Introduction
Weld East Fabricators partnered with ASSI International to design, prototype, and manufacture a mobile CCTV tower now deployed in the field and used by WA Police. The ASSI CCTV Towers project is one of our most comprehensive product development engagements, spanning from initial drawings in January 2022 through to the delivery of refined production units in September 2024. It involved every facet of the prototyping process: client consultation, drafting for fabrication, engineering reviews, mid-production design revisions, and iterative refinement across multiple orders.
Project Brief and Design
ASSI International came to us with a clear need but an evolving concept. The brief called for a transportable mast with a CCTV camera housing box at the top. That box needed to tilt downward to allow camera servicing, solar panels had to be mounted at the top of the mast, and a secure compartment was required at the base to store the batteries.
We worked closely with the client to help them translate that vision into a buildable design. Through a series of concept reviews, we agreed on a two-component, hinged steel mast with an aluminium camera box at the top. Placing a lockable battery compartment at the base – rather than at height – was a deliberate engineering decision, distributing weight more effectively and reducing tipping risk.
Design Evolution and Prototyping
As fabrication progressed, the client returned on multiple occasions to raise new challenges. Some arose from the operating environment, others from changes in componentry or newly identified requirements. Each visit prompted further design work, on-the-fly fabrication adjustments, and careful re-evaluation of the overall structure.
The result of that process was a working prototype completed in mid-March 2022 – one that functioned well in the field and, to our knowledge, remains in active use.
From that baseline, the design continued to evolve across several revisions:
- Revision two addressed a security concern identified after deployment. The client needed to conceal the bolts anchoring the mast to its concrete block base, reducing the risk of theft or vandalism. We designed a purpose-built steel box to enclose the bolt assembly whilst allowing the mast to pass through unimpeded.
- Revision three focused on the aluminium camera box. The redesign delivered a more rigid base structure, the addition of nacelles to retain cameras securely within the housing, larger solar panels mounted at increased angles to maximise light capture, and a revised top mount configuration.
Alongside the core product, we also developed a range of ancillary items to improve the towers’ practical usability. A dedicated transport frame was fabricated to allow safe truck transport with the mast in the lowered position. A third solar panel mount was also designed and fitted beneath the camera box, with the ability to tilt out from the mast and rotate around it – allowing the operator to position the panel for optimal sun exposure throughout the day.
Project Outcomes
The ASSI CCTV Towers project delivered a field-ready, purpose-built product that has been refined through genuine collaboration and real-world testing. Each revision addressed practical challenges identified in use, resulting in a final design that the client considers perfected. The towers are now deployed in active use, including by WA Police.
This project demonstrates what can be achieved through a long-term fabrication partnership built on open communication, technical capability, and a willingness to iterate until the product is right. From concept drawings through to production runs, our team contributed design input, drafting, engineering checks, and hands-on fabrication at every stage.
For projects that require more than a single manufacturing run – where the product needs to be developed, tested, and refined – our team is equipped to support that process from beginning to end. If you have a project with similar requirements, contact our general fabrication team to discuss how we can help.
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