Machine FEA and assessment
Calculations and findings to develop the design or identify the next assessment action.
View the assessment packageStackers · Reclaimers · Shiploaders · Ship unloaders
Structural and mechanical engineering for bulk handling machines.
Engineering calculations and practical recommendations to develop a new machine, assess an upgrade or plan a repair.
Design, FEA and independent review for asset owners, equipment manufacturers and engineering firms.
Find the engineering support you need
Whole machine assessment Structural, mechanical and operating interfacesDesign and site experience Equipment manufacturers and operating assetsPractical engineering output Assessed options, design documentation and actions
Engineering services
What does your machine need?
Incomplete records, production demands and procurement deadlines can restrict your options. ACE assesses the available information and identifies the calculations, design work or investigation needed.
New machines and upgrades
Resolve loads, component requirements and supplier interfaces while design options remain open. Identify issues that could lead to changes after procurement.
Explore design servicesRecurring damage and repairs
Repeated repairs consume shutdown time. Investigate the damage and develop an assessed repair scope, including site constraints and follow up.
Explore investigation and repairCondition assessment and life extension
Use condition and operating records to prioritise assessment and repairs, and identify the checks needed for continued service.
Explore asset assessmentsIndependent FEA peer review
Documented review findings, responses and outstanding matters for your design team.
View the review packageWhole machine assessment
Assessed options and interface loads that account for the effects beyond one component.
View the machine assessment
Tender preparation · Design freeze · Procurement
AS 4324.1:2025 Design and Commercial Impact Review
Start with a gap study against the applicable 2025 requirements. Identify design changes, evidence needs and connected interfaces, then assess options and their cost and programme implications within the agreed scope.
Explore the review and deliverablesACE project experience
Assessing a new linear stacker
as a complete machine.
New machine design
Linear stacker
Structural and mechanical assessment during design development
ACE assessed how load assumptions, machine balance and mechanical forces affected stability, wheel reactions and connected structures, and carried out an AS 4324.1:2025 gap study.
The work identified governing constraints, compared design options and documented recommendations and interface actions for the OEM’s detailed design.
Read the project exampleHow to engage
How we work with your team
- 01
Discuss the project
Tell ACE about the machine, the issue or proposed work, and your timing.
- 02
Confirm the engineering scope
Receive a proposal setting out the work, deliverables and fee.
- 03
Receive the agreed engineering documents
Receive the agreed calculations, assessed options, design details or repair priorities, with assumptions and outstanding checks clearly identified.
About ACE
Structural and mechanical engineering.
ACE Engineering Group provides structural and mechanical design and assessment for new machines and operating assets in mining and bulk materials handling.
Design reviews, investigations and repair assessments consider the loading, operating duty, condition and practical constraints of each machine.
About ACE and technical leadership ↗Experience in design and site assessment
ACE’s principal engineer has worked in equipment manufacturer design teams and operating mine and port environments.
Download capability statement
PDF · 4 pages
Download Anthony’s engineering CV
PDF · 2 pages · Qualifications, capabilities and project experience
Technical Insights
Practical guidance for design,
repairs and upgrades.
Repairs and continued service
Why fatigue cracks return after repair
Cracks that return after repair can have several causes. Learn how to compare the intended repair with the installed detail, investigate the loading and establish the evidence needed for continued operation and the next repair.
Machine modifications and shutdowns
A lighter bucketwheel drive is not automatically a cheaper upgrade
A lighter bucketwheel drive can avoid strengthening while adding supports, services and access work elsewhere. Compare electromechanical and hydraulic arrangements, including the HPU location, against the same duty and complete installation scope.
New machine design and review
Design review before procurement
A useful review establishes what can be released and what must remain held. Connect supplier changes, operating limits and field lessons to the evidence and conditions needed for the next equipment order or drawing release.
Start a conversation
Discuss your design, upgrade or repair.
Contact ACE to develop a machine design, assess an upgrade, establish a repair scope or prepare substantiated evidence for review.