STRUCTURAL & MECHANICAL ENGINEERING
3D Coordinated Design for Mining & Industrial Operations
Comprehensive structural and mechanical engineering from conceptual design through detailed engineering, integrity management and lifecycle support. We deliver designs that are clash free, constructable and optimised for long term performance.
THE INDUSTRY CHALLENGE
Design Failures Are Costing You More Than You Think
These problems occur across mining and industrial projects every day:
- Clashes discovered during construction: rework costs 5 to 10 times more than fixing in design
- Designs that cannot be built: no consideration for crane access, erection sequence or site constraints
- Maintenance challenges: components inaccessible creating safety hazards and extended downtimes
- Structural failures in service: inadequate design for actual operating loads and conditions
- Aging infrastructure with unknown condition: no systematic integrity management
- Reactive maintenance culture: fix it when it breaks at three times the cost
- Overdesigned structures: conservative assumptions waste material and money
The root cause is engineering disciplines working in silos without integration and without consideration for the full asset lifecycle.
THE ENALENI SOLUTION
Enaleni delivers integrated structural and mechanical engineering using parametric 3D modelling, advanced analysis and lifecycle thinking. Every design is coordinated across all disciplines, validated for constructability and optimised for long term performance and maintainability.
Our Engineering Philosophy
- All disciplines integrated within one coordinated model
- Clash free before fabrication and construction
- FEA and dynamic analysis applied throughout design development
- Optimised structures engineered for fit for purpose performance
- Erection sequences defined during early design stages
- Crane access and site constraints incorporated from day one
- Safe access platforms and clearance zones integrated into design
- Components positioned for efficient inspection and maintenance
- Structural Integrity Management Systems programs implemented
- Assets managed from commissioning through end of life
CORE CAPABILITIES
Structural Engineering
- Steel Structure Design: Trusses, frames, platforms, pipe racks, conveyor gantries
- Concrete Structure Design: Foundations, plinths, slabs, retaining walls, bunkers
- Equipment Foundations: Static and dynamic loading, vibration isolation
- Building Design: Industrial buildings, workshops, offices, change houses
- Connection Design: Bolted and welded connections, base plates, anchor bolts
- Seismic Design: Site-specific response spectra, ductility detailing
- Load Path Optimisation: Efficient material use and cost-effective structural solutions
Mechanical Engineering
- Conveyor System Design: Belt selection, drive sizing, take-up systems, transitions
- Material Handling Equipment: Feeders, screens, crushers, mills support structures
- Bins, Hoppers and Silos: Flow analysis, structural design, liner systems
- Chute Design: DEM-optimised geometry and wear liner specification
- Rotating Equipment Support: Pumps, fans, compressors and drives
- Piping Stress Analysis: Thermal expansion, support design and system flexibility
- Pressure Vessel and Tank Design: API, ASME and SANS compliant solutions
3D Modelling & Analysis
- Parametric 3D Modelling: Tekla Structures, AutoCAD Plant 3D, SolidWorks
- Finite Element Analysis: Linear, non-linear, buckling and fatigue assessment
- Dynamic Analysis: Modal, harmonic and seismic response spectrum studies
- Vibration Analysis: Equipment-induced, flow-induced and wind-induced response
- Clash Detection: Automated interdisciplinary model coordination
- Constructability Validation: Erection simulation and crane studies
- Digital Twin Foundation: Models structured for operational intelligence integration
STRUCTURAL INTEGRITY MANAGEMENT SYSTEMS (SIMS)
Enaleni provides comprehensive Structural Integrity Management Systems to ensure your critical infrastructure remains safe, reliable and compliant throughout its operational life. SIMS transforms reactive maintenance into proactive asset stewardship.
What is SIMS?
A Structural Integrity Management System is a systematic risk based approach to managing the structural health of your assets. It integrates inspection, assessment, monitoring and maintenance planning into a unified framework that extends asset life, reduces risk and optimises maintenance spend.
SIMS Framework
- Asset register development: comprehensive inventory of all structural assets with criticality ranking
- Condition assessment: baseline and periodic inspections using visual, NDT and advanced techniques
- Risk based inspection planning: inspection frequencies based on consequence and likelihood of failure
- Degradation modelling: corrosion rates, fatigue accumulation and remaining life estimation
- Fitness for service assessments: API 579-1 and ASME FFS-1 evaluations for damaged components
- Repair and reinforcement design: engineered solutions for identified deficiencies
- Life extension studies: strategies to safely extend asset life beyond original design
- Monitoring system integration: strain gauges, accelerometers, corrosion probes and tilt sensors
- Digital SIMS platforms: centralised data management, dashboards and automated reporting
- Conveyor structures and gantries
- Pipe racks and pipe bridges
- Storage tanks and vessels
- Process plant structures
- Bins, silos and hoppers
- Stacker and reclaimer structures
- Ship loaders and port infrastructure
- Buildings and industrial facilities
- Bridges and elevated roadways
- Chimney stacks and flare structures
- Visual inspection and photographic documentation
- Ultrasonic thickness testing UTT
- Magnetic particle testing MT
- Dye penetrant testing PT
- Radiographic testing RT
- Phased array ultrasonic testing PAUT
- Drone based inspection for difficult access
- 3D laser scanning for deformation monitoring
- Vibration monitoring and analysis
- Coating condition assessment
BENEFITS OF PARTNERING WITH ENALENI
The Results Our Clients Achieve
Twenty three consecutive projects delivered with no major construction conflicts.
Clash free and constructable designs accelerate installation schedules.
Achieved through systematic Structural Integrity Management Systems implementation.
Proactive integrity management prevents costly reactive interventions.
Risk based inspection focuses resources where they are most needed.
Comprehensive documentation and audit trails aligned with MHSA and OHSA requirements.
Demonstrated integrity management lowers overall asset risk profile.
CASE STUDIES
Case 1: Conveyor Gantry SIMS Implementation
Challenge: A large mining operation operating 47km of conveyor structures, many exceeding 30 years in service, had no structured inspection regime. Reactive maintenance exceeded R8M annually, with frequent unplanned stoppages disrupting production.
Our Solution:
- ✔ Comprehensive asset register with criticality ranking
- ✔ Baseline structural condition assessment across all conveyor systems
- ✔ Risk-Based Inspection (RBI) programme implementation
- ✔ Repair prioritisation based on risk profile and remaining life
- ✔ Deployment of a centralised digital SIMS platform
Results:
- ✅ Unplanned repairs reduced by 67%
- ✅ Annual maintenance costs reduced from R8M → R4.2M
- ✅ 3 critical defects identified and mitigated before failure
- ✅ Estimated asset life extension of 15 years
- ✅ Achieved full regulatory compliance
Case 2: Brownfield Plant Retrofit — Zero Clashes
Challenge: A major screen house upgrade required new equipment installation within an existing structure during a highly constrained shutdown window. The risk of clashes, rework, and schedule overruns was significant.
Our Solution:
- ✔ ParaMatic™ high-resolution 3D laser scanning of existing structures
- ✔ Fully coordinated structural and mechanical 3D modelling
- ✔ Finite Element Analysis (FEA) validation of modifications
- ✔ Detailed erection and shutdown sequence planning
- ✔ Prefabrication optimisation to minimise site work
Results:
- ✅ Zero structural or mechanical clashes during installation
- ✅ Completed 4 hours ahead of shutdown schedule
- ✅ No rework required
- ✅ R2.1M saved versus traditional retrofit approach
STANDARDS AND COMPLIANCE
All assessments, designs and inspections are conducted in accordance with recognised national and international standards to ensure safety, durability and regulatory compliance.
- SANS 10162: Steel structures
- SANS 10100: Concrete structures
- SANS 10160: Basis of structural design and actions
- AISC 360: Steel construction
- ACI 318: Concrete structures
- API 579-1 / ASME FFS-1: Fitness-for-Service assessment
- API 653: Tank inspection and repair
- CEMA: Conveyor equipment standards
- ASME B31.3: Process piping
- ISO 19902: Fixed offshore structures principles applicable to onshore facilities
INDUSTRIES WE SERVE
Mining & Minerals Processing
- Concentrators
- Smelters
- Refineries
Bulk Materials Handling
- Conveyors
- Stackers
- Reclaimers
- Ship loaders
Power Generation
- Coal handling systems
- Ash handling systems
- Boiler structures
Ports & Terminals
- Bulk handling facilities
- Storage infrastructure
- Ship loading systems
Cement & Aggregates
- Kilns
- Mills
- Silos
- Material handling systems
Petrochemical
- Pipe racks
- Vessels
- Process structures
Manufacturing
- Industrial buildings
- Production facilities
WHAT YOU GET
Deliverables designed to provide technical clarity, practical value and long-term asset reliability.
- Coordinated 3D Models: Fully integrated structural and mechanical models
- FEA Reports: Finite element analysis results with clear engineering recommendations
- Construction Drawings: Fabrication and construction-ready documentation
- Connection and Material Specifications: Detailed connection designs and material requirements
- Erection Methodology: Sequencing plans and construction methodology guidance
- SIMS Programmes: Structural Integrity Management Systems with risk-based inspection plans
- Condition Assessment Reports: Documented findings with repair specifications
- Life Extension Strategies: Remaining life assessments and engineered extension solutions
- Digital Integrity Platforms: Ongoing monitoring and centralised integrity management systems
