Real work, real outcomes.
What the problem was, what was done, and what the result was. Filter by type below.
260t Block — Weld Connection Risk
SPMT acceleration introduced lateral loads not accounted for on a tack-welded HSS-to-keel connection, with personnel nearby during extraction.
Two 6-axle SPMTs extracting a 260t block. Lateral loads from acceleration not in the original design.
FEA + first-principles weld calc. 0.05g acceleration limit recommended. P.Eng approved — risk eliminated.
FEA Peer Review — Non-Physical Loads
A 10-lug equalizer lift model produced unequal load distribution despite being designed to share load evenly.
Lug connections modelled with fixed constraints instead of RBE3 elements, creating artificial stiffness.
Corrected model, verified with freebody diagrams. Authored a company-wide FEA guide on RBE3 usage.
80t Workstation — Structural vs Transport
A pin jig layout concentrated heavy loads exactly where SPMT access needed to stay clear — a direct conflict.
Non-uniform geometry overloaded existing jigs in the SPMT zone. Block also found outside crane reach.
Jack stands aligned to bulkheads resolved the overload. Block relocation avoided rework and delay.
Lift Bracing Redesign — 60% Reduction
A bracing design not guided by structural load paths required excessive material and welding.
Bracing distributed uniformly rather than along primary load paths — unnecessary fabrication complexity.
FEA-guided redistribution cut bracing by ~60%. Weld geometry simplified, integrity FEA-verified.
Filter Drum: 6 Months → 12+ Years
An industrial filter drum fractured at critical locations after only 6 months of service.
Recurring fractures, root cause unknown. Client needed a long-term fix without full replacement.
FEA identified fatigue as root cause. Load path redesign extended service life to 12+ years.
Full Keel Block — All Fabrication Stages
A full-breadth keel block required engineering input across extraction, transport, blocking, and lifting.
Fabricated lug plate found thinner than specified during lift plan development.
FEA confirmed adequacy under straight-lift conditions only — documented and executed safely.
Technical work, shown in detail.
Worked FEA examples — the model, the analysis, and what the results actually mean. Each opens as a full walkthrough.
Selected project highlights
Ship Block Heavy Lift & Transport
FEA-based structural verification for lifting, rotation, transport, and workstation support of ship block assemblies up to 250t, including blocks for a Canadian Coast Guard vessel program.
3000t Lifting Connector
Performed structural FEA and contributed to detail engineering of a 3000-tonne hydraulic lifting connector for offshore pile installation, through to DNV-approved construction documentation.
Monopile Gripper
Contributed to structural analysis and detail engineering of a custom offshore lifting tool for monopile installation, through to Lloyd's Register-approved construction drawings.
Loading Towers & Carousels
Structural analysis and sea fastening calculations for cable-lay loading towers and carousels, including detailed ship deck FE models for underdeck stress verification.
Filter Drum Fatigue Redesign
Failure investigation and structural redesign of an industrial filter drum fracturing after 6 months of service — fatigue life extended to 12+ years.