed significantly.
This post revisits the importance of transfer station detailing through a modern digital-engineering lens, where accurate site data, constructability, and fabrication certainty are no longer optional.
Why Transfer Station Detailing Still Causes Problems
Across mining, ports, and heavy industry, poorly detailed transfer stations continue to drive:
Excessive spillage and dust generation
Premature liner wear and structural damage
Increased maintenance intervention
Safety risks to operators and maintainers
In many cases, these outcomes are not caused by poor design intent — but by incomplete or assumed site information during the detailing phase.
When existing structures, conveyor alignments, or interfaces are guessed rather than measured, even small discrepancies can lead to costly rework once fabrication or installation begins.
From Assumed Geometry to Measured Reality
Historically, transfer station detailing relied on:
Legacy drawings of unknown accuracy
Manual measurements taken during shutdowns
Partial surveys that missed critical interfaces
Today, engineering teams have access to engineering-grade 3D laser scanning (LiDAR), allowing designs to be based on what actually exists on site, not what drawings suggest should exist.
This shift enables:
Accurate conveyor centreline definition
Verified structure and chute interfaces
Clash-free integration with existing assets
This approach is now standard practice in many high-risk upgrades delivered by Hamilton By Design, where fabrication accuracy and site fit-up are critical.
Even with improved tools, some fundamentals remain essential.
1. Interface Definition
Transfer stations rarely exist in isolation. They connect to conveyors, walkways, access platforms, and legacy steelwork — often installed decades earlier.
Accurate interface definition using laser scanning significantly reduces:
Misalignment during installation
Site modifications
Fabrication delays
2. Wear Liner Integration
Effective detailing must consider:
Liner thickness and fixing methods
Replacement clearances
Load paths into the supporting structure
Modelling liners digitally as part of the chute system allows engineers to validate access and constructability before steel is ordered.
3. Fabrication Reality
A detail that works in 2D often fails in fabrication.
Modern workflows now link:
LiDAR scanning
3D CAD modelling
Fabrication drawings
Digital QA checks
This integrated process ensures components fit first time, reducing site risk.
The fundamentals of transfer station detailing have not changed — but expectations have.
Modern projects demand:
Verified as-built geometry
Fabrication-ready deliverables
Reduced site risk
Confidence before steel is cut
By integrating accurate reality capture with detailed mechanical design, transfer stations can move from being a persistent risk to a reliable, maintainable asset.
Conveyors play an essential role in industrial and processing environments, but they also present significant safety risks if not properly guarded. In Australia, AS 1755 — Conveyor Safety Requirements provides the baseline framework for identifying hazards and designing protective measures that keep people safe throughout the life of a conveyor system.
This standard is more than a checklist — it is a guideline for engineering-led safety design that considers how conveyors are used, how people interact with them, and how hazards can be controlled effectively.
Compliance with AS 1755 helps ensure that:
moving parts like pulleys and rollers are guarded
nip points and shear areas are effectively enclosed
access for maintenance is safe and controlled
guarding does not create new hazards by restricting visibility or movement
how engineering design fits into safety compliance
challenges in retrofitting guarding on existing conveyors
why documentation and measurement are essential parts of safety design
Whether you are planning a new conveyor installation or upgrading existing equipment, understanding and applying AS 1755 is a critical part of safe operation.
Hamilton By Design provides engineering-led design and documentation for conveyor guarding systems, supporting safer operation and compliance across processing and industrial environments.
Our approach to conveyor guarding is grounded in a detailed understanding of Australian Standards for conveyor safety, combined with practical experience in mechanical design and fabrication support. Rather than treating guarding as an add-on, we develop solutions that integrate with existing plant, structures, and maintenance requirements.
Conveyor guarding designs are developed using advanced 3D CAD modelling and reality-capture workflows, allowing existing conditions to be accurately understood before fabrication. This enables compliant, fit-for-purpose guarding solutions to be designed efficiently, reducing rework and installation issues on site.
Hamilton By Design supports projects where conveyor guarding must be:
Designed to suit existing equipment and layouts
Aligned with relevant Australian Standards
Clearly documented for fabrication and installation
Integrated with broader mechanical and structural systems
More information on our mechanical engineering, 3D scanning, and fabrication support services is available at: https://www.hamiltonbydesign.com.au
Hamilton By Design Mechanical Engineering | Structural Drafting | 3D Laser Scanning Central Coast, NSW
3D LiDAR scanning is now widely used across engineering, fabrication, and building projects — but not all scan data is created equal.
While many tools can generate dense point clouds, the real question for engineers and asset owners is whether those measurements are accurate, repeatable, and defensible. This is where AS ISO 5725 – Accuracy and Precision of Measurement becomes highly relevant.
AS ISO 5725 is not a scanning standard in itself. Instead, it defines the principles used to evaluate whether a measurement system can be trusted. When applied to 3D LiDAR scanning, it highlights the importance of calibration, measurement uncertainty, and the difference between data that looks correct and data that actually is correct.
In practical terms, poor measurement control during scanning can lead to downstream issues such as:
Fabricated steel that does not fit on site
Misaligned bolt holes and interfaces
Incorrect assumptions about clearances
Delays during engineering review or certification
These issues are often discovered late in a project, when changes are most costly.
We’ve published a detailed technical article explaining how AS ISO 5725 applies to 3D LiDAR scanning, what accuracy and precision really mean, and what can go wrong when scanning tools are not properly calibrated.
This article is intended for engineers, fabricators, and decision-makers who rely on scan data to support design, fabrication, and certification outcomes.
Unlock Bespoke Light Fabrication Solutions for Your Project
When standard steel products just won’t cut it, having a trusted partner who designs for real-world fabrication makes all the difference.
At Hamilton By Design, we specialise in light fabrication product design tailored specifically for residential and commercial applications. Whether you need something as simple as a custom ute tray, or more complex fabricated steel like balustrades or brackets, we develop designs that are fit-first-time and fabrication-ready.
We don’t rely on guesswork. Our process combines:
Engineering-led design principles
Accurate CAD modelling and documentation
Optional engineering certification support
From concept through to fabrication documentation, our work ensures your steel products integrate with your project without costly changes on site.
Discover more about how we approach bespoke steel product design and fabrication development on our website.
Preserving Reality with 3D Scanning & BIM Across Greater Sydney
In the built environment, what actually exists on site often differs from what’s on paper. As buildings age, undergo renovations, or change hands, drawings become outdated, undocumented changes accumulate, and critical details disappear behind walls, ceilings, and floors — long before engineers or asset owners ever need them. Hamilton By Design
That’s why Hamilton By Design is excited to bring engineering-grade 3D scanning and as-built BIM documentation to projects across Greater Sydney — from the CBD to Parramatta, North Sydney to Inner West, and beyond. Hamilton By Design
📍 Why Reality Capture Matters
Traditional plans and legacy drawings rarely reflect the true as-built condition of a space. Missing details or assumptions can lead to costly surprises during refurbishment, services coordination, sustainability upgrades, or compliance checks.
With reality capture — detailed 3D scanning combined with fit-for-purpose BIM — you get a digital record of what actually exists on site. This isn’t a conceptual or idealised model; it’s an engineering truth that supports better planning, design, and decision-making. Hamilton By Design
🔍 What This Means for Your Projects
✔ Accurate representation of existing conditions
✔ Reduced uncertainty and fewer assumptions
✔ Better coordination for refurbishment, fit-outs, or upgrades
✔ Engineering-ready models that support long-term asset planning
✔ Documentation that remains useful throughout the asset lifecycle Hamilton By Design
Whether you’re retrofitting commercial premises, documenting facilities for compliance, or planning future works, having precise as-built information early can save time and reduce risk.
🔗 Discover the Full Service
To learn more about how 3D scanning and BIM can help your project across Sydney — from early reality capture to engineering documentation — check out the full service page here:
Why Sydney Projects Need Next-Level 3D Engineering Documentation
In Sydney’s dynamic built environment—where commercial towers, industrial facilities, heritage buildings, and complex infrastructure sit cheek-by-jowl—accurate documentation isn’t just a technical nicety. It’s a project risk control. When plant rooms are tight, vertical services snake through ceilings, and staged upgrades must be delivered without surprises, “close enough” drawings can mean delays, cost overruns, and compliance headaches.
That’s where engineer-led 3D engineering and scanning services make all the difference. At Hamilton By Design, we go beyond pretty point clouds and generic scans, delivering precision-engineered BIM-ready documentation and defensible as-built records you can rely on to support major decisions—from due diligence in property transactions to fit-first-time fabrication and refurbishment planning in Sydney’s demanding market. Hamilton By Design
Whether you’re planning a major services upgrade, preparing a building for sale, or coordinating a complex refurbishment in the CBD, our Sydney 3D engineering services help you:
Eliminate assumptions about what’s “in the walls” and base decisions on verified reality;
Reduce costly rework and avoid clashes between structural, mechanical, and architectural elements;
Produce documentation that supports compliance pathways, design coordination, and construction sequencing;
Create clear, defensible records that stand up in commercial negotiations, due diligence, and long-term asset planning. Hamilton By Design
By capturing reality with engineering intent and delivering outputs tailored to your project’s purpose—whether BIM models, coordinated drawing sets, or evidence-quality documentation—Hamilton By Design helps Sydney professionals manage risk, cut uncertainty, and move forward with confidence.
Machine guarding remains one of the most critical — and often misunderstood — aspects of industrial safety in Australia.
Over the past decade, Australian regulators, courts, engineers, and asset owners have all contributed to a clearer understanding of what effective machine guarding really means. Yet incidents, prosecutions, and near misses continue to occur, often where risks were known but not properly engineered out.
At Hamilton By Design, we’ve worked alongside manufacturers, processing plants, and industrial operators to support safer machinery through engineering-led design and practical implementation. Drawing on this experience, we’ve recently published a detailed article exploring what ten years of machine-guarding practice in Australia has taught us.
What the article covers
In the full blog post, we explore:
How machine guarding expectations have evolved in Australia
Key lessons for leaders and asset owners responsible for safety outcomes
Practical insights for engineers involved in machinery design and modification
The role of Australian and international standards in modern machine guarding
Why safety must be considered early — not retrofitted later
Rather than treating guarding as a compliance checkbox, the article focuses on safety-by-design principles and long-term risk reduction.
Why this matters
Machine guarding failures don’t just lead to injuries — they result in downtime, legal exposure, reputational damage, and long-term operational risk. For leaders and engineers alike, understanding past lessons is essential to building safer, more resilient industrial environments.
Read the full article
To explore the insights in detail, read the full blog post here:
If you’re responsible for machinery safety, engineering design, or asset management, this article provides valuable context and practical guidance grounded in real Australian industry experience.
Why Your Next Project in Brisbane Needs Professional 3D Scanning
Are you planning an industrial upgrade, retrofit, brownfield work, or fabrication-ready design in Brisbane? One thing every successful engineering project has in common is accurate measurement of what already exists — and that’s where 3D scanning makes all the difference. Hamilton by Design
At Hamilton By Design, we approach 3D scanning as an engineering measurement task, not just a visual capture exercise. This means the data you get from us is precise, reliable, and ready for engineering decisions, reducing the risk of rework, clashes, and guesswork on site. Hamilton by Design
3D scanning uses engineering-grade LiDAR laser technology to capture millions of spatial measurements that form a highly detailed digital “point cloud.” This digital twin of your site or asset can be used for:
Accurate site documentation
As-built capture of structures, pipes, and steelwork
Retrofit planning and clash detection
Fabrication-ready models and tight shut-in planning
Scan-to-CAD workflows for design and engineering execution Hamilton by Design
Unlike simple visual scans or photogrammetry, engineering-grade scanning measures geometry, not just appearance — which means you can trust the data for precise engineering outcomes. Hamilton by Design
🚀 Why Brisbane Businesses Are Turning to 3D Scanning
With Brisbane’s growing industrial and construction sector, accurate measurement and modelling are becoming mission-critical. Here’s why:
✔ Reduced errors and risk — precise data means fewer surprises during fabrication and installation. Avian ✔ Faster decision-making — engineers and fabricators work from the same accurate baseline. Avian ✔ Integration with CAD & BIM — point clouds can be converted into detailed 3D models for design and planning. Avian ✔ Less site time — scanning captures everything in fewer site visits, lowering project costs. Bridge FAB
Whether you’re managing a complex industrial shutdown, preparing for fabrication, or validating as-built conditions, professional 3D scanning gives you the confidence to move forward with clarity and precision. Bridge FAB
🛠️ Engineer-Led Scanning for Stronger Project Outcomes
At Hamilton By Design, 3D scanning isn’t a standalone service — it’s part of an integrated engineering workflow. From site capture to CAD modelling and fabrication-ready deliverables, we provide single-source accountability so every downstream task works from reliable data. Hamilton by Design
This approach helps ensure your steelwork, pipe spools, and structures fit first time — every time. Hamilton by Design
💡 Ready to reduce risk, increase accuracy, and streamline your next project? Click below to see how our Brisbane 3D scanning services can help:
