For more than 30 years, Alliance Engineering Consultants (AEC) has forged a reputation across Australia as a trusted name in solving some of the most complex lifting and structural engineering challenges.
With a team of highly skilled professionals and a track record that spans the oil and gas, mining, local government and construction sectors, the Perth-based consultancy is known for its inventive and practical engineering approach.
AEC’s ethos is straightforward: bring a “can-do” attitude to every project, no matter how daunting the conditions. Whether it involves decommissioning structurally compromised equipment, navigating constraints like confined spaces or no-hot-work zones, or preventing workplace hazards, AEC consistently delivers custom engineering solutions.
The following three examples from the past year exemplify the expertise, each showcasing how Alliance Engineering’s specialist team translated problems into practical, safe, and cost-effective outcomes.
Lifting the unliftable
One of AEC’s notable projects involved removing a severely corroded and structurally condemned container from an offshore gas facility. The project’s complexity was heightened by operational constraints: no hot work allowed, limited crane availability, and minimal offshore manpower due to bed space and other critical tasks.
Lead Structural Engineer Steve Keating was tasked with solving the issue. Drawing inspiration from both anatomy and architecture – specifically, the human skeleton and the internal structure of the Statue of Liberty – Steve proposed designing a lightweight internal skeleton for the container. This internal frame would take the load during lifting, compensating for the compromised structural integrity of the container’s corroded walls.
AEC used 3D laser scanning and local non-destructive testing (NDT) data to identify points on the container with sufficient thickness of steel. The lightweight frame was designed with bolted connections, eliminating the need for welding. All assembly work was done internally, avoiding costly external scaffolding and ‘Working at Height’ risks.
Further complicating the job was the need to calculate the combined centre of gravity of the container and frame to prevent lifting instability. Once complete, the container was safely hoisted and loaded into a rated offshore container for backload to shore.
The successful lift was achieved with minimal offshore crew intervention and received high praise from the operations team. Removing or relocating the ‘unliftable’ is where AEC thrives.
Assessing dropped object risk
In another recent job, AEC was urgently brought in to assess the risk posed by corroded steel elements falling from a 30-metre-high tower onto a covered walkway below. With operations ongoing, there was an immediate need to understand the risk and determine what protective actions might be required.
Senior Engineer Matt Kazazi led the analysis, conducting finite element analysis (FEA) using SolidWorks Premium, a 3D design tool, to simulate the impact of falling debris. Close-up imagery using drones was used to map the trajectory and potential impact points, which revealed that objects falling from above 17 metres could possibly perforate the stainless-steel canopy.
To validate the simulation, drop tests were conducted over a weekend by Matt, Yasmin Santana, and Mike Hubble. These physical tests confirmed that perforation occurred at higher elevations, and a fail-safe height threshold was established. As a result, a mobile trolley system was developed to safely contain or deflect debris that might occur from 20 metres or above.
This combined theoretical and physical validation allowed the client to avoid a blanket restriction on operations, keeping work on schedule while ensuring personnel safety. It also added valuable real-world data to AEC’s expanding knowledge base. AEC encourages the practice of proving the theoretical with physical tests.
Structural surprises on rail bridges
Alliance Engineering was also engaged by a construction firm to laser-scan a pair of rail bridges in Perth. The goal was to verify whether the proposed new access-way design – prepared by another party – aligned with the actual as-built status of the structures.
Lead Designer Mike Hubble led the project, conducting detailed 3D laser scans despite operational limitations such as restricted access and a narrow night-time work window due to active rail services. Underdeck scanning required boat travel to each pier location, adding logistical complexity.
The scans revealed significant level differences from pier to pier and across the tracks – details not reflected in the original plans.
This information not only helped avoid major design clashes but also enabled quick adjustments to the proposed structures, including walkways, grating panels, handrails, ramps and additional bracing.
The survey also helped fabricate numerous structural elements and grating panels with precision, based on the actual site geometry. One not surprising outcome was the determination that levels were considerably different from pier to pier. This insight was shared with the asset managers for future remediation planning.
The client praised Hubble’s meticulous work, noting the importance of verifying assumptions when working with legacy structures. The project ultimately demonstrated how advanced scanning technology can reduce costly errors and enable faster, more accurate fabrication.
These three examples highlight what Alliance Engineering does best – deploying technical expertise and creative problem-solving to engineer safe, efficient, and practical solutions under pressure.
Whether it’s working offshore under tight restrictions, managing risk on critical infrastructure, or delivering pinpoint accuracy in structural fabrication, AEC brings deep industry experience and a sharp eye for detail to every job.