Good EPCM is disciplines that don't hand off.
A plant is not a stack of separate engineering packages: it is one system where the process flowsheet sets the mechanical duty, the mechanical layout sets the civil loads, and the electrical reticulation has to reach all of it. When those disciplines are split across firms, the gaps between them become the project's risk.
We hold all of them in-house. Mechanical, electrical, process, civil, mining and bulk materials-handling engineers sit together (co-location, not coordination meetings) and the same team carries the project through procurement, construction management and commissioning. We validate in software before steel is ordered, and stay on site through ramp-up.
One team
A single accountable team from study through handover: no interfaces lost between vendors.
Simulation-first
ANSYS, SolidWorks, Nastran, Aspen and ETAP. Every discipline validated digitally before procurement.
On the ground
The engineers who design the plant stay through construction and commissioning.
From live site to a 3D model you can engineer on.
For brownfield work we don't guess at the as-built condition. We measure it. LiDAR scanning turns a working plant into a dimensionally-accurate 3D model, so design happens against reality from the first line.
Scan the live site
We survey the working asset, mines, plants and processing facilities, with both tripod-mounted (terrestrial) and drone-borne LiDAR, capturing millions of points to millimetre accuracy.
Build the point cloud
Individual scans are imported into Autodesk ReCap Pro and registered into a single, measurable point cloud, cleaned, aligned and ready for analysis.
Replicate in 3D
The point cloud is rebuilt as a true-to-life model in Plant 3D (or equivalent), every pipe, structure and equipment item recreated as intelligent, as-built geometry.
Design against reality
Our engineers design directly on the as-built 3D model. Brownfield tie-ins, modifications and new works fit first time, because they are built against the real plant, not assumptions.
What each discipline delivers.
Mechanical
Mechanical equipment and systems design, from equipment selection and materials engineering through FEA verification, piping layout and design reviews that keep every package buildable and compliant.
- Mechanical equipment design & specification
- Static & rotating equipment selection
- Materials selection & corrosion assessment
- Piping design support & layout development
- Pressure vessel & tank design support
- Structural & mechanical interface definition
- Design for manufacture & assembly (DFMA)
- Finite element analysis (FEA) & structural verification
- Fatigue, vibration & thermal stress assessments
- Mechanical design reviews & compliance checks
Electrical & Control
Medium-voltage reticulation, protection coordination, MCCs, drive packages and SCADA integration, for greenfield builds and live brownfield upgrades.
- Medium-voltage reticulation (11 / 22 / 33 kV)
- Protection coordination & arc-flash studies
- Motor control centres & VSD packages
- Cable routing, racking & containment
- Substation & transformer design
- SCADA, PLC & instrumentation
- Power-quality & harmonic studies
- Earthing & lightning protection
Process
Flowsheet development, mass and energy balances, equipment sizing and the diagrams that turn a concept into a buildable, operable plant, fully integrated with every other discipline.
- Geological & geotechnical studies
- Process flow diagrams (PFD) development
- Piping & instrumentation diagrams (P&IDs)
- Mass & energy balances
- Equipment sizing & specifications
- Process simulation & performance modelling
- Control philosophy & instrumentation definition
- Utility & off-site system definition
- Hazard identification & operability studies (HAZOP)
- Process design criteria & bases of design
- Integration with mechanical, electrical & civil disciplines
Civil & Structural
Earthworks through to the steel and concrete that carries the plant. Heavy industrial structures designed to category-4 standards.
- Earthworks, bulk & detail
- Reinforced-concrete foundations
- Heavy industrial steel structures
- Mill, crusher & tank foundations
- Conveyor gantries & support trestles
- Buildings, control rooms & substations
- Stormwater & containment
- Geotechnical interface design
Mining
Open-pit and underground mine design, planning and optimisation, from concept studies through to fleet productivity and operational improvement.
- Open-pit & underground mine design
- Mine planning, scheduling & production optimisation
- Drill & blast design and optimisation
- Geotechnical & ground-control support
- Haulage, materials handling & mine infrastructure layout
- Equipment selection & fleet-productivity assessment
- Mining studies (concept, pre-feasibility, feasibility)
- Operational improvement & cost-reduction studies
- Integration with processing plants & surface infrastructure
Bulk Material Handling
Materials handling and processing equipment from ROM tip through to product stockpile: conveying, crushing and screening, mills, pumps, tanks and the reclaim and dust systems around them.
- Conveyor design (CEMA / DIN 22101)
- Transfer chute engineering (DEM analysis)
- Crushing: primary, secondary, tertiary
- Screening & classification
- Cyclone clusters & classification
- Mill packages (SAG, ball, regrind)
- Feeders, hoppers & surge bins
- Static equipment: tanks, vessels, hoppers
- Slurry & process pump systems
- Thickeners & clarifiers
- Leach & CIL / CIP adsorption circuits
- Elution & electrowinning circuits
- Stockpile geometry & reclaim systems
- Stackers & boom conveyors
- Piping, valves, FEA & CFD
- Dust management & enclosure