Finite Element Analysis (FEA) in Mine Site Structural Verification

Ensuring Reliability, Safety, and Compliance in Harsh Mining Environments

In modern mining operations, where equipment is large, loads are extreme, and downtime comes at enormous cost, Finite Element Analysis (FEA) has become one of the most important engineering tools available. From fixed plant infrastructure to mobile equipment, FEA allows engineers to analyse stress, strain, deformation, fatigue, and failure mechanisms with a level of precision that is impossible through hand calculations alone.

At its core, FEA works by breaking a structure into thousands—or sometimes millions—of small “finite elements.” These elements collectively form a mesh that represents the geometry, material properties, and boundary conditions of the component being analysed. Numerical methods are then applied to calculate how the structure responds under various loading scenarios, including static forces, dynamic vibration, thermal expansion, fatigue cycles, pressure loads, and impact events.

For mine sites, where structural components operate continuously under harsh and unpredictable conditions, FEA is no longer optional—it is fundamental to safe design, life-extension, and compliance verification.

Trang Imagineering delivers advanced FEA as part of its structural and mechanical engineering services, supporting mining clients in identifying vulnerabilities, validating new designs, and extending the operational life of critical equipment.

Why FEA Is Essential for Mining Operations

Mining equipment and infrastructure are exposed to the harshest combinations of loading, environmental exposure, and operational stress found in any Australian industry. Conveyor gantries experience high cyclic loads. Crusher structures vibrate continuously at variable frequencies. Tanks and chutes handle abrasive slurries. Mobile plant support structures endure impact and fatigue.

Traditional engineering analysis methods can only partially capture these conditions. FEA, however, provides:

• Detailed insight into stress concentrations

• Accurate prediction of fatigue life

• Assessment of failure modes under extreme scenarios

• Ability to simulate real-world loads and interactions

• Evidence-based verification for compliance and certification

This data-driven approach helps mine operators make confident decisions—before problems become shutdowns, structural failures, or safety hazards.

Applications of FEA in Mining

Trang Imagineering applies FEA across a wide spectrum of mining infrastructure. Below are some of the most common applications and why they matter.

1. Crusher Housings and Support Structures

Crushers generate some of the harshest vibration spectra in mining. Their housings, support frames, and foundations are subjected to:

• High-frequency vibration

• Dynamic impact loading

• Thermal variation

• Shock events from uncrushable tramp metal

FEA allows engineers to:

• Predict crack initiation locations

• Assess vibrational modes and resonance risks

• Validate thickness, bracing, and support geometry

• Design reinforcement plates and retrofits

• Extend service life without major rebuilds

This prevents costly unplanned shutdowns and improves reliability.

2. Conveyor Gantries, Galleries, and Transfer Towers

Conveyors operate continuously, often over long spans and in exposed conditions. Their structural components experience:

• Repeated cyclic loading

• Dynamic belt tension

• Chute impact from rock and ore

• Wind loading

• Misalignment-induced vibration

FEA supports:

• Fatigue assessment in high-cycle regions

• Buckling checks for slender members

• Gusset and stiffener optimisation

• Design verification in accordance with AS4100 and AS3990

• Retrofit evaluation for capacity increases

Given the continuous nature of mining production, FEA-led improvements to conveyor structures can significantly reduce downtime risk.

3. Slurry, Process, and Leach Tanks Under Internal Pressure

In modern mineral processing plants—especially hydrometallurgical circuits—tanks must withstand:

• Internal pressures

• Sloshing loads

• Thermal expansion

• Nozzle and agitator-induced stresses

• Corrosive and abrasive contents

FEA enables:

• Accurate stress evaluation around nozzles, manways, and supports

• Assessment of shell deformation under pressure

• Verification of compliance with API-650, API-653, and AS1692

• Design of reinforcement pads, ribs, and anchor points

• Analysis of agitator shaft loads and dynamic effects

For tanks handling corrosive solutions, FEA also assists in determining safe operating envelopes and expected life.

4. Chutes, Hoppers, and Wear-Exposed Components

Wear is a constant challenge in mining. Chutes, hoppers, bins, and transfer points experience:

• Abrasive wear from ore

• Impact forces from falling material

• Erosion due to slurry velocity

• Blockages creating irregular loading conditions

FEA helps engineers:

• Identify high-stress plate zones

• Determine thicknesses and liner configurations

• Analyse impact forces and transient loads

• Prevent buckling or shell deformation

• Model dynamic interactions during blockages or surges

This level of insight leads to longer-lasting designs and more predictable maintenance cycles.

Key Advantages of Using FEA for Mine Site Verification

1. Identifies Weaknesses Invisible to Hand Calculations

Hand calculations work well for simple beam, column, or plate problems—but mining infrastructure rarely fits into neat textbook formulas. Real equipment contains:

• Complex geometry

• Welded brackets, gussets, stiffeners

• Cut-outs and penetrations

• Asymmetric loads

• Non-uniform supports

FEA can simulate these complexities to pinpoint stress hotspots that traditional methods would overlook.

2. Supports Compliance with Australian and International Standards

Mining structures must comply with stringent codes to ensure safety. FEA ensures alignment with:

• AS4100 (Steel structures)

• AS3990 (Mechanical equipment)

• AS/NZS 1170 (Loads, wind, earthquake)

• AS4041 / ASME B31.3 (Piping)

• API-650 & API-653 (Storage tanks)

• ISO and OEM specifications

FEA provides documentation and evidence to satisfy regulators, certifying engineers, and internal audit requirements.

3. Optimises Retrofits and Extends Asset Life

Mining assets often remain in operation far beyond their original design life. FEA is invaluable for:

• Assessing remaining life

• Designing reinforcement plates and stiffeners

• Reducing stress concentrations

• Evaluating crack propagation risk

• Supporting fitness-for-service evaluations

Rather than replacing expensive structures, FEA-led retrofitting can provide years of additional safe operation at a fraction of the cost.

4. Reduces Unplanned Downtime and Maintenance Costs

By predicting failures before they occur, FEA allows maintenance teams to:

• Plan shutdowns

• Replace components proactively

• Avoid catastrophic failures

• Reduce the frequency of inspections

• Improve reliability of production-critical equipment

In mining, where each hour of lost production is costly, predictive engineering is a direct financial advantage.

5. Improves Design Efficiency and Material Usage

FEA can be used during design stages to optimise:

• Material thickness

• Structural layout

• Support spacing

• Weld size and location

• Overall weight and cost

This leads to lighter, stronger, and more economical designs.

Trang Imagineering’s Approach to FEA in Mining

Trang combines advanced numerical modelling with practical engineering knowledge gained from decades of working with mining equipment, fabricators, and site maintenance teams.

Our process includes:

✔ Detailed 3D CAD modelling
✔ Accurate material property selection
✔ Realistic boundary conditions that reflect site constraints
✔ Simulation of static, dynamic, thermal, and fatigue loads
✔ Failure mode evaluation and risk reduction
✔ Fabrication-ready reporting and drawing recommendations

Trang engineers understand that FEA is not just “pretty pictures.” It is a tool that must produce actionable, buildable, site-ready solutions.

This means our reports include:

• Clear stress maps and interpretations

• Practical reinforcement methods

• Deflection and vibration assessments

• Compliance statements

• Fabrication sketches or detailed designs where required

• Recommendations for inspection frequency and maintenance

Our work bridges the gap between theoretical modelling and real-world mine operation.

Conclusion: FEA Is Now Non-Negotiable for Safe, Efficient Mining Operations

As mining equipment becomes larger, production targets increase, and regulatory standards tighten, relying solely on traditional design and inspection methods is no longer sufficient. Finite Element Analysis has become a cornerstone of engineering assurance—helping mines avoid failures, extend asset life, and meet stringent compliance requirements.

Trang Imagineering provides the advanced modelling capability required by modern mine operators, backed by practical experience and a commitment to safe, reliable, and efficient plant operation.

With FEA-driven engineering, mine sites gain:

• Greater operational confidence

• Reduced downtime

• Extended equipment lifespan

• Safer workplaces

• Clear compliance documentation

• Stronger return on investment

Regardless of whether the task involves a crusher frame, slurry tank, conveyor gantry, mobile plant attachment, or a retrofit of ageing infrastructure, Trang ensures mine operators make informed decisions backed by accurate engineering analysis.