Hanson Sand Quarry

Introduction

Incon was engaged to undertake a structural inspection of fixed plant infrastructure at the Hanson Sand Quarry located in Golden Grove, South Australia. The engagement focused on performing a routine (minor) inspection of operational plant structures to assess their condition, identify potential deterioration, and ensure ongoing structural integrity. The inspection formed part of Hanson’s asset maintenance and risk management framework.

Project
description

The project involved a visual structural inspection of quarry fixed plant and associated infrastructure, including:

Conveyors, crushers, and processing equipment
Silos, surge bins, and storage systems
Structural steel elements (columns, beams, bracing)
Access systems (walkways, ladders, stairs)
Foundations, base plates, and connections
Ancillary structures including workshops and site buildings

The inspection followed a structured checklist aligned with industry inspection standards.

Challenge

The quarry environment included heavy machinery, vibration-prone equipment, and exposure to dust, moisture, and abrasive materials, all of which accelerate structural wear.
Inspection of elevated and confined components such as silos, conveyors, and overhead bins required careful planning and safe access considerations.
Key risks identified in quarry environments include:

Corrosion of steel members and connections
Wear and fatigue in vibrating equipment supports
Deterioration of protective coatings

Inspections needed to be conducted efficiently without impacting ongoing quarry operations.

Solution

Incon delivered a systematic and engineering-driven inspection approach:

Utilised a structured checklist covering all critical components, including:

Structural members (beams, bracing, welds, bolts)
Vertical supports and foundations
Access systems compliant with safety standards (e.g. handrails, ladders)
Plant elements such as bins, silos, and mechanical supports

Each element was assessed for:

Corrosion and coating condition
Structural integrity and deformation
Connection performance (bolts, welds, plates)
Suitability for operational loads (including vibration effects)

Provided clear, actionable observations to guide maintenance, repair, or further detailed investigation where required.

Key Engineering Value Delivered

Systematic inspection aligned with industry best practice
Early-stage defect identification reducing lifecycle costs
Practical, actionable recommendations for site teams
Minimal disruption to live quarry operations

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