Retrofitting Legacy Mining Equipment: Engineering for Longevity

Mining is an industry built on massive capital assets — conveyors, crushers, tanks, mills, structural frames, processing equipment, platforms, pipes, pumps, and material-handling systems that operate under some of the harshest conditions anywhere in Australia. Many of these assets were originally designed decades ago, for loads, production rates, environmental conditions, and regulatory standards very different from today’s reality.

Yet mines across NSW and the broader Australian mining sector depend heavily on legacy equipment that continues to operate well beyond its intended design life.

Replacing major infrastructure is expensive, time-consuming, and often impractical. Shutdowns are costly. Supply chains for specialised equipment can stretch months or years. In many cases, the most efficient, cost-effective and environmentally responsible solution is retrofitting — upgrading existing assets to safely extend their life and maintain performance.

Trang Imagineering specialises in engineering-led retrofits that give aging mining infrastructure new life. Through structural strengthening, mechanical optimisation, materials upgrades, coating improvements, and standards-based engineering assessments, we help mines operate safely, reliably and sustainably — without the cost of full equipment replacement.

Why Retrofitting Is Critical in Modern Mining

Mining companies face increasing pressure to maintain uptime, reduce capital expenditure, and meet stringent safety and compliance requirements. Retrofitting enables operators to achieve these goals without the disruptions associated with replacement.

Key reasons mines retrofit instead of replace include:

1. Equipment is operating well beyond original design life

Many assets were installed 20, 30, even 40 years ago. Over time, loads have increased, throughput has risen, and environmental exposure has taken a toll. Retrofitting reinforces ageing equipment so it can continue to function safely.

2. Replacement can be cost-prohibitive

Large structural or mechanical components — such as conveyor gantries, tanks, crushers, and hoppers — can cost millions to replace. Retrofitting typically costs a fraction of full replacement.

3. Shutdown windows are extremely limited

Major replacement projects require extended shutdowns. Retrofitting can often be completed in stages, during short maintenance windows.

4. Sustainability and waste reduction

Retrofitting is environmentally responsible engineering. It reduces scrap, decreases material consumption, and aligns with ESG goals.

5. Compliance expectations have changed

Standards such as AS4100, AS3990, AS1657 and API650 are more stringent today. Retrofitting allows mines to bring old equipment up to modern requirements.

How Trang Imagineering Retrofits Legacy Mining Equipment

Retrofitting is not simply “patching” old equipment. It requires structured engineering analysis, careful planning, and precise execution. Trang Imagineering provides a complete retrofit engineering service, ensuring upgrades are safe, compliant and effective.

Below are the most common retrofit techniques we apply.

1. Reinforcing Welds and Structural Joints

Welds are one of the first areas to show fatigue in ageing assets. Over years of vibration, impact, thermal expansion and cyclic loading, weld cracking can occur — especially in:

• Conveyor trestles

• Crusher frames

• Vibrating screens

• Transfer stations

• ROM bins

• Hoppers and chutes

• Pump skids

• Tank supports

Trang assesses weld conditions through:

• Visual inspections

• Non-destructive testing (NDT)

• Fatigue analysis

• Load path modelling

• FEA (Finite Element Analysis)

Where required, we design:

• Weld doublers

• Improved weld preparations

• Additional welds or revised weld geometry

• Strengthening plates

• Stiffening around weld-critical regions

These upgrades significantly increase fatigue life and reduce the risk of catastrophic weld failure.

2. Adding Stiffeners, Bracing and Structural Strengthening

Many legacy structures were not designed for today’s production levels or modern safety requirements. Additional stiffeners or bracing can drastically improve capacity and extend life.

Typical strengthening strategies include:

• Web stiffeners for beams

• Gussets and angle bracing

• Local plate thickening

• Reinforced connections

• Support re-distribution

• Load-spreading frames

• Vibration mitigation measures

These modifications elevate structural performance without requiring a full rebuild.

Trang uses structural analysis, AS4100 and AS3990 compliance checks, and FEA modelling to determine the most efficient strengthening approach.

3. Applying Advanced Coatings and Surface Treatments

Corrosion is one of the most common degradation mechanisms in mining equipment — especially in:

• Tanks and process vessels

• Pipework

• Structural steel exposed to slurry or chemicals

• Outdoor gantries and walkways

• Dusty, high-UV environments

• Areas with poor drainage or water retention

Trang provides guidance on:

• High-performance industrial coatings

• Abrasion-resistant linings

• Chemical-resistant epoxy systems

• Galvanized and duplex coating strategies

• Surface preparation requirements (Class 2.5, etc.)

Advanced coating systems can extend asset life dramatically, delaying replacement by decades when properly maintained.

4. Upgrading Materials to Modern Alloys

Older equipment often uses steels or components that are now outdated or inferior to contemporary materials.

Modern upgrades allow:

• Better fatigue performance

• Increased resistance to abrasion

• Reduced corrosion

• Improved weldability

• Enhanced toughness

• Suitability for more aggressive or higher-throughput operations

Typical upgrade applications include:

• High-strength structural steels

• Stainless or duplex piping

• AR plate for chutes and hoppers

• Modern high-toughness pressure vessel materials

• Alloy components for heat or chemical exposure

Trang assesses compatibility, weldability, and performance under load to ensure safe material substitution.

5. Mechanical System Upgrades & Component Optimisation

Retrofitting is not limited to steelwork. Trang also supports mechanical optimisation such as:

• Replacing worn bearings, rollers, and mechanical interfaces

• Improving alignment and load distribution

• Increasing vibration resistance

• Reinforcing motor mounts and gearboxes

• Strengthening rotating equipment frames

• Redesigning worn or failing components

These upgrades improve reliability while minimising capital expenditure.

6. Safety Improvements and Access Upgrades (AS1657)

Legacy mining infrastructure often has outdated or non-compliant access systems — ladders, platforms, stairs, walkways, handrails.

Trang upgrades these systems to meet:

• AS1657

• WHS requirements

• Site safety policies

Access retrofits reduce risk for maintenance teams and align operations with modern safety expectations.

Benefits of Retrofitting Legacy Mining Equipment

Retrofitting delivers significant advantages compared to full equipment replacement.

1. Lower Cost Than Replacement

Retrofitting typically costs 10–30% of full replacement, depending on asset type.

Capital budgets stretch further, and mines can allocate funds toward production improvements instead of reactive replacements.

2. Reduced Downtime and Faster Implementation

Retrofit work can be completed:

• During short shutdown windows

• In staged increments

• With minimal disruption

Replacement often requires long lead times, shipping delays, and major shutdowns.

3. Improved Safety and Compliance

Retrofitting allows mines to:

• Eliminate structural weaknesses

• Reduce fatigue risks

• Bring equipment up to AS and API standards

• Improve access and maintenance safety

• Document compliance for regulators and insurers

Safety improvements delivered proactively are always cheaper than reactive responses to incidents or failures.

4. Longer Asset Service Life

Strategic retrofits can extend equipment life by 5, 10 or even 20+ years.

This is high-value engineering.

5. Sustainability and Waste Reduction

Less demolition.
Less steel fabrication.
Lower carbon footprint.
Reduced landfill.
Better utilisation of existing assets.

Retrofitting is the engineering equivalent of recycling — but smarter, targeted, and performance-driven.

Retrofitting Is Practical, Sustainable Engineering — and Trang Imagineering Leads the Way

Modern mining demands reliability, safety, compliance, and cost-efficiency. Retrofitting allows mines to meet these needs without unnecessary capital expenditure, while improving sustainability and extending the life of existing infrastructure.

Trang Imagineering delivers:

• Structural assessment

• Mechanical diagnosis

• Fatigue and FEA modelling

• Strengthening design

• Access and safety upgrades

• Materials engineering

• Coating and corrosion strategies

• Long-term service life planning

Every retrofit is engineered to Australian Standards and backed by practical experience across mining, industrial, and heavy-equipment environments.

Retrofitting is not just repair — it is engineered longevity.

And Trang Imagineering provides the expertise that helps mines operate safely, sustainably, and profitably for decades to come.