Tom Price 10M Conveyor Redesign
CADDS group were commissioned to undertake a full structural check of our clients 10M conveyor structure, and to produce the required redesign and fabrication deliverables to increase throughput.
The 10M structure was designed in the late 60’s and has multiple modifications made over the years, this provided a challenging environment to operate and design in, and therefore the use of customized process’ and technology was essential. Extensive use of BIM was required to coordinate the creation of the existing structure, and to produce the required deliverables.
Cadds Group were required to:
• Design of a new 10M GTU structure.
• Replacing the current 900mm belt with a 1050mm belt.
• The existing 35° impact frames were replaced with 45° retractable frames.
• All the idler frames were replaced with a standard design.
• Stringer sections were lowered to suit the new impact frames.
• Pulleys were upgraded, skirt and underflow modifications, motors and gearboxes upgraded and modifications are to be made to the head chute.
• Design of a new counterweight structure with a single idler connection to suit a 1050mm wide belt and increase in throughput required.
• Moving back of the head pulley to change impact angle of flow into the head chute
With the final deliverables to be:
• Engineering report on the structural adequacy of the 10M conveyor gantries, trestles and foundations to take increased loading due to the addition of the WTS flow.
• Design drawings of all required modifications.
• Design drawings for all new structures.
• As-built updates of all relevant 10M drawings.
• Complete shop detailing deliverables for all required modifications and new structures.
To achieve this CADDS Group utilized our 3D scanning capabilities to produce a point cloud of otherwise unmeasurable areas. Critical points in the point cloud were then identified and these points were referenced into our Tekla model.
We were able to completely as-build the existing structure by combining critical points from the laser scan, information obtained from existing drawings and site measurements.
The engineering team utilized .ifc data for structural analysis on existing members which was in turn imported back into our Tekla working model for the accurate modifications to be made.
Tekla Bimsight was used thoroughly for collaboration between the different disciplines in multiple locations, whose input was required to complete the project. Without this additional platform to share ideas and provide direction, we would have had to resort to traditional methods of communication leading to longer turnaround time during design and increasing the likelihood of miscommunication.
CADDS Group were also required to produce fabrication drawings, reports and CNC data. For this we utilized the same working design model giving us improved accuracy and control over the parts being issued for fabrication and increased confidence that fabrication deliverables matched design.
At present the model contains roughly 221.5 tons of existing steelwork and 86 tons of new steelwork totaling over 300 tonnes of steelwork surveyed, engineered, designed and fabricated utilizing a central model for the entire project lifecycle.