Our Approach

Igneum provides independent structural audits for mobile bulk handling equipment — stackers, reclaimers, stacker-reclaimers, bucket wheel excavators, ship loaders, trippers, and spreaders — to AS 4324.1:2025, ISO 5049-1, FEM Section II, and associated design codes.

A machine structural audit is more than a stress check. It is a systematic review of the design basis, load assumptions, structural adequacy, stability, fatigue life, and compliance with the governing standard — covering every aspect that determines whether the machine is fit for its intended service. We perform audits for new machine supply, structural modifications to existing machines, and fitness-for-service assessments of ageing equipment.

Our audit process follows the framework established by AS 4324.1:2025 Appendix K, adapted to the specific needs of each engagement.

What a Structural Audit Covers

• Design basis and technical specification — Review of design codes, material specifications, bulk material properties, operating parameters, load limiting device settings, and confirmation that all required load cases are identified.
• Load assumptions — Verification of main loads (dead, live, encrustation, digging resistance, dynamic effects, conveyor forces, travel), additional loads (wind, temperature, abnormal digging, travel skew, erection and maintenance), and special loads (boom grounding, collision, earthquake, equipment loss) across all required load combinations.
• Structural adequacy — Review of calculations for primary load-carrying members, correct application of the design method (permissible stress to AS 3990 or limit state to AS 4100) with AS 4324.1 modifications, and assessment of buckling-critical members and plate elements.
• Finite element analysis — Where FEA is used, review of modelling assumptions, mesh quality, boundary conditions, and assessment methodology against established practices.
• Fatigue — Verification of fatigue design life (minimum 100,000 operating hours per AS 4324.1), stress range derivation, weld detail classification, and damage accumulation under variable amplitude loading.
• Stability and drifting — Overturning stability ratios and resistance against drifting under operating, relocation, and extreme wind conditions.
• Connections — Bolted joints (including high strength friction grip with AS 4324.1 derated capacity factors) and welded details at fatigue-critical locations.
• Wire ropes, stays, and hydraulic cylinders — Safety factors, duplication requirements, broken element load cases, and dynamic amplification.
• Slewing bearing selection — Verification of slew bearing selection for design life and upset condition survival.
• Mass and balance verification — For new machines or significant modifications: attendance at weighing, review of as-built mass and centre of gravity against design assumptions.
• Ancillary structures — Supporting structures, rails, tie-down and restraint systems, and major maintenance works.

Equipment Types

• Bucket wheel excavators and reclaimers
• Stacker-reclaimers and stackers
• Ship loaders and continuous ship unloaders
• Scraper reclaimers and portal scrapers
• Trippers and belt wagons
• Spreaders
• Conveyor drive heads and transporters

Key Benefits

• Standards-based scope — Systematic coverage of AS 4324.1:2025, ISO 5049-1, and FEM Section II, with every assessment traceable to a specific clause.
• Independent verification — We act as an independent design audit engineer on behalf of the owner, separate from the machine supplier.
• Load assumption scrutiny — Detailed review of the load derivation, where errors in the design basis have the greatest consequences.
• Fatigue life assurance — Variable amplitude damage accumulation, weld detail classification, and stress range evaluation within the AS 4324.1 fatigue framework.
• FEA review and independent analysis — Review of supplier FEA models and, where required, independent finite element analysis of critical regions.
• Whole-of-life perspective — Findings framed in terms of structural risk, remaining fatigue life, and operational constraints to support informed decisions.