Engineering Archives - Hawkins Forensic Investigation

Hawkins Hosts Annual Spring Drinks Reception at The Whitworth Gallery

Chloe Duggan — Thu, 02 Apr 2026 13:18:02 +0000

Hawkins welcomed clients, colleagues, and industry professionals to our annual Spring Drinks Reception at The Whitworth Gallery in Manchester, bringing together guests for an evening of forensic insight, professional development, and networking.

Attendees were greeted with refreshments on arrival before settling in for a CILA accredited CPD presentation delivered by Hawkins’ sexperts and a guest speakers. Marketing Director and Chartered Civil Engineer Andrew Reeves opened the evening with an update on recent developments across the business, including:

Hawkins’ continued global expansion into Abu Dhabi, South Africa and Italy
The successful acquisition of A. Lamb Associates and Morham + Brotchie Partnership, strengthening our quantum and delay expertise
The expansion of Hawkins’ multidisciplinary team, now over 150 forensic experts supporting clients across more than 70 specialist disciplines

Forensic CPD: From Collapse to Cleanup

Our CPD presentation, From Collapse to Cleanup, guided attendees through a real-world, multidisciplinary forensic investigation. The session explored the structural failure and collapse of a racking system, followed by the clean‑up of potentially hazardous materials. It also examined a related personal injury incident involving a slip on a wet surface during remediation.

Presenters included Hawkins experts George Jackson, Claire Mann, and Ian Tatner, and quantum expert, Nigel Jackson of ALA , supported by guest contributor Mike Clementson of Claims Care Consultants

Interactive Exhibits & Networking

Following the presentation, guests enjoyed a networking reception with flowing drinks and canapés. Attendees explored a series of real-life casework exhibits, immersed themselves in a VR fire investigation experience, and took part in interactive demonstrations – including the popular “guess the accelerant” scent challenge and hands-on use of the pendulum slip-resistance tester featured in the presentation.

Hawkins extends its thanks to everyone who attended and contributed to the success of the evening. Information about future events can be found here.

Thank you to everyone who joined us. Details of our upcoming events can be found here.

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A Structure is Only as Strong as its Weakest Link

Matthew Carrington — Mon, 09 Mar 2026 15:41:10 +0000

Construction projects of all kinds, over a wide range of scale, require structural engineering design input to direct the way they are built. The structural engineering design is almost always implemented in conjunction with architectural design, other specialisms, and the knowledge and skills of the contractor and specialist sub-contractors.

Civil and structural engineering design is a complex field where many engineers are highly qualified, with professional accreditations from engineering institutions after several years of industry experience, following a university degree. However, there is no safeguard against less qualified or less experienced people also trading as civil or structural engineers.

This article discusses the typical aspects of structural engineering design that are required in most construction projects. It includes case studies investigated by Hawkins, where the action of the structural engineering designer could be at fault.

“The strength of a structure depends on the strength of its elements and the way they are joined together.” – Gustave Eiffel

Weak Links

Some building faults might be related to issues with the structural engineering design, or omissions in it. Others may be due to the actions of other parties in the design or construction team, or faulty materials. The design process for each project must consider all the potential modes of failure of the structure. Any one thing could be missed in the design process and cause an issue with the performance of a building. Sometimes, a combination of circumstances needs to coincide to cause a failure. Almost every construction project is a prototype due to the varying combinations of building shape, location and formation of the team performing the work. The following sections describe five links in the structural engineering design chain.

1. Design Issues

It is possible for a structural engineer to completely design the strength and stiffness of the individual elements for the structure but miss a wider issue that can lead to damage or failure.

For example:

The lateral sway stability of part of a building can be reduced by replacing the vertical support from a solid masonry wall with a steel beam;
Loads on a gravity retaining wall at a change of level of external ground that were not allowed for in the design can occur if drainage is not detailed (Figure 2);
Overall structural capacity can be exceeded if a whole category of loading is omitted, such as wind or snow load.

2. Site Issues

There are cases where the design might have considered the typical scenario for the type of structure they designed, but there was something different on site that they did not allow for.

For instance:

If a designer assumed that a wall was a cavity brick/block wall, when it was in fact a solid stone wall, then the wall would be heavier than assumed. A beam installed to create an opening and support the wall could then be overloaded;
A wall that was retaining higher ground could collapse if the rest of the building that was providing lateral support to the wall was removed without considering the interaction (Figure 3);
The effect of a row of small trees on building foundations movement can be greater than the individual trees;
Different ground conditions can have more or less aggressive reactions to the concrete they are in contact with. The wrong mix of concrete might look suitable initially, but in aggressive ground conditions, it can degrade over time.

3. Calculations

Sometimes, the structural designer can miscalculate their designs.

Examples might include:

An assumed length of a beam was not updated in the design calculation when the length of the opening was longer than first planned;
In a structural assessment, the engineer might have used the material properties for normal density concrete when the element was lightweight or aerated concrete, which can only provide lower strengths;
In computer aided design, using finite-element modelling or calculation sheets prepared by a software company, the wrong input for the situation being built can lead to an understrength member. This might arise from one wrong tick in a box within the software options.

4. Stages of Design

There have been cases where the structural engineer provided sufficient design information for a preliminary stage of the design, such as submission to building control, to gain approval for the project to proceed. Then, the client or contractor did not go back to the engineer to ask for detailed design and construction details, or did not correctly apply the submitted preliminary design.

These cases have included:

Where relative positioning between structural members and their supports was critical to the building performance, but the individual member capacity design was sufficient to pass the building control plans check;
Where the order of construction would be critical to the capacity of the structural members. During construction, an unrestrained steel beam would have considerably less capacity to carry vertical loads until it was restrained by the floors to both sides (Figure 4);
Often, changes that appear to make the building simpler to construct can introduce complications to the way they would perform. The changes would need further structural design and could cause a problem if the designer had not been notified.

5. Missing Design

We have investigated cases where an item was overlooked as needing civil or structural engineering design. This can occur at interfaces between specialist contractors’ responsibilities:

i. Roof vents (Figure 5);
ii. Cladding boards (Figure 6).

These will likely perform satisfactorily in normal conditions but might not be sufficient for high winds or rain. This would likely present in the failure of several of the same items. Identifying the fault early might allow the rest of the items to be remediated.

Failures can exhibit a range of states of distress and at different times in the life cycle of a building.

The questions which must be considered when investigating the root cause of the failure will vary with the scenario, including:

Was the designer provided all the necessary and correct information?
Should the designer have found out the correct information by looking into the situation more than relying on drawing or reports they were provided?
Was there information that the designer needed to show in more detail to a competent contractor?
Was there a coordination responsibility to make sure the correct information was provided?
Should a competent contractor have given feedback to the designer that the situation was not as allowed for in the design?
Did the client appointment limit how much the designer could do in any of these aspects?

In some cases, we have been able to advise that urgent action needed to be taken to avoid further damage occurring. This can save people spending time in a position of danger looking for material damage or conducting intrusive investigations that might tip the situation further towards collapse.

“The best design is the simplest one that works”. – Albert Einstein

Conclusions

Sufficient structural engineering design relies on considering all the relevant design issues and all the particular conditions on the site. The structural engineer must complete the design calculations correctly and present the construction information clearly to the contractor. Greater levels of detail are required for the construction issue of the structural drawings than for the building control submission. That is a situation where misunderstandings can arise. Also, there are proprietary and peripheral items related to construction that might not be part of the scope of a structural engineering appointment but would have benefitted from a review by a structural engineer.

How can Hawkins Help?

Hawkins’ Built Environment team can review when something has gone wrong and assess the relevant specialism or party that might have contributed to the issue. Professional experience is important in engineering, including experience of investigation.

About the Author

Jolyon Antill is a Chartered Civil Engineer based in our Reigate office. Graduating with a first-class Master’s Degree in Civil and Structural Engineering, Jolyon has 27 years of design consultancy experience.

His range of industrial and commercial project design work includes new builds, renovations, and structural surveys, both in the UK and overseas. Jolyon also has extensive experience in regional civil and structural engineering consultancies working on educational, residential, leisure and commercial projects. If you have a civil or structural issue and need Jolyon or one of the team to investigate, please contact us.

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Hawkins International Webinar Series

Chloe Duggan — Thu, 26 Feb 2026 15:53:49 +0000

From April to June 2026, join experts from across Hawkins as they host our International Webinar Series, featuring specialists from our global office locations.

This series covers a wide range of topics, including material and mechanical failures, lithium‑ion batteries, bridge forensics, bolted connection failures, and risk in indoor climbing.

For webinar details and to register, please see below.

If you would like further information on each webinar before registering, simply click on the titles. Our events page provides details of other Hawkins events that you may find of interest.

Forensic Investigation of Materials and Mechanical Failures in MENA

Presented by Dr Tom Peat

Thursday 16th April 2026 at 9.30am BST

Mechanical Engineer Dr Tom Peat will explore Hawkins’ forensic investigation capabilities across the Middle East and North Africa, with a particular focus on materials and mechanical failures relevant to legal disputes and insurance claims. He will outline how metallurgical analysis, failure reconstruction, and engineering forensics are applied to determine causation and support liability assessments within the energy, infrastructure, and industrial sectors.

An Introduction to Bridge Forensics

Presented by Eng Phin

Thursday 30th April 2026 at 9.30am BST

In this webinar, Structural Engineer Eng Phin introduces the fundamentals of bridge forensics, with a focus on pre‑stressed concrete (PSC) bridges – one of the most common bridge types in Hong Kong and worldwide. The session covers key topics including structural systems, failure modes, and common investigation techniques.

A Bolt From the Blue: Why Bolted Connections Can Unexpectedly Fail

Presented by Patrick Walsh

Thursday 14th May 2026 at 9.30am BST

Civil Engineer Patrick Walsh will examine the most frequent design and installation errors in bolted connections that can lead to unexpected failures. The session will highlight how issues such as incorrect surface preparation, improper bolt pre‑tensioning, and misunderstandings of bolt behaviour can significantly increase the risk of structural failure.

Lithium Ion Batteries: Chemistries, Failures and Fire

Presented by David Reid Rowland

Thursday 28th May 2026 at 9.30am BST

In this webinar, mechanical engineer and forensic expert David Reid Rowland draws on two decades of investigative experience to demystify how lithium ion batteries work, why they fail, and what makes their fires so destructive and difficult to extinguish. He also explores real-world examples involving consumer products, marine cargo, and electric vehicles, highlighting the importance of regulation, protective systems, and safe handling practices.

Forensic Insights: Uncovering Failures in Mechanical Systems

Presented by Albert Law

Thursday 11th June 2026 at 9.30am BST

In this webinar, Mechanical Engineer Albert Law explores the forensic engineering approach applied to mechanical systems such as air‑conditioning units, pumping systems, fans, and other mechanical equipment. Attendees will gain an understanding of how mechanical failures are investigated, the methodologies used to identify root causes, and the role of forensic analysis in improving system reliability and safety.

Climbing: Lets Tie in & Consider the Risks

Presented by Jason Buchwitz

Thursday 25th June 2026 at 9.30am BST

In this presentation, Materials Engineer Jason Buchwitz will explore the construction and characteristics of indoor climbing walls, review trends in climbing-related accidents, and examine existing risk reduction measures, while considering which risks are unavoidable elements of the sport.

We look forward to presenting to you.

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Forensic Investigation of Materials & Mechanical Failures in MENA

Chloe Duggan — Tue, 24 Feb 2026 14:52:44 +0000

In this presentation, Mechanical Engineer Dr Tom Peat will explore Hawkins’ forensic investigation capabilities across the Middle East and North Africa, with a particular focus on materials and mechanical failures relevant to legal disputes and insurance claims.

He will outline how metallurgical analysis, failure reconstruction, and engineering forensics are applied to determine causation and support liability assessments within the energy, infrastructure, and industrial sectors.

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An Introduction to Bridge Forensics

Chloe Duggan — Tue, 24 Feb 2026 14:52:18 +0000

Bridges are designed for long service lives, often 100 to 120 years, and must remain safe and reliable throughout their lifespan. While a bridge may appear to be a straightforward structure enabling transportation, its performance has a direct impact on economic activity and the daily lives of the communities that rely on it. At the same time, bridges are frequently located in challenging environments and subjected to heavy loading, both of which can accelerate deterioration.

In this webinar, Structural Engineer Eng Phin introduces the fundamentals of bridge forensics, with a particular focus on Pre‑Stressed Concrete (PSC) bridges – one of the most common bridge types in Hong Kong and around the world. The session covers key topics including structural systems, typical failure modes, and widely used investigation techniques.

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A Bolt From The Blue: Why Bolted Connections Can Unexpectedly Fail

Chloe Duggan — Tue, 24 Feb 2026 14:51:44 +0000

Bolted connections are one of the most common points of root‑cause failure in steel structures. Although the overall strength and reliability of a steel structure depend heavily on the performance of its connections, these critical details are often treated as secondary and may receive limited attention during design.

In this webinar, Civil Engineer Patrick Walsh will examine the most frequent design and installation errors in bolted connections that can lead to unexpected failures. The session will highlight how issues such as improper bolt pre‑tensioning, incorrect surface preparation, and misunderstandings of bolt behaviour can all significantly increase the risk of structural failure.

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Forensic Insights: Uncovering Failures in Mechanical Systems

Chloe Duggan — Tue, 24 Feb 2026 14:50:45 +0000

In this webinar, Mechanical Engineer Albert Law explores the forensic engineering approach applied to mechanical systems such as air‑conditioning units, pumping systems, fans, and other mechanical equipment. You will gain an understanding of how mechanical failures are investigated, the methodologies used to identify root causes, and the role of forensic analysis in improving system reliability and safety.

The session will highlight common failure modes, key diagnostic techniques, and lessons learned from real‑world cases. This presentation will introduce the fundamentals of mechanical breakdowns and demonstrate how informed design and maintenance practices can help prevent future incidents.

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Stefano De Rosa

Kirsten Beckwith — Mon, 09 Feb 2026 14:56:57 +0000

Stefano si è laureato in Ingegneria Chimica con lode all’ Università degli Studi di Napoli Federico II sia alla triennale che alla magistrale. Poi ha fatto un dottorato in Ingegneria dei Prodotti e Processi Industriali presso la stessa università con una tesi in fluidodinamica computazionale (CFD). Ha ottenuto il titolo di dottore di ricerca nel 2025.

Durante il suo dottorato, Stefano ha studiato una vasta gamma di argomenti di meccanica dei fluidi (tra cui fluidi complessi, flussi multifase, combustione e deformazione di materiali sotto l’effetto di fiamme), inerenti a vari ambiti industriali. Si è occupato di modellazione, soluzione ed analisi di fenomeni complessi, sfruttando approcci differenti e investigando varie condizioni di processo, pubblicando i suoi risultati in giornali scientifici di settore.

Dopo aver completato i suoi studi, ha passato un breve periodo come ricercatore all’Università Sorbonne a Parigi, dove aveva già passato sei mesi in visita durante il suo dottorato, prima di cominciare la sua carriera da ingegnere forense.

Stefano si è unito ad Hawkins a febbraio 2026 come Associato nell’ufficio Italiano di Roma.

LINGUE

Stefano parla fluentemente Italiano, Inglese, Francese e Spagnolo.

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Stefano De Rosa

Chloe Duggan — Mon, 09 Feb 2026 14:23:10 +0000

Stefano graduated with highest honours from the University of Napoli Federico II, where he earned both a bachelor’s and a master’s degree in Chemical Engineering. He then pursued a PhD in the Engineering of Industrial Products and Processes, completing his thesis in Computational Fluid Dynamics in 2025.

During his doctoral studies, Stefano worked on a broad range of topics in fluid mechanics, including complex fluids, multiphase flows, combustion, and flame‑induced deformations, across various industrial applications. He modelled, solved, and analysed complex phenomena using diverse methodological approaches and process conditions, publishing his findings in peer‑reviewed journals.

After completing his PhD, Stefano spent a brief period as a researcher at Sorbonne University in Paris, where he had previously undertaken a six‑month visiting research placement during his doctoral programme, before progressing into a forensic engineering role.

Stefano joined Hawkins in February 2026 as an Associate based in our Rome office.

LANGUAGES

Stefano is fluent in English, Italian, French and Spanish.

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Understanding Chiller System Failures: Causes, Consequences and Prevention Strategies

Chloe Duggan — Mon, 09 Feb 2026 10:00:48 +0000

Chiller systems are a vital component of modern cooling infrastructure, ensuring efficient climate control in various industries, from commercial buildings to data centres. However, when a chiller fails, the financial and operational impact can be substantial. According to a 2022 report from the U.S. Department of Energy, heating, ventilation, and air conditioning (HVAC) failures, including chillers, account for approximately 40% of unscheduled maintenance costs in commercial facilities. Mechanical failures are rarely isolated incidents; they are often symptomatic of underlying inefficiencies that accumulate over time. Proactively identifying and addressing these issues is key to maintaining system performance and reliability. In the sections that follow, we explore some of the common failure points that can compromise chiller system integrity and efficiency.

Compressor Failures: A Silent Threat to System Integrity

The compressor is at the heart of every chiller system, responsible for circulating refrigerant and facilitating heat exchange. According to data published in 2021 by the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE), compressor failures account for up to 38% of all chiller system breakdowns. Failures within this component can be attributed to several factors, including overheating, inadequate lubrication, or refrigerant imbalances. Motor burnout, often caused by voltage imbalance or thermal overload, is responsible for over 20% of compressor electrical failures. Early warning signs such as a 10-15% increase in energy consumption or temperature deviations of 2-5°C from setpoints should never be ignored, as they often precede major compressor damage.

Heat Exchanger Degradation: A Hidden Efficiency Loss

Heat exchangers are integral to a chiller’s thermal transfer process, yet their functionality can decline due to corrosion, fouling, and refrigerant leakage. These issues directly impact heat transfer efficiency, forcing the system to operate at higher energy levels to compensate for performance deficiencies. Fouling and scaling can reduce heat exchanger efficiency by 10-30%, depending on the fouling material and thickness. Fouling deposits on heat exchanger surfaces further restrict thermal conductivity, driving up operational costs. A 0.5 mm thick fouling layer can increase energy consumption by up to 20%. While the effects of degradation may not be immediately noticeable, cumulative damage significantly increases the risk of mechanical failure and operating costs over time.

Circulatory Disruptions: Pump & Piping Vulnerabilities

Fluid circulation within a chiller system depends on a network of pumps and pipelines, where even minor disruptions can compromise efficiency. Cavitation, caused by vapor bubble formation, can reduce pump efficiency by up to 40% and significantly shorten pump lifespan. Vapor bubbles can also lead to severe internal damage, while corroded or obstructed piping restricts flow rates, leading to reductions of up to 25% and impacting cooling performance.

The Impact of Refrigerant Leaks on System Performance

A well-maintained refrigerant system is fundamental to chiller efficiency, yet leaks caused by component wear, vibration-induced cracking, or improper installation can severely impact cooling capabilities. Even a 10% reduction in refrigerant charge can diminish heat transfer and lead to a 15% drop in system efficiency. Beyond the financial strain, refrigerant leaks pose environmental concerns and regulatory compliance challenges. Moreover, refrigerant losses significantly contribute to global warming. Hydrofluorocarbon (HFC) based refrigerants have Global Warming Potentials (GWPs) ranging from 1,300 to over 3,900. This means that, over a 100-year period, these gases can trap 1,300 to nearly 4,000 times more heat in the atmosphere than the same amount of carbon dioxide, significantly contributing to climate change.

Operational and Financial Implications of Chiller Breakdowns

The consequences of chiller failures extend beyond equipment replacement costs. Industries reliant on climate-controlled environments face significant operational disruptions. These include healthcare, manufacturing, and data centres, all of which face significant operational disruptions when cooling systems malfunction. For instance, in data centres, cooling system downtime can cost hundreds of thousands to several million USD per day, depending on the size, design, and technology in use. These costs stem not only from the immediate loss of service and potential data corruption, but also from cascading effects on business continuity and regulatory compliance. In high-density environments, where servers generate substantial heat, even a few minutes of cooling failure can cause significant hardware damage.

Unplanned downtime introduces financial liabilities, including emergency maintenance expenses and productivity losses. Furthermore, compromised system components pose safety risks, overheated electrical systems increase fire hazards, while refrigerant leaks present health concerns for occupants.

Expert Analysis: The Role of Mechanical Specialists

Diagnosing chiller failures requires more than just identifying damaged components; it requires a thorough understanding of the root causes behind malfunctions. Mechanical specialists provide invaluable assessments, determining whether failures stem from improper maintenance, design defects, or operational mismanagement. These expert evaluations assist businesses assign liability, whether to manufacturers, installation teams, or maintenance personnel, and also provide actionable insights to improve long-term performance and prevent recurring failures. According to the International Facility Management Association (IFMA), organisations that employ predictive diagnostics experience 30-40% fewer equipment failures compared to those relying solely on reactive maintenance.

Recovery Strategies and Risk Mitigation

A mechanical failure does not always equate to complete financial loss. Businesses may explore recovery options such as insurance claims or legal recourse if system malfunctions can be attributed to negligence or defective equipment. Additionally, implementing predictive monitoring systems can reduce unplanned downtime by up to 50%, enabling businesses to detect performance inefficiencies before they escalate into major failures. Investing in risk mitigation strategies ensures operational resilience while minimising costly disruptions.

Prioritising Proactive Maintenance for Long-Term Reliability

While mechanical failures can result in significant setbacks, preventive maintenance remains the most effective solution for extending chiller lifespan and reducing unexpected breakdowns. Routine inspections, refrigerant system monitoring, and timely repairs all contribute to optimal system performance. Given that chiller systems operate through interdependent components, neglecting any individual element can lead to widespread inefficiencies. Strategic maintenance provides consistent cooling capacity, operational stability, and cost savings over the long term. Well-maintained chillers can last 20–25 years, whereas neglected systems may fail after just 10–12 years. This approach not only maximises cooling capacity and operational stability but also yields annual energy savings of 15-20%.

Conclusion: Prevention Over Repair

Chiller malfunctions can lead to extensive financial and operational consequences, impacting productivity, budgets, and safety. Understanding failure mechanisms and implementing proactive maintenance strategies are essential for ensuring uninterrupted performance. By investing in expert diagnostics and preventive interventions, businesses can safeguard their cooling infrastructure and avoid costly repair scenarios. For chiller systems, early intervention is consistently more cost-effective than reactive repairs.

About the Author

Albert Law is a Chartered Mechanical Engineer and Associate at Hawkins, based in our Hong Kong office. With over a decade of experience in mechanical, electrical, and plumbing (MEP) design and project management, Albert has worked on high-profile projects across Asia and the Middle East, including railway systems, data centres, and commercial buildings. He holds a Master’s degree in Building Services Engineering and is a member of several professional bodies, including the Institution of Mechanical Engineers (IMechE), the Chartered Institution of Building Services Engineers (CIBSE), and the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE). If you have an incident you would like Albert to investigate, please get in touch.

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