Hamilton By Design

  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...

  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 u...

  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 Acce...

 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...

  Why Measured Reality Matters More Than Ever 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...

   What Engineers Need to Know 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 For detailed information on how to apply AS 1755 in your conveyor projects — including practical guarding design considerations...

 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 Aust...

  Why Accuracy Matters in 3D LiDAR Scanning 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 clearanc...

  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. 👉 Read the full detail...