Finite Element Modelling: Structural–Mechanical Analysis of Piling Rigs, Attachments, and High-Load Interfaces

Client context
A specialist contractor operating large rotary piling rigs with custom mechanical attachments, operating close to equipment limits.

Engineering challenges

• High torsional, axial, and bending loads transmitted through rig attachments

• Fatigue and wear risks under repetitive duty cycles

• Uncertainty around load paths between rig, attachment, and ground

• Need to demonstrate mechanical integrity to OEMs and H&S stakeholders

What we did

• FEA of attachment frames, pins, bolted joints, and welded details

• Load-case derivation based on real operating envelopes and duty cycles

• Fatigue screening for critical details under cyclic operation

• Independent mechanical verification report suitable for OEM and insurer review

Outcome

• Delivered a clear understanding of true mechanical capacity and limiting components

• Early identification of stress concentrations and targeted reinforcement solutions

• Extended asset life and reduced unplanned downtime

• Strengthened safety case for continued operation