Plant Layouts, Structural Design & Process Modeling
Engineering grounded in field reality, not just CAD.
Drawings only matter if the steel fits when the crane shows up. The TSS Group engineering group designs aggregate facilities the way our field crews build them, dimensioned, sequenced, and practical for real-world operations. We blend structural integrity with process optimization so your crushing, screening, washing, and conveying systems operate at peak efficiency from day one.
- Fabrication and erection drawing packages
- Equipment selection and capacity modeling
- Plant layout and process flow design
- Structural analysis of towers, platforms and supports
Design services for the aggregate industry
We model the circuit before we cut steel, feed rates, product sizes, transfer points and surge capacity, then design the structure that supports it. Deliverables include general arrangement drawings, structural details, foundation loading, and shop-ready fabrication packages.
- Chute, hopper and transfer point design
- As-built documentation and plant upgrade studies
- General arrangement and plant layout drawings
- Crushing and screening circuit flow sheets
- Structural design, load calculations and foundation loading
Why Aggregate Producers Choose TSS Engineering
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Turn-Key Handoff:
Seamless transition from CAD models and PE-stamped drawings to our in-house fabrication shop and field installation crews. -
Licensed & Experienced:
Combined decades of aggregate, quarrying, mining, and heavy industrial engineering experience across the Mid-Atlantic and Southeast.
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Field-Tested Engineering:
Designed by engineers who work alongside millwrights and riggers, eliminating constructability issues before fabrication begins. -
Process-Driven Design:
Tailored to maximize TPH, minimize wear at transfer points, and eliminate material bottlenecks across your entire circuit.
Complete Plant Engineering Process
We design circuits around your exact geology, target gradation, and site constraints, modeling every transfer point, load distribution, and surge node before cutting a single piece of steel.
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Structural Design & FEA:
Structural analysis, load calculations, and foundation loading packages engineered to withstand extreme vibration and heavy impact. -
Detailing & Fabrication Sets:
Shop-ready fabrication drawings, bill of materials (BOM), and phased erection drawing packages for seamless field assembly.
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Site Assessment & Scanning:
3D laser scanning and site walks to verify existing plant geometry, foundation points, and spatial limits. -
Circuit & Flow Modeling:
Capacity modeling to match crushing, screening, and washing equipment to your target tonnage requirements.
Core Engineering & Technical Capabilities
| Service Area | Deliverables & Capabilities |
| Plant Layout & Flow Sheets | General Arrangement (GA) drawings, 2D/3D plant layouts, process flow diagrams (PFD), and aggregate circuit mass-balance modeling. |
| Structural Design & Steel | Structural analysis for crusher towers, screening decks, transfer stations, conveyor trusses, access walkways, and PE-stamped foundation loads. |
| Chute & Transfer Point Design | Custom rock box design, heavy plate chutes, dead-bed setups, wear liner configuration, and dust containment enclosures. |
| Mining & Geologic Services | Reserve estimation, geologic 3D modeling, mine planning, pit optimization, geotechnical review, and M&A due diligence. |
Technical and mining services
Through our expanded technical services group of professional mining engineers and geologists, six decades of combined experience, we also support geologic modeling, reserves calculations, mine planning, fleet and CAPEX planning, pit optimization, geotechnical review and M&A due diligence.
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Mine Planning & Pit Optimization:
Phased extraction plans, overburden stripping ratios, haul road routing, and bench design to lower mobile equipment costs. -
Geologic Modeling & Reserves:
Core sample evaluation, deposit modeling, and mineral reserve calculations to support long-term CAPEX investments.
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Fleet & CAPEX Planning:
Mobile equipment sizing, haulage cycle calculations, and capital expenditure forecasting for plant retrofits and expansions. M&A -
Due Diligence:
Operational audits, reserve verification, and structural/mechanical asset evaluations for aggregate acquisitions.
Proven Engineering for High-Tonnage Operations
Our engineering group has delivered actionable drawing packages and mining evaluations for leading producers, including CRH, Martin Marietta, and Vulcan Materials.
Featured Engineering Projects:
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Mine Plan:
Executed full geologic deposit modeling and 20-year pit development planning for a greenfield granite quarry operation.
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Circuit Expansion Modeling:
Redesigned a 750 TPH tertiary crushing and screening circuit to increase sub-base production while reducing recirculating loads by 18%.
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3D Laser Scan & Structural Retrofit:
Scanned an aging wash plant structure to engineer a drop-in screen deck replacement without disrupting existing support piers. Quarry Reserve &
Frequently asked QUESTIONS
How does TSS ensure engineering drawings are buildable in the field?
Our design engineers work directly with our shop fabricators and field millwrights during the drafting phase. By incorporating 3D laser scanning and field constructability reviews, we catch bolt-pattern conflicts, crane clearance issues, and structural interference on screen before steel reaches the job site.
Do you provide PE-stamped engineering drawing packages?
Yes. We deliver fully stamped engineering drawing packages, including structural steel design, foundation load calculations, and equipment support details, compliant with state and local building codes across our operational footprint.
Can TSS engineer upgrades for an existing plant without original blue prints?
Yes. Using high-precision 3D laser scanning technology, we generate accurate point-cloud models of your existing plant, structural steel, and foundations. This allows us to engineer custom chutes, retrofits, and equipment swaps that fit existing structural interfaces perfectly.
What software tools do you use for circuit modeling and structural engineering?
We utilize industry-standard CAD, 3D modeling, and structural analysis software alongside specialized mineral processing and mass-balance modeling tools to simulate flow rates, material trajectories, and dynamic equipment vibration.
What is included in your mining and geologic advisory services?
Our team of professional mining engineers and geologists handles geologic modeling, core sample evaluations, verified reserve calculations, long-term mine planning, pit optimization, haulage fleet sizing, and technical due diligence for asset acquisitions.
