Australian Stainless #65

AUSTRALIAN STAINLESS Specialising in stainless steel and its applications

Photo credit: Ertech

ISSUE 65 2019

FEATURE

Water delivery efficiency with stainless steel Stainless steel is playing an important role in delivering effective infrastructure to achieve water savings, securing a sustainable environment and future for irrigation communities in Australia.

Murray Irrigation’s Private Irrigation Infrastructure Operator Program (PIIOP) Round 3 in New South Wales is a modernisation project focused on upgrading larger infrastructure within the main canals of its irrigation assets, including Mulwala and Wakool Canals.

Mulwala Canal is Australia’s largest irrigation canal, and together with Wakool Canal runs 157km long. It has the capacity to deliver more than 1,500,000ML of water per year to irrigators in the Southern Riverina, helping to generate more than $500 million of gross agriculture revenue per year for the region.

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ASSDA Member AWMA successfully delivered 91 stainless steel water control gates across the project’s irrigation system assets, which has substantially increased water efficiencies, improved water flow, enabled ordering flexibility and significantly reduced water leakage through infrastructure upgrades.

The works included 21 Mulwala Canal Sites (65 LayFlat gates and 26 Undershot gates), Lawson Syphons (two Undershot gates), the Edward River Escape (two Bulkhead gates) and the Wakool Canal Offtake (three Undershot gates).

All water control gates were purposeengineered and manufactured

by AWMA to meet exact site and operational requirements. Fabricated from 230 tonnes of grade 304 stainless steel, 6mm sheet, with some components machined from grade 316, material for the project was supplied

by ASSDA Member Vulcan Stainless.

The stainless steel water control gates required 7.5km of weld, then pickled to improve corrosion resistance and tested in-house to international ISO 9001 quality standards.

Photo credit: Murray Irrigation

Photo credit: AWMA

Photo credit: AWMA

ASSDA Member Arcus Wire Group were also engaged by AWMA to assist in the design and supply of 20mm, 7x19, grade 304 stainless steel wire rope cables for the purposes of raising and lowering the water control gates. 130 cables were supplied (two cables installed per LayFlat gate), with an individual Minimum Breaking Strength (MBS) of over 27,000kgf. Arcus Wire Group and AWMA collaboratively designed the bespoke cable end terminations to suit

the specified MBS, and the manufacture of these products were completed inhouse by Arcus Wire Group.

Stainless steel was specified for its longevity and durability, particularly with the water control gates being submerged in irrigation water. In addition, stainless steel was chosen over aluminium in the materials specification to extend the nominated asset life from 25 years to 50 plus years. The gates have been

integral to improving the efficiency and productivity of water delivery, and the use of stainless steel offers an economically maintainable and longer lasting infrastructure solution.

All new gates installed are stainless steel and telemetry-enabled for remote control, a capability that has radically changed the way Murray Irrigation manages water delivery to its customers.

Stainless steel was specified for its longevity and durability ASSDA MEMBER CONTACTS Arcus Wire Group \ Josh Sheedy, Sales Manager \ +61 448 124 067 \ josh@arcuswire.com \ arcuswire.com AWMA \ Michael Anthony, Sales Manager \ +61 419 669 006 \ mike@awmawatercontrol.com.au \ awmawatercontrol.com.au Vulcan Stainless \ Stephen Orridge, Business Unit Leader \ +61 3 9238 7100 \ stephen.orridge@vulcansteel.com.au \ vulcansteel.com.au

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TECHNICAL

Stainless steel and fire resistance What is the fire rating of stainless steel? This is a common enquiry from ASSDA Members and the construction industry, especially with the current concerns about flammable cladding. The three major branches to this question are covered in this article.

Will stainless steel burn, and if it does, will it give off fumes or facilitate the spread of fire?

This question is readily answered because stainless steels are steels. It is recognised that steels do not burn and only start to melt at about 1400oC. This means that stainless steels do not have a “fire rating” as such, so the tests of AS/ NZS 1530.3 (or the equivalent tests in BS 476) are not required.

Heating in a fire will obviously have an appearance effect because, unlike the transparent nanometer-thick passive layer formed in moist air, stainless steels heated above about 300oC in air discolour as they grow a less dense oxide layer. This develops from the rainbow colours seen beside welds to a dark and non-protective oxide layer whose thickness depends on the time of exposure and temperature reached. The street rubbish bin shown suffered from

a fire but remained functional for almost a year (until the repair cycle reached it) with a decorative rainbow oxide. By way of comparison, powder coated bins would suffer from unsightly burn marks and corrosion.

For austenitic alloys such as 304 and 316, the temperature limits for lifetime section loss due to oxidation is about 870oC (with temperature cycling) so they are routinely used in high temperature furnaces and ductwork.

The current trend to apply decorative coatings to stainless steels would require an assessment to determine the combustibility, potential fumes and flame spread of the coating. Tests to AS/ NZS 1530.3 would be appropriate.

Will stainless steel provide a barrier to flames and if it does, how rapidly will the heat penetrate the barrier sufficiently to cause damage (usually a specific temperature rise) on the far side?

A satisfactory demonstration is supplied by reference BS 647 Part 22 tests carried out for a British Stainless Steel Association (BSSA) member, Stewart Fraser, who manufacture 316 framed doors which include a cavity filled with non-combustable boards. The results are given at www.bssa.org.uk/topics. php?article=106.

It showed slight discolouration and distortion on the flame impingement side with the sheltered side of the door reaching only 98oC after 60 minutes.

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The test was continued for another 80 minutes without the failure of flame containment or subsequent opening of the door in its frame. Similar testing was carried out on a 1.5mm thick 2304 duplex sheet fabricated into a simulated ship’s bulkhead with enclosed ceramic wool insulation. With a bright orange glow of an 1100oC metal temperature on the flame side, the “safe” side reached 30oC after 40 minutes and 110oC after 60 minutes. The test was terminated after 120 minutes with containment still satisfying IMO resolution A518 (XIII).

Microstructural effects of a short-term heat cycle (less than a couple of hours of exposure, such as a fire) could include carbide precipitation (sensitisation) in an austenitic alloy which was not an L grade (i.e. carbon >0.03%). Duplex and weldable ferritic grades should not have sufficient carbon for sensitisation.

Sensitisation would degrade the corrosion resistance but not affect mechanical properties. Both duplex and ferritic grades can suffer 475oC embrittlement, however data produced by the International Molybdenum Association (IMOA) shows that this requires more than two hours in the 400oC to 500oC range for a 50% reduction in toughness. This duration is unlikely in most fires.

What are the effects (both during and after an event) to the mechanical properties of stainless steel? How do these compare with structural carbon steels?

There are tests as well as a theoretical basis which demonstrate that both austenitic and duplex stainless steels have superior high temperature properties compared to carbon steel. The table below shows the deflection and failure modes of three metre long commercial electrical cable trays loaded to simulate actual loadings. They were heated with 18 LPG burners to obtain an average temperature of 1000oC to 1050oC for at least five minutes. [Nickel Institute publication No. 10042]

Material

Result

Comment

316L stainless steel

Maintained integrity for five minutes. Burners continued until gas exhausted after 45 minutes. Centre sag 80.5mm – see picture.

Maximum average ladder temperature 707oC with max. individual 757oC.

Galvanised Maintained integrity for carbon five minutes. Centre steel sag 166.5mm.

Cable tray fire test

Molten zinc dripped.

Maximum average ladder temperature 642oC .

Aluminium

Collapsed after 26 seconds.

Fell outside monitoring zone so no temperatures measured.

Fibre glass

Collapsed before all burners ignited.

Subsequently ignited with fume emission.

The publication also considers the life cycle costs (LCC) of the use of aluminium, galvanised steel or stainless steel for stairways, handrails, gratings and firewalls, as well as cladding for corridors and accommodation modules on North Sea platforms. Fire risk controls are obviously a major concern although corrosion resistance is also critical.

On an LCC basis, stainless steel was most economical especially when its reduced requirement for maintenance periods were included.

In addition to the above testing in cable tray applications, substantial research and application work has since been carried out and codified. Installations include 2205 duplex hangers suspending the slab which forms the floor of the emergency ventilation duct in the CLEM7 tunnel in Brisbane [ISSF].

In short term fires such as on balconies or stairways, the temperature rise exposed to an ISO 834 fire temperature profile depends on thickness and emissivity. Polished stainless steels typically have low emissivity of <0.1 and hence a slower temperature rise. Conservatively, after 30 minutes a 12mm sheet of stainless steel with 0.2 emissivity would reach 620oC whereas steel (with no rust) and 0.4 emissivity would reach 750oC.

Ventilation duct support in 2205 stainless steel

When considering strength and deflection, the metal temperatures in a conventional fire do not reach levels to anneal the material so any cold work strengthening will raise the temperature for a 50% strength reduction. In addition, as shown in the graph, the reduction in Young’s Modulus, i.e. deflection from a specific load, is less than that of carbon steel for temperatures above ~200oC. By 600oC the modulus retention for stainless steel is 0.75 compared to 0.3 for carbon steel, i.e. less than half the deflection for a given load.

In summary, stainless steel has substantial advantages in structural use when fire risk is considered, and these advantages continue into higher strength and lower deflections at elevated temperatures.

Reduced Young’s Modulus with temperature

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IN THE MEDIA

Atlas Steels’ post incident safety revamp When Mark Ellis, a warehouse operations clerk for Atlas Steels, suffered a serious leg injury that resulted from an incident at its Ingleburn Service Centre, the business vowed it wanted to prevent this type of incident from reoccurring.

“It shook the business,”

says Regional Director, John Pearson. “ It was a terrible thing for Mark, his family and for all of our employees. You could see and feel the devastation.”

Ellis was injured when he stepped back and collided with a multi-directional sideloader forklift. Atlas’s quest to enhance safety saw the business introduce a number of measures across its operations. Other businesses working to prevent serious incidents can learn a lot from this example, particularly the important role of employees in coming up with ideas to improve workplace safety.

“The effect of this incident on all was dreadful”, says National SEQ Manager, Maree Mihaljevic. “We are extremely focused on engaging our people and strengthening our safety system and processes.”

A practical response

Atlas’s response to this incident included a series of practical measures. Service Centre Manager, Marc McAllister, says Atlas introduced an improved Traffic Management Plan and controls in consultation with its employees. One of the most important changes has been the introduction of a pedestrian awareness tool (PAT), a base plate that has a pole with a strobe light on top. If a pedestrian stops to work in an aisle they must place PAT in front of the aisle, or at a safe distance from them, and turn the light on. The light is at eye level with the sideloader forklift operator and provides additional visual

awareness to the operator who must not enter beyond the point of PAT placement.

As PAT is portable it can be used in a variety of locations.

The business has also increased training, particularly around traffic management and sideloader forklift operation, with an online interactive training system being built from the ground up and employees being put through refresher courses.

The way we do things around here

Consultation was conducted across the country resulting in the development of a Safety Charter that depicts a ‘Safety First’ approach and the agreed minimum safety expectations for all employees, supervisors and managers with signed ownership it is prominently displayed at each site.

Ellis has conducted a series of presentations to his workmates and to the wider steel distribution industry that Mihaljevic, says “Demonstrated that this was real, not just an anonymous report or statistic but a worker who has a name and family. It highlighted his journey, the injury impact on others and the importance of working together in implementing and maintaining safety systems and processes with the presentation correlating with Mark’s passion for golf.”

After the incident McAllister gained a forklift licence himself so he would have experience first-hand. “I try and regularly get out there and work with them,” he says. “I get to see the challenges they face, and we work through to improve. It also helps in strengthening our team.”

A continuous quest

After his incident, Mark Ellis has made a successful return to work; but the effects of his incident at Atlas Steels are long lasting. It has driven a quest to elevate safety so that no one suffers a similar incident.

Mihaljevic says Atlas’s efforts to improve safety are ongoing. “It’s relentless,” she says. “The importance of having well risk assessed safety systems and processes in place especially where mobile plant is in use is evident.”

There are learnings for everyone where mobile plant is in use says Pearson, “If you walk or drive into any workplace, follow the signs and directions of the employees and maintain situational awareness to ensure your own safety and the safety of others.”

Pearson adds other businesses can provide ideas that can be trialled and possibly implemented. He says it’s a never-ending search for improved risk management across the board to reduce the potential for injury.

But Mihaljevic says don’t disregard incidents that occur in other businesses.

“If you read something that happened in another company, don’t just think ‘that’s horrible’, act on it. Ask yourself if that incident or similar could happen in your business and what do you have to do to control that risk.”

Good safety leadership is paramount and its important to lead by example McAllister says. “Continue to engage and encourage open conversations regarding safety. Some of the best ideas will come from the warehouse floor.”

Atlas Steels acknowledges that this article was produced as a result of a SafeWork NSW Enforceable Undertaking.

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DESIGN

Luxe stainless A new luxury home renovation in Cottesloe, Western Australia is leading the way in cutting-edge bathroom design with a statement stainless steel wall.

ASSDA Member and Accredited Fabricator ALLOY’s stainless steel mosaic tiles are featured in the bathroom designed by Nina Dempster of Ozbyrd Design and architect Paul Jones RBA of a recently constructed addition by builder Adrian Zorzi.

The alluring back wall of the walk-in shower is lined with ALLOY’s “SWISS CROSS” 30x30mm stainless steel mosaic tiles. The mixture of the No. 4 and No. 8 brushed and mirror finish 304-grade solid tiles offers a textured finish with a glimmering light reflection and decorative appeal.

The client wanted a brilliant surface finish to enhance the space and grandeur, particularly with no natural light feeding into the area. Stainless steel delivers the brief, with its reflective sheen and the added benefits of the material’s hygienic properties and durable nature. It also plays an important aesthetic role in the camouflage of water spots.

The end result is a high quality, precisionengineered stainless steel product striking a balance between function and luxury style.

The entire shape of ALLOY’s mosaic tile has a unique bevelled edge, and its manufacture from 1.6mm thick sheet ensures the tile will not dent, crack or de-laminate. No surface treatment was required on the stainless steel, being installed in an indoor environment.

Photo credit: Ryan North, and are subject to copyright.

ASSDA MEMBER CONTACT ALLOY \ Dominic DiCamillo, Sales Manager \ +61 2 9565 2422 \ dominic@alloydesign.com.au \ alloydesign.com.au

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PacRim Stainless 2019

9–10 October

Register now at: pacrimstainless2019.lilregie.com

Sofitel Broadbeach

GOLD COAST

‘Waves of Change, Oceans of Opportunity’ Brought to you by the Australian Stainless Steel Development Association (ASSDA), PacRim Stainless is the premier annual event bringing together Australia’s stainless steel industry and colleagues from abroad in an exclusive networking environment.

SPEAKERS

PROGRAM OVERVIEW wo half-day conference sessions with an exceptional line-up of T speakers covering topics including: • Strategies to remain competitive in an ever-evolving manufacturing landscape to maintain and grow market share • Technological advancements in our industry and capitalising on new opportunities • Economic overviews and perspectives on local and global stainless steel market direction • Case studies from various industries Gala Dinner: Australian Industry Stainless Steel Supplier and Fabricator Awards Social networking activity at the Gold Coast’s latest attraction, Top Golf

Hon. Karen Andrews MP Minister for Industry, Science and Technology

Keith Abraham Founder, Passionate Performance Peter Munckton Chief Economist, Bank of Queensland

More info at pacrimstainless.com

Benjamin Young Founder and CEO, frank green

CONFERENCE SPONSORS: Join ASSDA, celebrating its 26th National Conference and 15th International Forum focusing on the Asia-Pacific region.

PLATINUM MEMBERS:

GOLD MEMBERS:

SILVER MEMBERS:

Fagersta Steels Midway Metals Stanch Stainless Steel Co., Ltd. Stoddart Viraj Profiles Ltd. YC Inox Co., Ltd.

Amity Pacific \ Aqseptence Group \ Arcus Wire Group \ Austral Wright Metals \ Australian Stainless Distributors \ Callidus Welding Solutions \ Ching-Hann Industries Co., Ltd. \ Dalsteel Metals \ Daming International Import & Export Co., Ltd. \ Metal Centre Australia \ Mideast Metals FZCO \ Prochem Pipeline Products \ Sanwa \ Stainless Steel Wire & Mesh \ Yue-Seng Industrial Co., Ltd.

AUSTRALIAN STAINLESS MAGAZINE MORE INFO: Enquiries or further information on any material presented in this publication should be directed to ASSDA: Level 9, 307 Queen St, Brisbane, Qld, Australia 4000 \ +61 7 3220 0722 \ assda@assda.asn.au \ www.assda.asn.au EDITORIAL: Contributions of story ideas specialising in stainless steel and its applications are welcome from Members of ASSDA. ADVERTISING: Advertise in the only publication that reaches are targeted group of 5000+ in the Australian stainless steel industry. Rates available at www.assda.asn.au.

CONTACT: Lissel Pilcher, Editor: lissel@assda.asn.au DISCLAIMER: ASSDA sources articles and advertisements from a variety of contributors and accordingly does not accept responsibility for the accuracy of the contents of this publication nor the suitability of specific applications referred to herein for any particular use. Competent advice should be sought before acting on any matter contained in this publication.