Diagnostics & Mechanical Failure Investigations
Led by Paul Schmitz MBA CEng MIMechE MIoA, we investigate mechanical and structural failures, near-misses, and non-conformances to determine why designs don’t meet their intended standards-and how to correct them. We combine evidence-preserving site work with targeted tests (vibration, strain, modal), FEA/EMA correlation, and standards-based analysis to produce defensible root-cause findings and practical, validated fixes.
What we solve
Fatigue cracking, fastener pull-out, fretting, wear, unexpected plastic deformation.
Resonance-driven failures, excessive vibration (ISO 20816/7919), dynamic amplification, instability.
Buckling, deflection, stiffness shortfalls in frames, skids, plinths, pipework, and supports.
Thermal/pressure cycles, pulsation, flow-induced vibration, start/stop and surge transients.
Manufacturing/assembly deviations, tolerance stack-ups, installation or maintenance errors.
Standards non-conformance (BS/EN/ISO/API clauses), warranty/acceptance test failures.
Methodology (forensic & standards-driven)
Preserve & Document - evidence control, photos, measurements, witness notes, service history, duty cycles.
Test & Measure - FFT/ODS/modal testing, strain gauging, FRFs, metrology; optional NDT, hardness, materials checks.
Analyse - root-cause tree (5-Why/FMEA), FEA/EMA correlation, load-case reconstruction, tolerance analysis, and compliance gap vs applicable standards (e.g., ISO 20816/7919, BS 7608 fatigue, Eurocodes/BS EN, API; BS 4142/BS 8233 for noise-related issues).
Design & Verify - corrective actions (isolation/damping, dynamic stiffening, redesign, materials/fasteners/spec changes) with acceptance criteria and validation testing.
Support - commissioning, sign-off evidence packs, and ongoing monitoring to prove durability and compliance.
Deliverables
Forensic root-cause report suitable for insurers, legal teams, and stakeholders (clear chain of evidence).
Compliance mapping: what failed vs which clause/limit-and the quantified path to conformity.
Redesign package: drawings/specs, change notes, materials/fasteners, installation procedures.
Validation dossier: before/after data (plots, strains, FRFs), acceptance criteria, sign-off statement.
Why Environmentally Sound
Experience: 29 years across vibration, mechanical design, and structural dynamics; hundreds of measurement-led investigations.
Credentials: Chartered Engineer (CEng MIMechE MIoA), MBA; accreditations include Constructionline Gold, SSIP, Achilles UVDB.
Evidence-first: Measurement → analysis → redesign → verification. Decisions backed by data, not opinions.
Confidentiality: IP safeguarded; NDAs available for sensitive matters.
Scope note: This is an engineering failure-investigation and corrective-design service. Expert-witness testimony can be arranged under a separate instruction if required.
Illustrative outcomes
API 619 compressor skid resonance
Problem: blade-pass resonance; ISO 20816 at Alert. Action: ODS/FRF testing, FEA/EMA correlation, tuned stiffening + damping. Result: levels reduced to Acceptable; pass at re-test.
Cleanroom plinths (VC-C)
Problem: floor-borne vibration exceeding VC-C. Action: ground vibration survey, isolation retrofit, operational changes. Result: compliance to VC-C with margin.
HVAC rooftop plant (BS 4142)
Problem: rating difference >5 dB at receptor. Action: resilient mounts, dynamic bracing, louvre spec. Result: rating difference reduced; condition discharged.
Related services
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FAQ: Our design passed FEA-why did it still fail?
Common gaps include unmodelled boundary conditions, real-world damping/stiffness, manufacturing tolerances, preload loss, or unanticipated transients. We correlate FEA with test (EMA/ODS/strain) to close that gap.
FAQ: Can you help when acceptance tests fail?
Yes-rapid triage, root cause, corrective action plan, and re-test criteria aligned to the governing standard so you can achieve sign-off.
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