Barair Systems Limited supported Stortec Engineering with finite element analysis, independent mechanical design review and CE/UKCA technical-file support for specialist scraper bridge equipment used in water and wastewater treatment applications.
The project brought together Barair’s independent mechanical engineering capability and Stortec’s practical expertise in specialist fabricated equipment for the water industry.
Project Overview
Stortec Engineering required independent engineering support for a specialist scraper bridge system. The equipment operates in a demanding process environment where structural integrity, reliable operation, safe access, appropriate guarding, drive-system performance and clear technical documentation are all important.
Barair’s role was to provide finite element analysis, structural assessment, independent design review and support for the CE/UKCA technical-file pathway.
The aim was to strengthen the engineering evidence behind the design and provide a more complete technical record for design assurance and compliance purposes.
The Engineering Challenge
Although scraper bridge equipment typically operates at low speed, the mechanical system must still be reviewed carefully. The structure has to transfer operational loads into its supports, accommodate drive-system forces, maintain adequate stiffness, and perform reliably in a water or wastewater treatment environment.
The review needed to consider:
- Structural stress and deflection.
- Load paths through the fabricated assembly.
- Support reactions and anchorage implications.
- Drive-system loading and torque effects.
- Local stress concentrations around key interfaces.
- Material assumptions and fabrication details.
- Access, maintenance and machinery safety considerations.
- Technical evidence required for CE and UKCA documentation.
The project required practical engineering judgement as well as numerical analysis. Barair therefore treated the finite element analysis as part of a wider engineering review rather than as a standalone software exercise.
FEA Work Undertaken
Finite element analysis formed a central part of Barair’s work.
The FEA was used to assess the structural behaviour of the scraper bridge assembly under representative loading conditions. The analysis helped identify how loads were transferred through the structure, where higher stress regions were likely to occur, how the assembly deflected under load, and what support reactions were generated.
The FEA work included:
- Review and preparation of the supplied design geometry.
- Development of a practical engineering analysis model.
- Identification of appropriate modelling simplifications.
- Definition of representative load cases.
- Application of support conditions and constraints.
- Review of material assumptions.
- Assessment of stress distribution.
- Assessment of deflection and stiffness behaviour.
- Interpretation of load paths and support reactions.
- Identification of areas requiring further confirmation, design review or supporting evidence.
Where appropriate, the FEA results were considered alongside engineering judgement and supporting hand-calculation checks. This helped ensure that the analysis remained grounded in practical mechanical engineering rather than relying solely on software output.
Why the FEA Was Important
The finite element analysis provided an engineering basis for understanding how the scraper bridge structure behaved as an assembly.
For specialist fabricated machinery, this is particularly valuable because loads can pass through the structure in ways that are not always obvious from drawings alone. FEA helped Barair and Stortec review the relationship between geometry, stiffness, support conditions, local detail and overall structural performance.
The FEA supported:
- Structural design assurance.
- Review of stress distribution.
- Review of deflection behaviour.
- Understanding of load paths.
- Assessment of support reactions.
- Identification of local design sensitivities.
- Technical-file evidence.
- Machinery safety and risk assessment review.
- More informed technical discussion.
- A clearer engineering record.
The analysis provided Stortec with useful engineering insight rather than a simple pass/fail result.
Independent Engineering Review
Alongside the FEA, Barair provided an independent mechanical engineering review of the scraper bridge system.
This included consideration of structural performance, drive loading, installation requirements, access and maintenance, guarding considerations, residual risk, and the information required to support CE and UKCA compliance documentation.
Barair’s role was to strengthen the design record by providing independent analysis, review and professional engineering judgement. Stortec retained ownership of the product design, while Barair provided external engineering assurance and technical-file support.
Collaboration with Stortec Engineering
Stortec Engineering were professional, constructive and technically engaged throughout the project.
The Stortec team brought valuable knowledge of fabricated water industry equipment, practical site conditions, customer expectations and manufacturing constraints. This helped ensure that the analysis and design review were relevant to real equipment and real operating environments.
The collaboration worked well because both companies brought complementary strengths. Stortec provided the product knowledge, fabrication experience and sector understanding. Barair provided independent FEA capability, mechanical design review, structural assessment and compliance documentation support.
Outcome
The project produced a stronger engineering evidence base for the scraper bridge system.
The work helped Stortec to:
- Understand the structural behaviour of the equipment under representative loading.
- Review stress and deflection characteristics.
- Interpret support reactions and load paths.
- Strengthen the technical basis for the design.
- Improve the CE/UKCA technical-file structure.
- Record assumptions, design considerations and outstanding actions.
- Support machinery safety and risk assessment review.
- Improve confidence in the design assurance process.
- Present the project in a clearer technical format.
The result was a more complete engineering record supported by finite element analysis, practical design review and professional documentation.
Recommendation
Barair Systems Limited would be pleased to recommend Stortec Engineering as a professional and capable engineering company with strong experience in specialist fabricated equipment for the water and wastewater treatment sector. Stortec demonstrated practical engineering knowledge, openness to independent review and a clear commitment to strengthening the technical evidence behind its products.
