Rotaspiral & Pipe Rack Process Structure

Project Overview

Robust Consulting Engineers was appointed to provide Structural Engineering services for the modification of an existing mineral processing plant to improve operational efficiency and increase production capacity. The project required the design of a new gravity-fed slurry transfer system between the milling plant and the Rotaspiral screening plant while making maximum use of the existing infrastructure.

Rather than introducing additional mechanical equipment, the client sought a practical engineering solution that would utilise gravity to transport slurry efficiently, reducing operating costs, maintenance requirements and mechanical complexity. Robust Engineers developed the structural engineering solution required to safely accommodate the new process configuration while ensuring the continued integrity of the existing plant.

The Challenge

The client required improvements to the mineral processing circuit to optimise production without disrupting existing plant operations or investing in costly additional mechanical equipment. The proposed gravity-fed system required significant modifications to existing steel structures, foundations and pipe support systems that had originally been designed for different loading conditions.

One of the principal engineering challenges was assessing whether the existing infrastructure could safely support the additional structural loads generated by the new pipeline and elevated process equipment. Raising the existing structure from approximately seven metres to thirteen metres introduced additional wind loading, increased structural forces and stability considerations that required detailed engineering analysis before construction could proceed.

The solution therefore needed to improve operational efficiency while maintaining plant safety, minimising downtime and making maximum use of the existing infrastructure.

Our Engineering Solution

Robust Engineers developed an innovative structural solution that enabled slurry to flow under gravity from the milling building directly to the Rotaspiral screening structure, eliminating the need for additional pumping equipment.

Our engineering team carried out detailed structural assessments of the existing steelwork and foundations to determine their suitability for the proposed modifications. Following the analysis, the supporting structures were redesigned to accommodate the increased loading associated with the elevated pipework and modified process arrangement.

The project included the structural design of new pipe rack support structures, steel bracing systems, trusses, foundation modifications and the extension of the existing support structure from approximately seven metres to thirteen metres in height.

Detailed engineering calculations, fabrication drawings and construction documentation were prepared to facilitate safe implementation of the modifications. Throughout construction, Robust Engineers provided technical support and construction monitoring to ensure that the modifications were implemented in accordance with the approved engineering designs and industry best practice.

Value Delivered

By adopting a gravity-fed process solution, Robust Engineers helped the client improve operational efficiency while reducing dependence on additional mechanical equipment, lowering long-term maintenance costs and simplifying plant operations.

Our engineering approach maximised the use of existing infrastructure, avoiding unnecessary demolition and reducing overall project costs. Through careful structural analysis and targeted strengthening, the existing facilities were successfully adapted to accommodate the new process requirements without compromising structural integrity or operational safety.

The project demonstrates Robust Engineers’ ability to integrate structural engineering with industrial process requirements, delivering practical solutions that improve productivity while extending the useful life of existing infrastructure.

Project Outcome

The completed modifications significantly improved the efficiency of the mineral processing circuit by enabling reliable gravity flow between key process areas while maintaining the structural safety of the existing facilities. The project enhanced production capability through smart engineering rather than costly equipment replacement, providing the client with a durable and cost-effective solution that continues to support efficient plant operations.

This project highlights Robust Engineers’ expertise in industrial structural engineering, plant modifications and the optimisation of existing mining infrastructure through innovative and practical engineering solutions.