Client Engagement
Initial contact by phone or through digital channels. The team gathers the basic access requirement, site type, height, load and any known constraints before the next step is decided.
OUR SERVICES
Custom Design
Engineering-led design for access challenges that standard products do not cover, on-site assessment, 3D modelling and full AS/NZS compliance.
Service Overview
Engineering problems
Engineering problems
need engineered solutions.
Most access challenges on industrial and commercial sites have dimensions, heights or constraints that standard products do not cover directly. A stairway needs to fit between two pieces of fixed equipment. A platform has to reach a specific working height while clearing an overhead obstruction. A walkway has to span a set distance with limited ground support points. These are engineering problems, not catalogue problems, and they need to be resolved before anything gets built.
Star Aluminium has been designing access equipment since 1999. The process starts with direct client engagement, either by phone or on-site, to understand what the access requirement actually involves. Where the job warrants it, a site assessment is conducted to capture accurate measurements and identify any constraints that affect the design. From there, engineering drawings are produced using 3D modelling software, giving you a clear picture of the finished product before fabrication begins. Every design is checked against AS/NZS standards and WHS requirements before it moves to production.
ISO 9001:2015 certification covers the full design process, from initial brief through to approved drawings. This means the process is documented, reviewed and traceable at every stage. If your project involves a staged rollout, multiple configurations or a site that is still under construction, the design team can work around incomplete information and revise drawings as conditions are confirmed.
The Process
How the Design Process Works
From initial brief to approved drawings, four documented stages.
Site Assessment
For complex or custom projects, an on-site worksite analysis captures precise measurements and identifies conditions that affect the design. This step removes the guesswork from the engineering stage.
Engineering & Design
Project blueprints are produced using 3D modelling software. Drawings are reviewed for compliance with AS/NZS standards and WHS requirements before sign-off. Customer approval is required before fabrication starts.
Custom Configurations
Custom design covers non-standard heights, deck sizes, load ratings, surface finishes and mobility requirements. If the standard range does not cover your application, the design team will develop a solution that does.
Frequently Asked Questions
When does a project require custom design rather than standard products?
Custom design is needed when the standard product range does not match the site geometry, load requirement or compliance brief. Common triggers include non-standard platform heights, complex multi-level access structures, restricted installation envelopes and applications requiring purpose-built equipment for specific machinery or vehicles.
What does the custom design process involve?
The process runs from initial brief through on-site assessment, concept design, 3D modelling and engineering review to approved fabrication drawings. Each stage is documented and reviewed with the client before advancing. AS/NZS load calculations are performed before fabrication begins.
How long does the custom design phase take?
Design timelines depend on project complexity. Simple custom configurations can move from brief to approved drawings in 1 to 2 weeks. Complex multi-level or integrated access structures may require 4 to 6 weeks for the design and engineering review phase. A project-specific timeline is confirmed at briefing.
What compliance documentation is provided with a custom design?
Engineering calculations, drawings, material certifications and compliance certificates are provided as part of the project deliverables. Compliance plates are attached to all fabricated components where required by the relevant Australian Standard.
Can custom designs be replicated for fleet or multi-site deployments?
Yes. Once a custom design is approved and fabricated, the same design can be reproduced for fleet rollout or multi-site deployment. Approved drawings are retained and production can be restarted without redesign on repeat orders.