For more than a decade, Advitech has supported a major coal export terminal in Newcastle with a long‑term structural integrity and reliability program designed to keep critical materials‑handling infrastructure safe, compliant and operating at peak performance. This enduring partnership has enabled Advitech’s engineers to build deep knowledge of the site’s assets, develop consistent inspection methodologies, and apply targeted engineering interventions that extend asset life while reducing operational risk.
The Challenge
As with many industrial facilities across Australia, much of the structural infrastructure at the terminal is operating well beyond its initial design life. Ageing steel structures, reinforced concrete elements and materials‑handling equipment face increasing exposure to corrosion, fatigue and mechanical wear. Without a proactive integrity strategy, operators risk unplanned shutdowns, higher maintenance costs and potential safety incidents.
The client required a program that not only identified deterioration early but also translated inspection findings into practical engineering solutions suited to a major, continuously operating export facility.
Advitech’s Approach
Advitech’s Structural and Civil Engineering team brings broad experience across industrial and mining sectors, specialising in structural design, assessment, remediation and asset management programs. Leveraging this capability, the team delivered a structured and repeatable integrity management framework built on three key components:
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Periodic Inspections and Condition Assessment
Advitech implemented a disciplined regime of periodic structural inspections using a mix of non-destructive testing techniques and drone‑based visual assessments. These covered conveyor gantries, transfer towers, bins, stackers, reclaimers, shiploaders and civil structures. Defects were categorised by risk and consequence, with recommended corrective actions and timeframes clearly documented to guide maintenance planning.
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Engineering Review and Technical Support
Inspection outputs were evaluated by Advitech’s structural engineers, who conducted detailed assessments where necessary and developed fit‑for‑purpose repair or strengthening solutions. Their design expertise – spanning steel and reinforced concrete structures, materials‑handling equipment and structural remediation – ensured all recommendations aligned with Australian Standards and site‑specific requirements. The team also assisted with developing technical scopes for shutdowns and corrective works to minimise production impacts.
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Integrated Asset Management
Advitech’s proactive asset management philosophy, incorporating periodic monitoring and NDT testing, enabled the client to track deterioration trends, prioritise investment and plan maintenance in a way that balanced operational continuity, cost and safety. This structured process provided increased visibility of asset health and supported long‑term capital efficiency.
Outcomes
Through consistent inspection cycles, data‑driven defect management and targeted engineering interventions, the program has significantly improved the reliability and predictability of the terminal’s structural assets. Early identification of issues has reduced the likelihood of unexpected failures, improved maintenance planning accuracy and supported safe operation of critical equipment. The client has benefited from extended asset life, reduced whole‑of‑life costs and greater confidence in compliance and operational resilience.
Lessons Learned
A sustained, systematic approach to structural integrity, combining modern testing technologies with experienced engineering judgement, yields substantial long‑term value for ageing industrial facilities. The success of this program demonstrates the importance of continuity: familiarity with site assets and consistent engineering oversight enables better decisions, faster interventions and more efficient use of maintenance resources.
Advitech’s structural and civil engineering specialists are ready to help asset owners strengthen their operational resilience. Contact the team to discuss tailored inspection, assessment and asset‑management solutions that support safe, sustainable and reliable operations.
