Australian Welding - June 2024

Manufacturing Specialist

Spearheads Robotic Innovation: Automation Transforms RCR Mining Technologies Page 24

Women in Welding: Bonnie Inkster, Fabricator at Walkinshaw Racing Page 28

Investing in the Latest Powered Air Respiratory Technology is Essential for Welder Safety and Productivity In light of new legislative changes, it is more important than ever for workplaces to adhere to the updated workplace exposure standards for welding fumes.

Embracing the Heavy Metal Welding Revolution In the dynamic world of heavy metal welding, having the right tools is crucial. Enter the CIGWELD Transmig 555i, a powerhouse machine that redefines industry standards and elevates your welding game to the next level.

Upton Engineering Strengthens Australia’s Manufacturing Future Upton Engineering and Manufacturing recently certified to AS/NZS ISO 3834.The Queensland business is a leading manufacturer and supplier of high tolerance equipment and machinery components.

Sustainable and Certified: How IMF Group is Taking Charge of its Future IMF Group have been building Australia’s future since 1994. Situated in the heart of the Hunter Valley’s industrial region, the company has grown to over 90 staff members.

Coslee Heavy Metal Fabrications Shines for Over 55 Years Coslee specialises in infrastructure for roadways, cranes and lifting equipment. The business underwent certification to AS/NZS ISO 9001, which is expected to bring a new layer of quality to its operations.

Hot Engineering Fires Up with Quality and Innovation Boilermaking and fabrication lie at the heart of Hot Engineering’s foundations. Staff use the latest advanced technology, and developments in the sector, to bring their clients’ ideas to life. 24

Manufacturing Specialist Spearheads Robotic Innovation: Automation Transforms RCR Mining Technologies

Women in Welding: Bonnie Inkster, Fabricator at Walkinshaw Racing

REGULAR COLUMNS

WELD AUSTRALIA CONTACTS

National Office PO Box 197

Macquarie Park BC NSW 1670 1800 189 900

office@weldaustralia.com.au weldaustralia.com.au

Chief Executive Officer

Geoff Crittenden 1800 189 900 g.crittenden@weldaustralia.com.au

ENGINEERING

Victor Blain, General Manager Engineering 0409 823 991 v.blain@weldaustralia.com.au

TRAINING

Guy Brooks, General Manager Training Operations 0488 743 322 g.brooks@weldaustralia.com.au

MARKETING

Michelle Bignold, Executive General Manager, Sales & Marketing 0437 106 726

m.bignold@weldaustralia.com.au

MEMBERSHIP

David Choudry, Membership Manager 0417 878 104 d.choudry@weldaustralia.com.au

QUALIFICATION & CERTIFICATION

Deniz Yalniz, Executive General Manager, Technical Services 0487 487 170 d.yalniz@weldaustralia.com.au

Subscription to Australian Welding is a Weld Australia member benefit included in annual membership fees. All rights reserved. No part of this publication may be reproduced or copied in any form without the written permission of Weld Australia. Weld Australia and its agents are not responsible for statements or opinions expressed by contributors in this publication, which are not necessarily those of Weld Australia. Publication of any advertisement does not constitute endorsement by Weld Australia of any product, nor warrant its suitability.

INTRODUCING WELD AUSTRALIA’S NEW CHAIR

Weld Australia would like to welcome

Madeleine du Toit who has taken on the role of Chair of our Board of Directors.

Madeleine du Toit joined the University of Wollongong as Professor in the School of Mechanical, Materials, Mechatronic and Biomedical Engineering in 2014, and currently serves as Associate Dean for Equity, Diversity and Inclusion in the Faculty of Engineering and Information Sciences.

She holds BEng, MEng and PhD degrees in Metallurgical Engineering, and a Masters degree in Welding Engineering. She is a Fellow of the Institution of Engineers Australia, a qualified International Welding Engineer (IWE) and a Certified Materials Professional (CMatP) with Materials Australia.

Madeleine served as the President of the Council of the Southern African Institute of Welding (SAIW) from 2010 to 2014, and has been a Director of Weld Australia, Australia’s premier industry body for welding and

joining, since 2015. She was elected Deputy Chair of the Board of Directors of Weld Australia in May 2023.

Madeleine established successful internationally accredited training programs for International Welding Engineers and International Welding Technologists in South Africa and in Australia, and currently facilitates the training of IWEs and IWTs in Australia in collaboration with Weld Australia.

Madeleine’s professional qualifications include:

• PhD degrees in Metallurgical Engineering

• Masters in Welding Engineering

• Masters of Engineering (Metallurgical)

• Bachelor of Engineering (Metallurgical)

• International Welding Engineer (IWE)

Madeleine answered a few questions for Weld Australia about her new role as Chair,

What excites you the most about taking on this role?

In my nine years on the Board of Directors, I’ve seen Weld Australia grow into a highly respected organisation within Australia and internationally. Through its training programs, certification activities, engineering services, membership, and advocacy, Weld Australia’s reach is now greater than ever before, and I am excited to work with Weld Australia to find more ways of leveraging this to benefit our members.

We are stronger when we work together, and the networks that are formed in classrooms, on site, at networking events, state committee meetings or technical seminars can help us bring about real change in the welding industry.

Are there any specific areas or issues you are particularly passionate about addressing?

In my new role as Chair of the Board of Directors, I want to tackle two main challenges.

We are facing a severe skills shortage in the welding industry, and estimates show that growth in renewable energy and defence, to name just two sectors, will require a significant investment in skills development in the years to come. This will require Weld Australia to continue advocating for skills development at the highest levels, while ensuring that we have the programs and resources available to train our current and future workforce. In this context I am very excited about the work done by Weld Australia in developing

Madeleine du Toit

the MEM resources that will ensure that TAFE students get access to the most modern and up-to-date training materials in welding and fabrication available in the world today.

I would like to see a stronger focus on promoting welding as an exciting career to young people. Weld Australia is doing great work embedding welding simulators in schools, but to solve the skills shortage in Australia, we need to reach more young people. We can no longer rely only on traditional demographics for our welding workforce, and for this reason I am excited about growing Weld Australia’s programs for women in welding, training of inmates in prisons, people living with disabilities, and creating opportunities for First Nations people.

What do you think are the biggest opportunities for the welding industry at the moment?

The biggest opportunities at the moment lie in developing the skills needed to position the welding industry to respond to growth in renewable energy, defence, roads, rail and construction, while simultaneously moving from traditional manufacturing to more advanced production.

Manufacturing is changing and evolving at a rapid rate, and to remain competitive, fabricators will have to transition to more advanced technologies involving artificial intelligence, automation, robotics, cobots, smart factories, data analytics, augmented reality, the Industrial Internet of Things, and other cutting-edge technologies. This will require training, upskilling and reskilling of the workforce, and Weld Australia is well positioned to support the local manufacturing industry in making these changes.

What do you think are the key benefits of being a Weld Australia member?

The key benefit of Weld Australia membership is being part of a network of welding professionals across Australia, and having the collective power of this network working for you. We need to advocate for welding at the highest levels, and the only way to make a real difference is through the collective power of a network of engaged individuals and companies.

Weld Australia brings people together to forge these networks, whether through industry networking events, seminars, training, or events organised by our state committees. Weld Australia’s mission is to facilitate the growth of world class welding in Australia, and to this end membership gives individuals and companies access to training opportunities, engineering services, resources, and certification, and disseminates research to facilitate technology transfer.

“ We need to advocate for welding at the highest levels, and the only way to make a real difference is through the collective power of a network of engaged individuals and companies.”

WELD AUSTRALIA DEMAND ANSWERS

Will the Australian Government manufacture wind and transmission towers locally or outsource to China—again?

Weld Australia calls upon the Australian Government to provide a clear and immediate public response regarding the manufacture of wind and transmission towers. Will wind and transmission towers be manufactured locally in Australia, or offshored to China—again?

The transition to renewable energy is paramount for Australia’s future, yet the foundational infrastructure for this transition-wind and transmission towers-remains neglected. Despite extensive lobbying and clear communication from industry leaders, the Australian Government has no concrete action or investment plan.”

For well over two years, industry leaders have been asking the Australian Government for a decisive plan to build these essential structures domestically. Instead, what we have received are vague promises and unspecified funding allocations. It’s time for the Australian Government to make a commitment: will these towers be built in Australia, or are we outsourcing this vital work to China?

Weld Australia commends the programs outlined in the 2024 Federal Budget, including an expansion of the Capacity Investment Scheme that will unlock over $65 billion worth of investment in renewables by 2030; and the muchanticipated Future Made in Australia Innovation Fund that will deliver $1.7 billion to power new ‘green’ industries.

The problem is: the federal government’s planned investments are earmarked for solar power, batteries and hydrogen projects. All these renewable energy technologies are long-term solutions that will come to fruition in 10 to 20 years’ time. We need a much more immediate solution. We need wind towers erected now. The Australian Government must stop prevaricating.

The Australian Government’s recent $1 billion investment in the Solar Sunshot program must be replicated in wind tower manufacturing. The domestic demand for wind towers over coming decades is huge-we need at least 6,000 wind towers nation-wide. Based on Australian Energy Market Operator (AEMO) scenarios, the market could range

from $20 billion anywhere up to $80 billion.

The sheer scale of wind and transmission tower manufacturing in Australia will require significant investment in plant and equipment. This investment is not only about building infrastructure but also about creating jobs and ensuring the long-term sustainability of our manufacturing sector.

Timing and Urgency

At least half of the remaining 14 coal generators on the eastern seaboard are set to close within the next decade. State governments are increasingly nervous that not enough new renewable energy generators, storage projects, and transmission lines are being built to keep power supplies and prices stable.

In mid-May, the New South Wales Government announced that it will pay Origin Energy up to $450 million over the next two years to extend the life of Australia’s largest coalfired power station, Eraring, into 2027. This decision follows a 10-year forecast by AEMO that highlighted an increased risk of blackouts in NSW due to the slow rollout of renewable

Geoff Crittenden (CEO, Weld Australia)

projects. The Victorian Government has already intervened to ensure two of its biggest coal generators do not shut prematurely.

Australia’s great energy transitionfrom fossil fuels to renewables - is not going well.

For example, Project EnergyConnect, a new 900km transmission line to allow for future connections from renewable energy sources is currently 12 months behind schedule. Similarly, commissioning of the Central West Orana Renewable Energy Zone Link in New South Wales has also been pushed out by 12 months-to August 2028.

Having met with the Australian coal fired power industry, all their engineers have contingency plans in place to extend the life of their plants.

It is almost a foregone conclusion that the coal fired power plants will have to be maintained to ensure the delivery of consistent, reliable power to the Australian public-Australia’s renewables transition is nowhere near ready.

Weld Australia demands transparency

from the Australian Government:

• Will wind and transmission tower manufacturing be undertaken in Australia?

• What are the concrete steps and timelines?

• Who will be responsible for making these decisions?

This is not a state issue-states should not bear the responsibility for funding these large-scale industrial projects. It’s a national priority that should have been addressed well over two years ago. The Australian Government must take immediate action to start these projects and provide the necessary funding or-at the very least-the confidence for local manufacturers to invest in their facilities.

The rhetoric of green energy and renewable investments is meaningless without the real work and real jobs that come with building the necessary infrastructure. Industry needs tangible answers, a definitive delivery plan and real investment for wind towers-and we need them now.

The Opportunity for Manufacturers and Fabricators

With the right policy levers, it’s conceivable to imagine significant

investment in new world-class steel manufacturing businesses supplying both components and complete solutions to support Australia’s energy transition.

Within five years, at least one largescale brand-new state-of-the-art wind tower fabrication facility could easily be making 100 towers a year, and supplying them into projects across renewable energy zones. While there might still be a need to import towers during peak demand periods, our reliance on overseas manufacturing to achieve our targets would be greatly reduced.

In Eastern Australia alone, four facilities would be capable of manufacturing sufficient towers for 500 MW of power generation per annum – a total of 2GW. Each facility would occupy around 20 hectares of land, cost about $170 million, employ 180 full-time workers, consume 40kt of locally-made steel plate per annum, and require access to road and rail for incoming materials and outgoing completed towers.

Given the infrastructure and land required, and the social license issues relating to movement from heavily-

“

The sheer scale of wind and transmission tower manufacturing in Australia will require significant investment in plant and equipment. This investment is not only about building infrastructure but also about creating jobs and ensuring the long-term sustainability of our manufacturing sector.”

populated port precincts particularly in NSW, all facilities could be located in regional areas, greatly boosting economic growth and employment in these areas. Due to the substantial cost of transporting tower sections by road, spreading facilities across the three Eastern states would be the most economical way to meet the needs of the market, while maximising and distributing the economic benefits.

The sovereign manufacturing capability would extend to other sectors, with new and existing fabricators potentially investing in capability to supply monopole transmission towers and componentry or complete system solutions for solar tracking. All of these investments would result in thousands of direct and indirect jobs.

For major steel manufacturers, the underpinning of a long-term sustainable market will enable them to continue realising their modernisation plans. This will mean multi-million dollar investments in sales and marketing to promote and sell Australian steel into the industry, ensuring a fit-for-purpose product suite. It could also stimulate further investment in product development and innovation to meet market needs, such as new chemistries, coatings or technologies.

At the same time, fabricators are hoping to not only see an increase in anchor cages, but a general boost to their day-to-day work. For example, a new Renewable Manufacturing Hub is in development in Western Sydney, with the opening target date of early 2027. Government spending could transform this facility into a powerhouse of capacity, with two of the fastest-cutting lasers in the world, Kinetic 5000 drilling machines with Oxy-cutting and drilling capabilities –all manned for 24 hours a day.

Towards a Global Renewable Superpower

Beyond the benefits to the manufacturing sector, signals within the Future Made in Australia Act could accelerate our decarbonisation

plans and support the shift to a circular economy that recycles endof-life products. For example, it’s possible to imagine using renewable energy to mine Pilbara iron ore, which is then used in locally-milled steel, powered by wind and solar that is also made with recycled, locallymade steel.

A policy lever like this would almost certainly open the door to partnerships and investments that cannot be imagined in our current climate. But most significantly, it means Australians will benefit from cheaper, cleaner energy sooner.

The precedent has already been set in the United States, where the Biden Government signed into law a similar piece of legislation, The Inflation Reduction Act of 2022 (IRA). A key feature of the IRA is a domestic content bonus tax credit if a certain threshold percentage of iron and steel is originated and manufactured in the United States – encouraging domestic supply chains.

The IRA has already unleashed a green energy boom, driving more than $360 billion in private sector clean energy manufacturing and helping cut household electricity rates by as much as 9% by 2030.

Together with the CHIPS and Science Act, it is responsible for the creation of over 113,000 new jobs.

As in the US, there is a real opportunity to transform Australia into a renewable energy superpower. However, the latest government initiatives must be backed by measurable and enforceable local content procurement requirements, stipulating that 60% of all fabricated steel used in renewable energy projects is manufactured in Australia by local welders.

This will provide local manufacturers with the long-term security they need to invest in skills and equipment – and help realise Australia’s comparative advantage on the global stage as a producer of abundant renewable energy.

The renewable energy revolution is Australia’s chance to undo some of the damage done over the past 60 years – both to the environment and to the Australian manufacturing industry. But for government funding to achieve its full potential, it is imperative that local content procurement requirements are attached to both the Capacity Investment Scheme and the Future Made in Australia program.

WELD AUSTRALIA APPOINTS THREE NEW DIRECTORS TO ITS BOARD

Weld Australia recently held its 2024 Annual General Meeting (AGM). It was at this meeting that Madeleine du Toit was appointed as our new Chair.

Richard Fowles (Senior Product Manager - Strategic Marketing, BOC) was re-confirmed as our Deputy Chair; and Simon Doe (National Manager, ANFF) and Adam Furphy (Managing Director, Furphy Engineering) also remain Directors.

Several new Directors were appointed to the Board in casual vacancies, including:

• Bec Cameron (Senior Welding Coordinator, MTE)

• Mick Cameron (Director and Chief Executive Officer, MC Quality Control)

• Brenda Micale (General Manager Training Services South Metro TAFE)

I’d like to congratulate Madeleine, Brenda, Mick and Bec on their appointments. I am looking forward

to working with all of them. I’d like to extend my thanks to Dan Hayward (Team Leader Integrity Engineering, Santos) and Chris Brugeaud (CEO SSS Manufacturing and IR4) who stepped down from the Board.

I’d also like to take this opportunity to thank David Lake, who stepped down as Chair, for his advice and support over the last 10 years. David’s career has spanned over 45 years, and encompassed roles at Olex Cables, BHP, Austral Bricks and ATTAR. He was, for many years, a welding inspector and metallurgist, writing and approving weld procedures and specifications in the mining and refining industries.

David has developed significant technical knowledge in areas ranging from engineering, materials science, metallurgy and nondestructive testing.

In addition to volunteering as a

member of Weld Australia’s Board for over 10 years, David also works with AINDT, Engineers Australia, Materials Australia, and the Australasian Corrosion Association. His commitment to advancing the industry is clear.

Finally, I’m pleased to announce that Ben Mitchell has stepped down from our Board, because he has joined the Weld Australia team as our new Executive General Manager, Strategic Partnerships. We’re excited to have Ben on the team—he brings a wealth of knowledge, experience and industry insights to the role.

To learn more about our Board of Directors, visit the Weld Australia website

Geoff Crittenden CEO,

Weld Australia

Read Bec Cameron’s Biography Read Mick Cameron’s Biography

Brenda Micale’s Biography

Investing in the latest powered air respiratory technology is essential for welder safety and productivity

In light of new legislative changes, it is more important than ever for workplaces to adhere to the updated workplace exposure standards for welding fumes. Inspections are underway, and employers must take the necessary actions to protect their welding workforce. With the recent announcement from WHS ministers, the Workplace Exposure Standards (WES) will be replaced and renamed Workplace Exposure Limits (WEL) to emphasise that these limits should not be exceeded. This change, effective from 1 December 2026, aims to align Australia with international terminology and reinforce the importance of these limits.

The reason for these regulatory changes is significant. The International Agency for the Research on Cancer (IARC) and Cancer Council Australia classify welding fumes as Group 1 carcinogens, indicating their potential to cause cancer in humans. Exposure to welding fumes can result in severe health implications, such as acute and chronic respiratory diseases, lung cancer, heart disease, and neurological issues.

In occupational health and safety, the hierarchy of controls is fundamental to minimising or eliminating exposure to hazards. This hierarchy starts with elimination and substitution, followed by engineering and administrative controls. Personal protective equipment (PPE), including Powered Air Purifying Respirators (PAPR), is often considered the last line of defence but remains crucial, especially in environments where hazards cannot be completely controlled by other means.

Given these stringent new limits, PAPR systems have become essential for welder safety. These systems not only provide a barrier against harmful particles but also actively purify the air welders breathe, using filters to reduce the concentration of airborne contaminants. This is particularly vital when engineering controls, such as fume capture and good general ventilation, cannot reduce the welder’s exposure to weld fume to acceptable levels.

Choosing the right PAPR system is critical. Employers must select systems that offer the best protection while also enhancing productivity. Models with longer battery runtimes, superior helmet comfort, and accessories like back harnesses are ideal. Additionally, optimal filter function with ease of maintenance is essential, with the best filters offering over 99.998% filtration efficiency. PAPR solutions are not one-size-fits-all. Welders and safety managers should trial various products to find the best fit for their needs. It is important to look for PAPR products that are certified to the relevant Australian Standards, ensuring peak performance, protection, and confidence.

As the last line of defence in the hierarchy of controls, PAPR systems when used in combination with the higher order controls, are pivotal in safeguarding welder health under the new legislative framework. Investing in highly certified, high-performance PAPR solutions is not just a compliance necessity—it is a vital investment in the wellbeing and productivity of your workforce.

BREAKING NEWS

Preferred partners selected for Hydrogen Jobs Plan in Whyalla

The Government of South Australia has selected preferred partners to deliver its Hydrogen Jobs Plan, featuring the world’s biggest hydrogen production facility, power plant and storage at Whyalla in the Upper Spencer Gulf. A consortium comprising ATCO Australia and BOC, a Linde company is the preferred hydrogen delivery partner.

The agreements follow a detailed six-month evaluation assessment process of 29 proposals received from companies worldwide.

The design and construction of the Hydrogen Power Plant will include 250 megawatts of electrolysers designed to Linde’s global engineering standards. In a world-first, the project will see the installation of 100% hydrogenoperated fast-startup turbines.

BOC Linde is a subsidiary of Linde, one of the world’s leading industrial gases and engineering companies with global revenue of US$33 billion and an established hydrogen business along the entire value chain.

TEi Services Wins Major Defence Contract

TEi Services will manufacture armoured doors, hatches, and covers at their Townsville workshops and deliver the completed items to Hanwha Defence Australia’s facility in Avalon, Victoria for integration onto their LAND 8116 Phase 1 vehicles. Valued at over $10 million, the contract marks a new era for the locally owned company. Having provided specialised trade repair support locally for Defence vehicle assets, this contract is the first big leap into Defence prime supply chains for the company. TEi Services is also well positioned to provide through-life maintenance support to the vehicles, the majority of which will be based at Army’s 3rd Brigade in Townsville.

Hanwha Defence Australia has been contracted by the Department of Defence for the LAND8116 Phase 1 Protected Mobile Fires program, a $1 billion project to acquire self-propelled artillery systems. Altogether, the Australian Army is acquiring 30 AS9s, a 155mm Self-Propelled Howitzer based on the Korean K9 Thunder, and 15 AS10 Armoured Ammunition Resupply Vehicles.

ANFF Awarded Significant Government Funding

The Australian National Fabrication Facility (ANFF) was recently awarded significant funding from the Queensland Department of Environment, Science and Innovation (DESI)’s Research Infrastructure Coinvestment Fund (RICF).

The funding will enable ANFF to support world-class, cutting-edge micro- and nanofabrication, which is essential to Queensland’s scientific and economic future and plays an important role in the state’s long-term vision to remain at the forefront of quantum and advanced technology research in Australia.

By enhancing their infrastructure, ANFF can drive forward impactful research and foster a thriving innovation ecosystem that transforms ideas into commercial solutions.

ANFF thanked the Queensland Government and DESI for their unwavering support, stating that together, they are paving the way for groundbreaking discoveries and technological advancements.

Photo: Huntsman test gun firing at ADF Port Wakefield P&EE, South Australia (courtesy of Hanwha Defence Australia and TEi Services)

WORLDSKILLS AUSTRALIA ANNOUNCES SKILLAROOS TEAM FOR LYON 2024

WorldSkills Australia recently announced the 2024 Australian Team, who will represent the country at the 47th International Competition, taking place in the French city of Lyon in September.

The contingent of 33 young apprentices, trainees, and students (known as the Skillaroos) is the largest the organisation has sent overseas since Lyon last hosted in 1995. The WorldSkills Australia delegation of competitors, trainers, officials, and team management, is the largest ever sent to an International Competition.

The 47th International Competition is set to be the biggest skills competition ever, with over 1,500 Competitors from 75 countries set to compete in 59 skills. More than 250,000 visitors are also expected to attend the event, which will run from 10 to 15 September.

Worldskills Australia’s participation in the International Competition aims to benchmark Australian skills excellence against global standards. Team Australia members represent the best in their fields, which include welding, plumbing, carpentry, baking, Industry 4.0, cyber security, and fashion design.

The journey for selection has spanned two years, beginning with a regional WorldSkills competition in 2022 that involved more than 3,000 competitors. Winners from each region then competed in the National

Championships in 2023, with medallists being eligible for selection in Team Australia that will travel to France.

Each Skillaroo will be accompanied by their Expert who have overseen their training and preparation to compete on the global stage, meaning the contingent wearing the green and gold will number close to 75.

WorldSkills Australia thanks its industry and TAFE partners who have supported the Skillaroos on their journey and enabled them to achieve their dreams of competing on the world stage. Weld Australia is proud to support the Welding Competitor, Harrison Field, and wish him all the very best of luck.

Global Skills Challenge 2024

In May, Melbourne played host to an international contingent of over 400 of the world’s best young apprentices, trainees, and young professionals, and their support teams, for the Global Skills Challenge.

The four-day event was a friendly competition designed to prepare competitors for WorldSkills’ 47th International Competition. Competitors from 19 countries took part, including the 33 members of the Skillaroos team.

More details on the Skillaroos 2024 team, including competitor profiles, can be found at worldskills.org.au

Harrison Field

Welding competitor Harrison Field and expert Mark Williams

“I’m carrying the torch to France”

At TAFE NSW we aim to turn potential into not just skills, but Skillaroos – just like Harry Field, a welding graduate from TAFE NSW Orange. Whether you or your employees want to learn a new skill, upskill or re-skill, there is a fabrication and welding course to help reach your goals.

Enrol now for Semester 2, 2024.

TAFE NSW WorldSkills Australia

PROTECTING WELDERS FROM OZONE

Ozone (O3) is an extremely toxic gas that is generated when the ultraviolet radiation produced by a welding arc reacts with oxygen in the air. Undetectable to the human eye, ozone can cause serious health issues to unprotected welders.

For this reason, in both Australia and New Zealand, a Peak Limitation of 0.1ppm has been established as the Workplace Exposure Standard (WES) for ozone. This simply means that by law, exposure to ozone must at no time exceed 0.1 parts, per million parts of air.

As such, any employer or ‘Person Conducting a Business or Undertaking’ (PCBU) must ensure that no workers are exposed to ozone in an airborne concentration that exceeds the WES.

However, exposure standards should not be considered as representing an acceptable level of exposure to workers; they do not identify a dividing line between a healthy and unhealthy work environment, but simply establish a legal maximum

upper limit. Therefore, employers must also reduce exposure to ozone to as low as reasonably practicable to protect all personnel in the workplace.

NEW Scientific Study on Reducing Ozone Exposure

An all-new study has just launched to help employers fulfil their legal duty as it relates to:

• Not exceeding the WES for ozone.

• Reducing ozone exposure to as low as reasonably practicable.

Among the key objectives of this study was understanding the levels of ozone that an unprotected welder may be exposed to across a variety of different welding processes, and whether a Welding Helmet with a Powered Air Purifying Respirator (PAPR) was an effective control in protecting the welder from exposure to ozone.

To that end, the study included measuring (in real-time) the atmospheric concentration of ozone generated from four of the most

common welding processes: GMAW (MIG), FCAW (Flux-Cored), MMA (Stick), and GTAW (TIG).

Overall, the results of this study serve to highlight the importance of introducing controls to minimise a welder’s exposure to ozone, and to offer clear and actionable guidance on effective protection.

You can download the new study for FREE via the AWS website: apexweldingsafety.com.au

This editorial was supplied as part of a paid sponsorship package.

• Available as a 250A or 400A fume torch kit

• Lightweight and ergonomic Translas fume gun with 360° swivel

• Portable and easy to carry extraction unit (16kg)

• High efficiency Nanofiber filter (99.7% efficiency)

• Automatically maintains the set extraction flow (fully adjustable)

• Automatic start/stop

• ‘No-Touch’ welding fume disposal

• Warnings when the filter is 85% and 100% full

PATHWAYS TO SUCCESS

Building on the momentum of the 2023 National Manufacturing Summit, which focused on the Renewable Energy: Challenges and Opportunities, the 2024 Summit embarks on an ambitious journey with its theme: Pathways to Success…Making the Renewable Energy Revolution a Reality

The 2024 Summit will delve into the practical aspects of manufacturing within the renewable energy sector, highlighting the essential components that will drive Australia’s transition to a sustainable future.

The Australian Government’s commitment to reducing emissions by 43% by 2030 and achieving net zero by 2050, as outlined in the Climate Change Act 2022, sets the stage for a transformative era in renewable energy. With an anticipated growth in renewable energy generation from 64GW to over 218GW by 2050, the manufacturing sector is at the forefront of this change, presented with unparalleled opportunities and significant challenges.

The Summit will see a diverse group of industry stakeholders assemble on 31 July and 1 August 2024. The Summit gathers leading representatives from all the major stakeholders in Australia’s manufacturing sector—business, unions, universities, the financial sector, suppliers, and government—to discuss the sector’s prospects, and identify promising, pragmatic policy measures designed to support an industrial turnaround.

Registration details will be announced shortly—be sure to keep an eye out!

VENUE

The 2024 National Manufacturing Summit will be held at the Amora Hotel in Brisbane

Discount

Room Rates for Delegates

Book your stay at the Amora Hotel during the Summit and enjoy an unparalleled 15% discount off the best available rate at the time of booking. This discount will apply from July 30 to August 2. This special offer is designed exclusively for our delegates, ensuring your experience is not just memorable, but also more affordable.

Rate URL: https://reservations.travelclick. com/113954?RatePlanId=8550782 Access Code: WELD24

EXPERT SPEAKERS AND PANELISTS

• Tania Archibald, Chief Executive Australian Steel Products, BlueScope

• Koen De Backer, International Expert in Public Policy

• Natalie Collard, CEO, Farmers for Climate Action

• Emeritus Professor Dr Roy Green, University of Technology Sydney

• Charlie Joyce, Researcher, Carmichael Centre and Centre for Future Work

• Bill Mundy, Consultant, B Mundy & Associates

• Michelle O’Neil, National President, ACTU

• Vesna Olles, Director of Strategy, Clean Energy, BOC

• Peter Ong, National President, Electrical Trades Union

• Jim Stanford, Economist & Director, The Australia Institute & Centre for Future Work

• Elizabeth Thurborn, Professor of International Political Economy, University of NSW

• Dr Philip Toner, Honorary Senior Research Fellow, University of NSW

DOWNLOAD THE PROGRAM

EMBRACING THE HEAVY METAL WELDING REVOLUTION

MEET THE CIGWELD TRANSMIG 555i

In the dynamic world of heavy metal welding, having the right tools is crucial. Enter the CIGWELD Transmig 555i, a powerhouse machine that redefines industry standards and elevates your welding game to the next level.

Power and Performance

The Transmig 555i boasts a formidable 555-amp inverter machine, delivering robust power for heavy metal applications. Whether in heavy fabrication, mining, oil and gas, civil construction, shipbuilding, or structural steel setups, this machine tackles the toughest jobs in the industrial space. With a rated duty cycle of 40% at 555A and 60% at 500A in MIG, TIG and STICK, it ensures consistent performance even under heavy loads regardless of the job type.

Energy Efficiency

Complying with European Union ECOPower regulations, the Transmig 555i stands out for its energy efficiency. It provides more output amperage for your energy dollar, making it a cost-effective choice compared to older machines. Lower running costs without compromising on power is a win-win for any serious welding and fabrication company looking to get the most bang for buck.

Advanced Features

A standout feature of the Transmig 555i is its AUTO-SET function, which simplifies setup. By selecting the material type, consumable diameter, and plate thickness, the machine automatically adjusts to provide optimal parameters and takes the guesswork out of welding. This ensures precision and ease, even for complex welding jobs.

Multi-Process 4-in-1 Capability

The Transmig 555i supports

MIG, STICK, TIG, and GOUGING processes, making it an extremely versatile multi-process machine. This allows seamless switching between different welding processes, ensuring superior results across various applications.

Ergonomics and Design

Paired with the TWECO Fusion 400 MIG Gun, the Transmig 555i package prioritises user comfort. The ergonomic handle reduces operator fatigue, enhancing productivity and minimising downtime. Its steel spring strain relief and pivot mechanism ensure smooth wire feed and durability, keeping you welding longer and minimise those pesky wire feed issues.

Mobility and Convenience

The Transmig 555i trolley complements the welding unit

with enhanced stability and convenience. Upgraded wheels, all-steel construction, and ample cable storage plus MIG Gun and MIG Pliers holders make it practical for any workplace. The low loader gas cylinder tray with safety chain simplifies transportation and connecting a full-size cylinder, adding to overall efficiency.

The CIGWELD Transmig 555i is more than just a welding machine; it’s a leap forward in heavy metal welding. Its combination of power, ECO efficiency, advanced features, and ergonomic design makes it an indispensable tool for professionals. Embrace the future of welding with the Transmig 555i – because serious work deserves serious equipment.

This editorial was supplied as part of a paid sponsorship package.

THE PORTABLE PLASMA CUTTER...

WITH MORE POWER THAN YOU THOUGHT POSSIBLE

Introducing the Cutmaster+ with all new ergonomic design for best in class portability without sacrificing performance.

• The Cutmaster+ is the perfect combination of power and portability for hand-held plasma cutting machines.

• Featuring an incredible arc stretch, the Cutmaster can be used in unusual cutting positions while maintaining cut quality.

• The Cutmaster+ series machines have remarkable power for machines of their size. The legendary 1Torch™ allows for the Cutmaster+ series to have a best-in-class pierce and cut capacity. The smallest machine in the range, the Cutmaster 40+ has a 12mm pierce and 25mm max severance cut, the Cutmaster 50+ has a 16mm pierce and 32mm max severance cut and the Cutmaster 70+ has a 20mm pierce and 38mm max severance cut.

• With an extraordinary duty cycle thanks to all-new hybrid cooling technology, the Cutmaster 40+ (40% duty cycle at 40A), Cutmaster 50+ (60% duty cycle at 50A) and Cutmaster 70+ (50% duty cycle at 70A) will have your hands giving up before your machine does.

• The Cutmaster+ series, 40+ (230/240V), 50+ (400/415V) and 70+ (400/415V) offer an industrial-grade housing to ensure they can take a battering and keep performing. With an IP23 all-weather rating, the Cutmaster+ machines are ready to work where you need it to – rain, hail or sunshine, day in and day out.

Weld Australia’s Excellence Awards are one of the most prestigious events on the welding industry calendar. The Awards embody and promote the highest standards of craftsmanship, quality and professionalism. The 2024 Welding Excellence Awards are a fantastic opportunity for welders, fabricators and educators across Australia to showcase their people and their operations. Winners will be awarded in each state for each of the award categories below. Award entries close on 23 August 2024.

Company of the Year

The Company of the Year Award recognises superior performance across a comprehensive range of business metrics including: innovation, quality assurance, market success, corporate social responsibility, health and safety, sustainability, and training and development of employees. There are three sub-categories:

• Company of the Year – Fabrication Award Criteria | Enter Now

• Company of the Year – Supplier Award Criteria | Enter Now

• Indigenous Company of the Year Award Criteria | Enter Now

Welding Professional of the Year

This Award recognises professionals who are making a valuable contribution to the Australian welding and fabrication industry. The individual should demonstrate a high level of skill, knowledge or craftsmanship, be dedicated to their profession, and have professional development plans in place. There are three sub-categories:

• Welding Professional of the Year – Welding Coordinator Award Criteria | Enter Now

• Welding Professional of the Year – Welding Supervisor Award Criteria | Enter Now

• Welding Professional of the Year – Welding Inspector Award Criteria | Enter Now

How to Enter the Welding Excellence Awards

Entries must be submitted via the specific online form for each category by 23 August 2024. These forms can be found via the Weld Australia website, by clicking on the relevant red button.

Entry forms can be saved. However, before starting your entry, it is recommended that you download the Award Criteria (also available via the Weld Australia website). You will need the information outlined in the Award Criteria on hand to complete your online entry form.

Project

of

the Year

Award Criteria | Enter Now

The Project of the Year Award recognises excellence in welding and fabrication projects, with a focus on exceptional craftsmanship, a commitment to Australian and International Standards, environmental sustainability and innovation. Projects must have been completed in the 12 months preceding 1 August 2024.

Health

and Safety in Welding Award Criteria | Enter Now

The Health and Safety in Welding Award recognises organisations that are leading the way in encouraging and promoting health and safety throughout the Australian welding industry, and ensuring the health and safety of their own team. Organisations will be judged on criteria such as design and implementation of innovative programs or initiatives, the outcomes of these programs, and the health and safety of their team.

Trades Person of the Year

This Award recognises tradespeople who are making a valuable contribution to the welding and fabrication industry. The individual should demonstrate a high level of skill, knowledge or craftsmanship, be dedicated to their profession, and have professional development plans in place. There are three sub-categories:

• Young Trades Person of the Year Award Criteria | Enter Now

• Young Indigenous Trades Person of the Year Award Criteria | Enter Now

• Trades Person of the Year Award Criteria | Enter Now

Training and Education Award – Organisation Award Criteria | Enter Now

The Training and Education Award recognises the outstanding achievements of a STEM or VET provider or program. Entrants may include secondary education and tertiary education providers. Criteria include delivery of quality, innovative training programs, involvement with industry, recruitment and retention of students, and corporate social responsibility.

Training and Education Award – Individual Teacher Award Criteria | Enter Now

This Award recognises the outstanding achievements of a STEM or VET teacher. Entrants will be judged on criteria such as delivery of quality, innovative training programs, high level of knowledge or craftsmanship, strong links with students, and dedication.

Attend the Awards

• Queensland & NT: Wednesday 9 October at Waters Edge, 39 Hercules Street, Hamilton

• NSW & ACT: Wednesday 24 October at Kirribilli Club, 11 Harbourview Crescent, Lavender Bay

• Victoria & Tasmania: Wednesday 6 November at Crowne Plaza Melbourne, 1-5 Spencer Street, Docklands

• Western Australia: Thursday 21 November at Burswood on Swan, 1 Camfield Drive, Burswood

• South Australia: Thursday 28 November at Kooyonga Golf Club, May Terrace, Adelaide

Ken Trevena Award – South Australia Only Award Criteria | Enter Now

This Award recognises someone who has demonstrated an outstanding welding expertise on a particular project, attained meritorious skill in a Weld Australia Course, made a contribution to the art and science of welding, or developed a welding principle, technique or process.

Mick Cudmore Award – Western Australia Only Award Criteria | Enter Now

This Award recognises someone who has demonstrated an outstanding welding expertise on a particular project, attained meritorious skill in a Weld Australia Course, made a contribution to the art and science of welding, or developed a welding principle, technique or process.

WITH THANKS TO OUR SPONSORS

Why Enter the Welding Excellence Awards?

An industry award win can act as a third party endorsement for your business. A win can give a seal of approval to your activities and is a sign of quality for potential customers.

Business awards can be an overlooked tool in your marketing toolbox. Make sure you maximise PR exposure and update your marketing materials. Winning an industry award can open doors to getting contracts, finding new supply channels and breaking into new markets.

Business awards validate your hiring stature among new recruits. By pitching yourself as the best, you can attract the talent you need to push your business forward.

MANUFACTURING SPECIALIST SPEARHEADS ROBOTIC INNOVATION

How Automation is Transforming RCR Mining Technologies

The port city of Bunbury, on Western Australia’s south coast, is the home of RCR Mining Technologies. For over 45 years, the company has designed, developed, and delivered award-winning solutions for clients. As an original equipment manufacturer, RCR is involved in the delivery of repeat, high-volume work. Automation has increasingly become a way to enhance workflow and production. The business recently invested in robotic welder arm technology, which has increased both quality and safety. It is part of an ongoing push to streamline operations and deliver better results for RCR’s international list of clients.

RCR Mining Technologies—an original equipment manufacturer and supplier based in Western Australia— specialises in apron and belt feeders, conveyors, and stackers.

As RCR’s Operations Manager, Mark Hayward has overseen a suite of changes to the company’s operations and processes. Robotics are one area that RCR has expanded into; taking full advantage of the endless opportunities offered by the technology.

“My task is to look at how we can do things differently and to do it more efficiently,” he said. “I know there are quite a few companies around WA that have been on the path of robotics and automation for a while now, but it is a fairly new direction for us.”

The company recently procured a robotic welder arm—poised to deliver faster results, enhanced safety,

and less wastage—for its Bunbury workshop.

Welding robots, although not entirely new, are an untapped area of potential for many businesses in the sector.

The robots work when an arm, equipped with welding equipment, performs precise welding tasks. The technology may be programmed to deliver a variety of projects in an autonomous fashion.

RCR’s robotic welder arm draws on the items requiring fusion, which are then locked, clamped, and bolted into position.

“It gets loaded from one side and you essentially press the button, and it spins around and welds it all out for you,” Hayward said.

The Benefits of Automation

The machine has been a gamechanger for RCR because it

produces welded Items in the same way every time, without skipping a beat when it comes to quality.

Additionally, it has reduced lifting requirements by up to 75 per cent and minimised manual handling.

As Hayward explained, previous processes were not scalable, so it made sense to adopt the innovative technology. “It has freed up a lot of resources for our team to allocate to other important tasks that can’t be automated.”

“Using the manual processes, we could produce eight items in a day. Now we’ve managed to reduce the cycle time from an hour per item down to about 20 minutes per item. On a really good day, we can get it to 15 minutes,” Hayward said.

The latest technology was installed at a challenging time for RCR— the company was facing labour shortages and an increasing

workload. It is an endless loop for many manufacturers in the sector, who are balancing a greater demand for parts with a reduced workforce.

Hayward said more workshop space, staff, and equipment may seem like obvious changes to operations, but every system is limited by its ‘ceiling’ of efficiency.

“We’ve managed to quadruple the production rate by using that robot, and the quality and consistency is very repeatable and very high. Nearly all of that high volume, repeat work can be automated where possible,” Hayward said.

The increased output has been met with a reduction in incidents, injuries, hazards and risks. “Safety is an important consideration, reducing a lot of risks associated with manual handling,” Hayward said.

While technology and automation offer a variety of benefits, Hayward

is speculative of company-wide adoption. “Many companies may consider automation, but it is important to look closely at your processes and eliminate the waste, before implementing automation technology,” he said.

Automation may also contribute to more sustainable and environmentally friendly practices. RCR has adopted a LEAN manufacturing workplace, which focuses on minimising waste during the manufacturing process without compromising on productivity. The company has heavily invested in research, programming and trials to ensure staff boast the confidence to work across all aspects of manufacturing.

RCR’s robotic welders have minimised environmental damage and protected staff from hot sparks, and other risks associated with manual handling. The operator is also totally removed from any fumes or arc radiation hazards.

“There are no fumes, no radiation, the operator is totally removed from that. One side is an operating side, and one side is a loading and unloading side. It’s a continuous cycle.

“The operator loads one side while the robotic welder arm is working on the other side. It then spins around, and rotates everything as well,” Hayward said.

RCR operates six sites across Bunbury, which also feature a fully automated recycling reclaim system. It allows the recyclability of items used in the manufacturing process, which leads to less waste and better production. The automation has had such a vast impact on the business, the upstream and downstream teams are unable to keep up.

This paves the way for more technology adoption and enhanced processes across the business. “We design it, we engineer it, we draft it, and then it goes through all

the stages of manufacturing, which is machining, fabrication, surface treatment, and then into assembly. We’ve got this robotic welder that sped up the process so we’re trying to continue that journey in other areas of our business too,” Hayward said.

Apprentices Driving Workplace Efficiency

The push for greater technology means RCR can better resource its business. Apprentices have been the key to securing the next generation of welders and fabricators.

A new pipeline of staff on the work floor means more skilled resources are freed up for other tasks that are unable to be automated.

As senior staff are repurposed to other areas of the business, apprentices are able to comfortably program and operate the robotic welder arm technology.

“We’re training all the apprentices and getting them involved in the

technology, while also getting the existing people here to embrace the change.”

“We now have a very well structured work experience and apprenticeship program to ensure we have a steady stream of graduating apprentices,” Hayward said.

Since 2020, RCR has nearly quadrupled its total number of apprentices. In fact, 20 new apprentices signed up with the company last year.

The apprentices are rotated around the business to increase their exposure to other trades and help upskill even further. RCR has also partnered with two local clients, which means apprentices can rotate through other workshops for increased experience.

“They might be doing a fabrication and welding trade then they will be seconded for three months into the

assembly workshop or the machining workshop.”

“We do occasionally have some apprentices who actually liked that more than what they were doing and changed pathways,” Hayward said.

The apprentice program includes existing employees, who are given the opportunity to upskill, and transfers from other companies.

“Essentially the goal is to have apprentices graduating from every single team, every single year.”

Three female apprentices—one boilermaker welder, mechanical fitter, and an industrial blaster painter—also took part in last year’s program.

“Traditionally, and still today, it’s a male dominated industry. But the fact that we’re seeing the female apprentices enter the program, and succeed at it, has been really great to see,” Hayward said.

Photo: TBC

RCR Mining Technologies was founded in 1979 when Ron Stevens, Clive Butcher and Robert Wovodich teamed up to provide fabrication services to the local industry.

From their humble home in Bunbury, the team soon expanded and began servicing clients from around the world.

“Our equipment is sold all across the world. You can see some in North America, South America, Africa, and even in Kazakhstan and Mongolia,” Hayward said.

The equipment is designed to withstand different climates and applications.

The Western Australian mining industry plays a vital role in the Australian economy, and the global resources sector. Today, the brand is an enviable operation tasked with delivering high quality

mining technologies, innovation and services.

“We’ve got six workshops down in Bunbury. As far as the advanced manufacturing goes, we do have one of the best surface treatment facilities in WA,” Hayward said.

Because of the fast turnaround for parts required across industry, RCR is always on the tools delivering services to its clients operating in the iron ore, gold and lithium sectors.

Across the three largest companies operating in the local mining sector (FMG, BHP, Rio Tinto), RCR Mining Technologies boasts a 50 per cent market share in apron feeders.

“We’re producing a very high volume of work at a very high standard of quality and consistency,” Hayward said.

WOMEN IN WELDING

Bonnie Inkster, Fabricator at Walkinshaw Racing

Bonnie Inkster’s journey to fabricating supercars showcases the power of pursuing your dreams. With seven years of welding experience, she has broken barriers in the male-dominated automotive industry. Her career in welding began with a bold move to Melbourne, enrolling in a motorsport course, which led her to work with top motorsport teams. Inkster’s dedication earned her the Empowered Women in Trades (EWIT) Apprentice of the Year Award earlier this year. She now aims to inspire the next generation of female welders, proving that with the right support and training, anyone can achieve their goals.

From bartending to working on supercars, Bonnie Inkster exemplifies the power of pursuing your dreams. Building on fundamental welding skills, she demonstrates how apprentices, given the right support and training, can help shape the future of the industry.

Inkster’s journey to becoming a welder and fabricator for Walkinshaw Andretti United has been a rewarding one.

“When I finished high school, I wasn’t sure what I wanted to do. So, I just stuck with bartending for a few years,” Inkster said.

“One day I was watching the supercars on the TV at work, and

I went, I’m going to do that. So, I packed two suitcases, flew down to Melbourne, signed myself up at a motorsport course at the Kangan Institute, and started my first trade there,” Inkster said.

“After that, I got a job in motorsport with a team. And from there, I wiggled my way into the fabrication side of things and really enjoyed it,” she said.

“I decided to get my trade certificate as it is more appealing than not having one. That way I learnt more skills as well. After the certificate, I got a job working with another motorsport team which is where I currently am,” Inkster says.

“ By entering a typically male dominated workforce, we are challenging stereotypes. We are able to inspire others to pursue careers based on our interests and abilities rather than social expectations.”

The opportunities available at Kangan Institute and Chisholm Institute played a significant role in Inkster’s development.

“My first trade was at the Kangan Institute, and that was at the Automotive Centre of Excellence at Docklands. I thought both the Kangan Institute and the Chisholm Institute had amazing facilities; I couldn’t believe it. I enjoyed my time at both the Institutes. I learnt a lot of skills along the way,” Inkster said.

Today, Inkster holds a Certificate III in Engineering Fabrication, a Certificate III in Light Vehicle Mechanical, and a Certificate II in Motorsport Technology.

Inkster won the Empowering Women in Trades (EWIT) Apprentice of the Year Award in February this year, beating out five other finalists to take out the award. Inkster has even more motivation to develop her skills and master her craft.

“I couldn’t believe it when I got it. Very humbling and overwhelming,” Inkster says.

EWIT is a community for females in the automotive and wider industries that aims to raise female representation and in turn help solve some of the skills shortages.

A Q&A WITH BONNIE INKSTER

Inskter answered a few questions about her career in welding so far.

Can you describe your job?

I am a fabricator at Walkinshaw Racing, the manufacturing and racing services side of the business, which works alongside Walkinshaw Andretti United.

The main part of my job is fabricating and welding parts and componentry for our Gen3 and Gen2 Supercars. We are one of four approved chassis manufacturers for the sport and are a one-stop shop for anything on the cars, I get to work on a variety of

different things, as well as travel as part of the crew to Super2 rounds with our two cars.

Prior to this job I worked for Sterling Pumps, where we manufactured pipes and pumps for the farming and irrigation sectors around Australia and the world.

What inspired you to chose a career in welding?

I got into fabrication while I was learning my first trade in the automotive space. I became a mechanic for another race team in Supercars and, during that time, I had the opportunity to start welding and fabrication. I enrolled at Chisholm Institute to study welding

and fabrication and it really took off from there. As soon as I started, I knew it was the path I wanted to follow. I think the thing that hit me immediately was the ability to challenge myself, there’s a range of different areas to learn and master, whether it be welding aluminium or chromoly.

I spent months away at the team fabricator workshop in Mt Gambier, where I got to learn and work on the chassis table, which was awesome.

I think the defining moment for me was when a colleague said to me “welding is one of those things you either have or you don’t, and you have it.” So, I thought to myself, if this

Photo: Bonnie Inkster accepts the 2024 Empowering Women in Trades (EWIT) Apprentice of the Year Award

bloke thinks I have it, I should commit to doing this full time and see where it takes me.

Why do you think women should consider a career in welding? Why not? Yes, it’s a hands-on job in a typically male dominated industry, but you are constantly learning and improving, which is extremely motivating. It’s already provided me with some amazing opportunities; I get to work on some really cool stuff, and the people around me are not only great mentors, but great people as well.

Do you have any advice for women considering a career in welding?

If you think it’s something you’d like to do, have a go, and say yes to every opportunity. I think most women would be surprised at how supportive everyone during my apprenticeships and at my workplaces have been.

Have you found working in a traditionally male dominated industry difficult?

Of course, there were some challenges when I started, but the best thing I did was just keep demonstrating my work ethic and ability.

What is the most interesting project you’ve worked on? Why?

Working in a Supercars team is never boring! The race car starts with us, which is a cool process to be involved in. We see the car evolve from a bunch of tubes, to a full chassis, into a race car, and into something that is (hopefully) winning on the track.

Working as part of the team, you appreciate the work that goes into building the cars a lot more, and it probably hurts a little more when you see the car crash as well!

Even things like fabricating and welding our data station that travels to each round, which becomes the hub for engineers in the garage, is really cool. Normally, computers and data stations sit at a desk and don’t move, whereas we create something

that travels to every state in the country, rolls in and out of the truck, and functions at all times.

What do you believe is the biggest challenge for the welding industry at the moment?

Like most trades in Australia right now, there is a shortage of welders, so getting young people involved in the industry is the biggest challenge. Hopefully we can continue to show what a rewarding job it is and show people that it’s a great industry to work in and make a career out of.

What about the biggest opportunity?

Being a positive role model for other women, both young and old whether it be in motorsport or welding, has been an amazing opportunity. Since

working with Walkinshaw Andretti United I have grown in confidence and this has enabled me to really step up to being an advocate for women entering trades.

Who has inspired you professionally and why?

The team here at Walkinshaw Andretti United and Walkinshaw Racing are great to work with. I think the biggest thing that sets this team and workplace apart is it feels like a family, we probably spend more time together than any other job, and everything we do, is to win.

It’s a fantastic place to work and learn, but always inspires me to do my very best at all times. There’s some fantastic knowledge and experience within these four walls.

CERTIFYING WELDING EXCELLENCE

Upton Engineering Strengthens Australia’s Manufacturing Future

An AS/NZS ISO 3834 certification identifies the quality requirements for fusion welded products. As an internationally recognised standard, it is no surprise many Australian companies are seeking to embark on this certification journey. Upton Engineering and Manufacturing is one of the companies who recently took the next step in their professional journey and certified to AS/NZS ISO 3834. The Queensland-run business is a leading manufacturer and supplier of high tolerance equipment and machinery components. Staff strive for perfection and quality for their clients based around Australia. As such, their recent certification to AS/NZS ISO 3834 goes hand-in-hand with the company’s enviable welding and fabrication program.

Experience is paramount in the welding and fabrication industry. However, companies should not be complacent with their existing skillset. Training and development should be a key component of all businesses operating in the sector.

At Upton Engineering and Manufacturing (UEM), a management team with a combined experience of 65 years drive the company’s push for high quality and safety.

The company was established in 2017, when Mitchell Upton began manual machining works for local companies in Gladstone, Queensland.

Today, the company continues to grow as an advanced manufacturing facility specialising in the precision, manufacturing and assembly of components for a diverse range of industries.

“The company distinguishes itself through its commitment to innovation,

quality and cutting-edge techniques,” Upton said.

As a one stop shop for manufacturing needs, UEM is proud to offer machining, prototyping, and fabrication services.

The team comprises first-class machinists, certified welders, skilled fabricators, welding inspectors, dedicated apprentices and trainees, and a quality manager.

Meanwhile, CAM programmers oversee UEM’s commitment of delivering quality products.

UEM’s expansion has seen staff leaning into the metal fabrication sector, which recognises the demand for integrated solutions among its clients.

It means the company is wellpositioned to take on even the most complex welding tasks in central Queensland.

“With a comprehensive range of

services, we deliver into a wide range of sectors such as defence and aerospace, resources, renewables and power generation, and oil and gas.”

“Our goal is to deliver a true sovereign manufacturing capability and help to drive Australian manufacturing forward,” Upton said.

Today, UEM leads the manufacturing and supply of high tolerance equipment and machined components. The company recently moved into a new state of the art facility able to provide superior CNC machining, fabrication, assembly and project services to the local industry and around Australia.

The CNC machine shop is equipped with integrated 3D modelling and machining capabilities. Using the latest cutting-edge welding technology, it means UEM can successfully operate jobs of up to five tonnes.

Photos

Top: An Upton Engineering team member hard at work.

Bottom: The Upton Engineering team.

“We take pride in highlighting our digital twin simulation technology, enabling precise planning and optimisation of manufacturing processes.”

“Additionally, our facility boasts five axis simultaneous machining capabilities, CAM software for streamlined production workflows, and advanced additive manufacturing for rapid prototyping,” Upton said.

UEM relies on a diverse background of staff with expertise ranging from aerospace machining to ISOaccredited welding.Together, staff are encouraged to share ideas and collectively shape the identity and quality standards of the company.

“We have quite a diverse range of staff members, from first year apprentices and trainees to seasoned senior tradesmen, who have wealth of talent across various disciplines.”

“Our commitment to innovation and excellence is reflected in our stateof-the-art facilities and advanced manufacturing equipment, ensuring we remain at the forefront of the industry,” Upton said.

The Next Generation Driving Change

The welding and fabrication sector relies on a solid pipeline of apprentices to ensure Australia’s sovereign manufacturing capabilities are strengthened into the future.

However, the sector remains challenged by the lack of human resources entering, and staying in the industry. This challenge has been exacerbated in recent times, with Australia facing a labour shortage.

UEM is no stranger to these challenges. As such, the company has taken matters into its own hands.

“This realisation has reinforced our belief in the paramount importance of training our own workforce. Through our apprenticeship program and commitment to hands-on training, we not only address the immediate skills gap but also cultivate a pipeline of talent tailored to our specific needs,” Upton said.

UEM continues to invest in the development of existing staff, and attracting fresh faces to the company. Upton said the company’s training and development program is tailored towards the expertise necessary to meet the evolving demands of the local industry.

“This proactive approach not only secures our company’s future but also contributes to the overall growth and resilience of Australian manufacturing.”

All staff receive mentorship and training opportunities, which are in line with Australian and international standards.

Reaching to New Heights With AS/NZS ISO 3834

An AS/NZS ISO 3834 certification controls the entire lifecycle of the welding process. This internationally recognised standard is a no-brainer for many Australian companies seeking to maintain their commitment to quality and remain competitive on the global stage.

From the design phase to the final weld inspection, this standard guarantees practitioners consider every aspect of a weld’s quality.

It offers a comprehensive approach to welding, and increases the overall quality and customer satisfaction. After all, it is impossible to undertake the complete verification of a welded joint without destroying it.

UEM recently underwent certification to AS/NZS ISO 3834 with Weld Australia’.

“Having ISO 3834 certification gives our customers the added confidence that our welding processes are systematically controlled, resulting in improved efficiency, consistency, and quality across all welding operations.”

“This level of control and standardisation not only minimises the risk of defects and rework but also enhances customer satisfaction by delivering products that meet or exceed their expectations,” Upton said.

Upton said the certification has increased UEM’s quality and competitiveness.

“We feel it opens up new opportunities for business growth and collaboration not only for our existing customers, but provides a solid foundation for expanding, particularly in industries where welding quality is of paramount importance.”

“Having this third party accreditation gives prospective customers who don’t know UEM the added confidence in our systems for projects that involve complex components and assemblies that require very high quality welding standards,” he said.

Upton also encouraged likeminded organisations to embark on the certification process with Weld Australia—the premier certification body across the nation.

“We feel it has also helped to foster continuous improvement within our organisation by promoting a culture of accountability, innovation, and ongoing skills development.”

“By adhering to the principles and requirements of ISO 3834, we gained valuable insights into optimising welding processes, identifying areas for enhancement, and implementing best practices to drive efficiency and quality,” he said.

A PATHWAY FOR VETERANS AFTER SERVICE

Serving Australia is one of the greatest honours for many people. However, life after service can be a complicated path to navigate.

After transitioning back to civilian life, many veterans remain committed to service in some way, shape, or form.

Upton Engineering and Manufacturing is a proud supporter of Veterans’ Employment. This program seeks to transition service members back into the workforce once they complete their service.

Upton said this passion was sparked after his own experiences in the Defence Force.

“Some of the trades and skills you learn in defence aren’t always recognised with employers in the civilian world.”

“However, we appreciate the unique attributes that veterans often possess, including discipline, teamwork, problem-

FURTHER INFORMATION

solving abilities, and a strong work ethic, which is the perfect fit for the work we are trying to do,” he said.

Veterans are highly valuable assets in many organisations because of their wide variety of skills and teamwork mentality. In fact, rates of employment for reservists (89 per cent) and veterans (75 per cent) are comparable to the national average (74 per cent).

“By actively recruiting and hiring veterans, we not only provide them with meaningful employment opportunities but also benefit from their unique perspectives and contributions to our company culture,” Upton said.

The Veteran Employment Program is an Australian Government initiative designed to champion the skills of veterans in the civilian workforce.

Since 2016, the program has helped Australian businesses maintain healthy working environments where veterans can showcase their skills and thrive.

For further information about Upton Engineering, their services and their career pathways, visit: uptonengineering.com.au

SUSTAINABLE AND CERTIFIED

How IMF Group is Taking Charge of its Future

IMF Group has been building Australia’s future since 1994. Situated in the heart of the Hunter Valley’s industrial region, the company has grown to over 90 staff members.

Starting as a family business, IMF Group has expanded its roots to become a competitive player in the local manufacturing space.

Today, a resolute workforce is focused on delivering high quality projects with a commitment to safety and ongoing professional development.

The business recently certified to ISO AS/NZS 3834.3. This Australian Standard cements IMF’s expertise and allows prospective clients to rest assured knowing they are in safe hands.

Thirty years ago, Peter Unwin established Industrial Maintenance and Fabrication (IMF) in Rutherford, New South Wales. Unwin’s vision was based on the core values of safety, excellence, openness and teamwork. Since then, these pillars have underpinned the company’s purpose of building Australia’s future.

Following Peter’s tenure, his son Scott assumed the company’s leadership. Scott transformed the business into a thriving enterprise with a turnover exceeding $20 million and a workforce of over 90 staff members.

The company has recently changed hands once again, with Farhad and Suzie Maleklou carrying on Unwin’s legacy by taking over both assets and employees.

John Mackenzie works closely with the Maleklou family as the company’s General Manager. He said the company has the expertise and confidence to take on a broad range of projects.

“IMF’s senior management team have significant experience and a wealth of knowledge in fabrication and

construction across the mining and infrastructure sectors.”

“As a fabrication business, IMF boasts a diverse team comprising boilermakers, riggers, draftsmen, and engineers, all with extensive backgrounds in the infrastructure, utilities and mining sectors,” Mackenzie said.

Today, IMF operates across steel construction, mining services, and design solutions.

“Under the entities, you’ve got design solutions; mining services out there to supply labour to the mining market; and then we’ve got steel construction that then carries out all the workshop-based activities and also onsite,” Mackenzie said.

Staff operate from a state-of-the-art facility spanning over 6,000m2. The dedicated team have a proven track record of delivering projects on time, on budget, and to a high quality standard.

IMF offers a range of capabilities to suit all clients, including commercial buildings, water treatment facilities,

large capacity tanks and pipe supports, structural steel and refurbishments

For example, IMF played a crucial role in the manufacture, delivery and installation of steelwork for the Westconnex M5 project. This infrastructure project—designed to transform the way Sydneysiders travel across the city—required steel fabrication and alignment from IMF Group. Similarly, the IMF team conducted steelworks on Sydney’s Central Sation.

Projects like these require immense planning, detailing and consultation with high-level clients. Taking these designs and bringing them to life relies on a dedicated team of fabricators and engineers, who understand the quality and longevity of materials and the environment. IMF’s state-of-the-art facilities are well-positioned to bring these bold turnkey ideas to life.

The company has one of the most extensive teams of designers across the country. These designers— experienced in fabrication and

mining—cater towards their clients’ needs by offering bespoke and innovative solutions.

The team uses 3D point cloud laser scanning, drawing verification, and clash detection, among others, to help facilitate and transform these visions. For example, collision detection features are used in Building Information Modelling (BIM) to rectify conflicts in a threedimensional figure. It means designers can better understand the overall construction constraints in a virtual environment before any ground is broken on a site.

Mackenzie said the company’s management are always pushing the boundaries when it comes to growing its technology and facilities. “We have made significant investments in capital equipment to enhance automation and quality,” Mackenzie said.

The company is adaptable to meet a variety of project sizes, including niche bespoke tasks and customised projects.

“ Here at IMF, we believe that training tradespeople is essential for the entire manufacturing industry to thrive and become more resilient.”

IMF’s talented team of welders and fabricators follow processes to meet quality assurance targets across all projects.

“Additionally, the site facilities have seen improvements, including the addition of new lay-down areas, brand-new offices, and refreshed amenities for the workshop,” Mackenzie said.

These facilities are supported by a cohort of experienced staff who boast workmanship and craft that is wellregarded across the sector.

Mackenzie said well-trained staff are complemented by a new generation of apprentices, who are determined to make a difference. “IMF places great emphasis on talent acquisition and development.”

The company currently employs five apprentices, but is actively seeking more trainees to add to its ranks.

“Here at IMF, we believe that training

tradespeople is essential for the entire manufacturing industry to thrive and become more resilient,” Mackenzie said.

The Federal Government recently announced the Future Made in Australia program, which seeks to take advantage of industrial and economic benefits as the nation transitions to net-zero emissions. However, Weld Australia analysis shows Australia will have a shortfall of at least 70,000 welders by 2030.

As such, a renewed pipeline of apprentices, and interacting with students is essential to begin bridging these gaps and securing a local manufacturing future.

A Sharp Focus On The Future

A business-as-usual approach is no longer sufficient for companies operating in the Australian manufacturing space.

Australia is on a path towards netzero emissions before 2050, and an

“ To achieve what our end users want, everyone here at IMF goes above and beyond. If that’s delivering early or doing last minute works for people, we are more than happy to take on whatever we can.”

emissions reductions by 43 per cent on 2005 levels before 2030. Meeting these ambitious targets requires a whole-of-community approach.

Local manufacturers have a critical role to play in this clean energy transition. IMF has taken this in its stride by implementing a series of steps to ensure operations run in an environmentally safe manner.

Mackenzie said this has become an area of increased focus for IMF. “One notable sustainability initiative is the installation of solar panels, accomplished without any government subsidy.”

The solar panels mean IMF meets 60 per cent of its energy requirements through renewable sources. The energy transformation is one part of IMF’s road towards more efficient practices across all facets of the workplace.

“To further enhance operations, IMF has implemented new processes and obtained certifications. Notably, we

are developing a software program to track project progress, and the new website is now up and running,” Mackenzie said.

Together, this means the business is able to ensure all projects run on schedule and meet tight budgetary requirements.

Moving Ahead With AS/NZS ISO 3834.3 Certification

Certification can be the difference between a prospective client choosing to work with a manufacturer or not. Australian standards are one way in which companies can shine a light on their professional development and training objectives.

As such, IMF recently certified to ISO AS/NZS 3834.3. This series defines the quality requirements for fusion welding of metallic materials. It is one of the most popular certifications in the Australian fabrication sector.

IMF successfully certified to part three in this series, which is focussed on

the standard quality requirements.

“While the certification process, particularly the technically demanding AS/NZS ISO 3834 was arduous, it has instilled valuable disciplines in the way IMF operates,” Mackenzie said.

Many organisations who begin their certification journey, will often begin collecting other certifications to develop their teams and remain competitive in the ever-evolving manufacturing sector.

“Certification to ISO 3834 goes hand in hand with IMF’s other ISO accreditations in ISO 9001, ISO 14001 and ISO 45001 as well as Steelwork Compliance Australia CC2 certification,” Mackenzie said.

The Weld Australia certification process allows practitioners to collaborate with likeminded professionals who mix theory with practice. All Weld Australia assessors and auditors have a minimum of three years practical experience working in the sector.

It means organisations can place their confidence in the rigorous training and auditing that the certification process demands.

Mackenzie said the recent certification means team members work together to meet high standards for their clients.

“I think the team here have the same end goal, which is to make sure the end user is happy. To achieve what our end users want, everyone here at IMF goes above and beyond. If that’s delivering early or doing last minute works for people, we are more than happy to take on whatever we can,” Mackenzie said.

Further Information

For more information about IMF Group and their capabilities, visit: imfab.com.au

ILLUMINATING SUCCESS

Coslee Heavy Metal Fabricators Shines for Over 55 Years

If you’ve driven on an Australian freeway, it’s highly likely that you’ve been guided by one of Coslee Heavy Metal Fabricators’ sign gantries or poles. For over 55 years, the company has been lighting up Australian streets and cities. The family-run business specialises in infrastructure for roadways, cranes and lifting equipment. The business recently underwent accreditation to AS/ NZS ISO 9001, which is expected to bring a new layer of quality to its operations. This certification helps upskill staff and develop a culture in which quality is never compromised.

Streetlights make us feel safe and guide us through dark places during the night and signage directs us to our destination. But have you ever stopped to think about the craftmanship behind these?

Coslee Heavy Metal Fabricators has been at the forefront of roadway infrastructure for over half a century. The company stands tall as the premier supplier of sign gantries and steel poles, which are made to last.

The business is owned by Matt Cosentini and his two sons Richard and Joe. Together, they lead a team of fabricators specialising in structural steel, road infrastructure, overhead cranes and lifting equipment.

James Johnson is the company’s Quality Manager and Welding Coordinator, who said the business’ success is a team effort.

“Coslee Heavy Metal Fabricators takes on jobs of all sizes, fabricating small brackets to huge projects of multiple components.”

Whether it is one light pole or a 50m gantry beam, customer service is central to guaranteeing Coslee’s projects are delivered hassle-free.

The company fabricates a variety of infrastructure for roadways and cranes including gantries, traffic lights, streetlights, barrier rails, and lifting equipment.

Approximately 40 staff, including 22 qualified welders, help the business meet the needs of their clients.

“The workshop has capacity to produce a turnkey product with drafting, shop priming, install, electrical and fitting personal employed.”

“With quality as paramount importance, the workshop is overseen by two welding supervisors,” Johnson said.

Coslee is focussed on being a ‘true blue’ Australian company. The business operates under an Australian Owned banner, and is proud to deliver services for Australians, by Australians.

This means Coslee understands the nature of the local welding and fabrication sector, and the challenges facing clients, particularly around costs, sustainability and durability.

“ ISO 9001 certification has improved the continuity of processes within the organisation, communication, scheduling, timing of incoming goods and outgoing product. It’s minimised waste, improved the allocation of our workforce and minimised down time.”

Galvanised for Greatness

Coslee’s works are available in galvanised or specialised paint systems for long term durability. Clients may also choose from a gamut of signs and poles in stock ready for purchase. The team of fabricators operate beside the Metropolitan Ring Road in Thomastown, Melbourne.

Johnson describes this location as ideal for over dimensional sized fabrication. “The facility consists of a 20,000 square metre site comprising of four fabrication workshops with a huge storage yard. Each factory comprises of overhead cranes, including an outdoor crane facility purpose built for the loading and unloading of open top shipping containers.”

The site’s storage yard is serviced by five forklifts and a mobile yard crane. Meanwhile, a semi with a truck mounted crane is used for onsite installation work.

“Current capacity allows for beams to be built up to 45 tonnes by 50m long in the workshop. Having four independent workshops means an environment can be created for the isolation of dissimilar metal projects,” Johnson said.

This facility is the launchpad for a suite of projects found across Melbourne and beyond. For example, the team has fabricated the iconic yellow poles outside the Melbourne Convention and Exhibition Centre, which greet guests entering the building for conferences and business. Coslee’s poles also support lights at Melbourne Olympic Park; allowing sport to take place well into the evening.

The company has also fabricated a network of sign gantries across Melbourne’s vast road network. The M80 Ring Road, Westgate Freeway, Hume Highway, Donnybrook Road Interchange, all feature infrastructure from Coslee. Similarly,

Coslee Heavy Metal Fabricators has fabricated sign gantries and poles for projects in New South Wales and Tasmania.

Bringing these works to life requires a dedicated team of welders and fabricators. However, Coslee also places a high value on training the next generation of welders and fabricators. The company is proud to support four apprentices, who gain practical skills collaborating with the experienced team.

It means junior staff learn the Coslee way of manufacturing, and can take on new tasks with utmost confidence. All welding procedures have a supporting procedure qualification record and destructive test reports. All non-destructive and destructive testing is carried out by subcontractors with National Association of Testing Authorities (NATA) accreditation.

Once a project has been completed, a Manufacturers Data Report is issued to the client. This document demonstrates that compliance measures have been met on the project. It is an important step

in Coslee’s pursuit for customer satisfaction, and building relationships based on quality and trust. In addition, Coslee produces quality records, including a traceability process, which is embedded into its quality assurance framework.

This occurs when required materials are traced from their material certificate to their location within a structure. Welders, consumables, inspection and testing can also be traced back to specific welds completed on a job.

Certification Meets Craftmanship Certification cannot be understated in the welding and fabrication sphere. In an increasingly competitive sector, companies are developing their skills and reaching for new heights with ongoing certification.

In light of this, Coslee holds a variety of accreditations, including to AS/NZS 5131 CC3, and AS/NZS ISO 3834.2. The company was also recently certified to AS/NZS ISO 9001 through Weld Australia’s premier certification program.

Johnson said the certification has already delivered a raft of benefits to Coslee. “ISO 9001 certification has improved the continuity of processes within the organisation, communication, scheduling, timing of incoming goods and outgoing product. It’s minimised waste, improved the allocation of our workforce and minimised down time.”

The recent certification goes hand in hand with Coslee’s proven abilities and existing certifications. In all, the company is well-equipped to continue taking on big projects.

“ISO 9001 combined with ISO 3834.2 accreditation has definitely refined the processes within the company,” Johnson said.

“The accreditation process from start to finish was straight forward, Weld Australia provided guidance and identified areas for improvement along the accreditation process.”

“The final audit was straightforward, the auditors were knowledgeable in fabrication and were able to provide usable constructive feedback,” Johnson said.

WELD AUSTRALIA’S ISO 9001 CERTIFICATION SERVICES

First adopted in 1987, over one million organisations from more than 170 countries have certified to ISO 9001 Quality management. The AS/NZS ISO 9001 standard is based on a number of quality management principles including a strong customer focus, the motivation and implication of top management, the process approach and continual improvement.

Achieving certification to ISO 9001 means that an organisation has successfully implemented a quality management system that meets the criteria defined in the standard. Certification helps ensure that customers get consistent, goodquality products and services, which in turn brings many business benefits.

The Benefits of AS/NZS ISO 9001 Certification

Obtaining ISO 9001 certification offers several advantages. It showcases a commitment to quality, assuring

clients of standardised, consistent outcomes. This recognition differentiates you in a competitive market, elevating your business reputation. The certification processes can help streamline your operations, reducing wastage, and improving efficiency, to translate into cost savings. It also emphasises continual improvement, promoting innovation and adaptability.

This certification enhances customer trust and satisfaction, potentially increasing client retention and referrals. Some clients mandate ISO 9001 certification for contractual purposes, widening market opportunities. In essence, ISO 9001 can accelerate growth and boost credibility.

Why Choose Weld Australia for Certification?

Weld Australia is a highly respected and independent third-party, and is proud to be the International

Institute of Welding (IIW) Authorised Nominated Body for Company Certification. Weld Australia’s certification process ensures a rigorous audit and testing system is in place. This positions your business as a leader in the highly competitive welding and fabrication space.

When Weld Australia conducts your certification audits and assessment, you have access to our highly qualified team of experts. All our assessors are:

• Qualified and experienced in quality system auditing

• Welding industry experts, with extensive experience

• Certified in Integrated Management System (IMS) Certifications

• Experts in quality management systems, auditing principles and AS/NZS ISO 19011 Guidelines for auditing management systems.

For further information, contact qnc@weldaustralia.com.au

FURTHER INFORMATION

For further information about Coslee Heavy Metal Fabricators and their capabilities, visit: coslee.com.au

HOT ENGINEERING FIRES UP WITH QUALITY AND INNOVATION

Boilermaking and fabrication lie at the heart of Hot Engineering’s foundations. Company Director Hamish Bryant leads a team of professionals to deliver a high-quality range of projects focussed on unique project requirements and safety.

Staff use the latest advanced technology, and developments in the sector, to bring their clients’ ideas to life. Additionally, the company’s strong pipeline of apprentices means Hot Engineering has the confidence to take on new projects into the future.

The business became one of the first in New South Wales to apply for a certification to AS/NZS ISO 9001 with Weld Australia.

Hot Engineering is a locally owned and run engineering workshop based in Mudgee, in the New South Wales central west.

The business was established in 2017 by Hamish Bryant (Director) and Truman Goonrey. Together, Bryant and Goonrey have over 15 years’ experience working across Australia’s diverse mining and construction sectors.

Today, the company has grown to 26 staff—from boilermakers and administration to mechanical fitters and yardman–who have high quality standards with a focus on safety. Hot Engineering provides a range of services from boilermaking, fabrication and machining, through to heavy equipment and pump repairs and structural steel erection.

An Expanding Workforce

Bryant said the company was able to grow during, and beyond, the pandemic, which wreaked havoc on the Australian manufacturing sector.

“Hot Engineering put on one new apprentice every year, we have had two signed off since establishing Hot Engineering and we currently have a first year, a second year and third year apprentice with us,” he said.

This strong pipeline of apprentices secures the next generation of manufacturers, and ensures Hot Engineering is able to remain competitive as the sector rebounds from the economic impacts of the global health emergency.

Hot Engineering’s apprentices travel over 120km to Dubbo, where they undertake their studies. Together, this ensures apprentices gain theoretical and practical experience to build their careers.

Making It Work

Hot Engineering’s Mudgee facility offers flexibility and advanced machinery to ensure all projects meet quality, environmental, and safety requirements.

For example, the CNC plasma cutting table has transformed the way in which Hot Engineering cuts metals. Fabricators are able to save time, money and materials, which means resources can be better allocated to other parts of the business.

Bryant said Hot Engineering has a variety of projects, which they are proud to have worked on. “We have a four year contract with Glencore, where we undertake non-destructive testing and repair all the underground

quick detach systems equipment for the Ulan West and Ulan Underground coal operations.”

“It’s very important that we have a great relationship with such a global company,” he said,

Hot Engineering’s team of boilermakers, engineers and fabricators are steadfast in providing tailored solutions to its clients.

For example, Mudgee’s Woolpack Hotel boasts a steel staircase courtesy of Hot Engineering. The company has also manufactured custom fire pits and bespoke ute trays to meet the demands of a variety of its regional clients.

“The continual growth of Hot Engineering is due to our products, our customer relationships and our people. In order to be successful we are focused on employing motivated, talented, competent and informed people who can initiate and manage a constantly changing and challenging environment that exists in our rapidly growing company,” said Bryant.

“We see our people as part of our competitive advantage and we believe that our shared and ‘lived’ values are essential to continued growth.”

Certification Sparking Quality

Hot Engineering was the first company to apply for the AS/NZS ISO 9001 Quality management certification in New South Wales through Weld Australia.

The certification focuses on the quality management systems associated with welding practices. It helps businesses—regardless of their size—bring good practice into their everyday work.

Bryant said AS/NZS ISO 9001 has helped his team progress to the next level.

“The certification will instil confidence in both our existing and prospective clientele, reassuring them that our

Further Information

For further information about Hot Engineering and their capabilities, visit: hotengineering.com.au

operations conform to globally recognised standards of quality.”

“This commitment to excellence not only fosters a conducive working environment cherished by our employees but also ensures that our clients receive products of esteemed calibre,” he said.

“The certification process was easy and straightforward. Weld Australia made the process simple and easy to navigate through,” Bryant said.

Bryant said he hopes to use Hot Engineering’s recent certification to inspire other companies to embark on the same journey.

“Hopefully this will help other companies to make sure quality comes first and take the steps needed to become certified.”

“ To be successful we are focused on employing motivated, talented, competent and informed people who can initiate and manage a constantly changing and challenging environment that exists in our rapidly growing company.”

AN UPDATE FROM OUR HOTLINE

Weld Australia offers a ‘Hotline’ service to all Corporate Members. The purpose of the Hotline is not to provide a solution, but to advise the enquirer on practical next steps. For further advice, Weld Australia’s highly experienced welding consultants can speak to you over the phone or visit your site in person. If you have a Hotline query, complete our online form: weldaustralia.com.au/hotline.

Weld Australia recently received a request for assistance from a member with medical issues that could preclude him from future work as a welder should appropriate protective clothing not be available.

The welder had recently undergone surgery to divert the bowel to a stoma. This required the use of a colostomy bag, which is made from plastic and worn under clothing. In addition, the welder required the use of a nylon hernia belt.

The member has valid reasons for concern with the wearing of nylon or plastic under clothing whilst welding or performing hot work. Molten spatter can easily melt and/ or pierce plastic and nylon, but more importantly, if the clothing worn by the welder catches fire, the nylon and plastics can melt and cause severe burns to the wearer.

In many cases, welders typically wear cotton drill clothing which can be pierced by molten weld spatter, and, it is also flammable unless treated to be flame resistant. Cotton drill clothing whilst difficult to ignite, is not naturally flame resistant and will readily burn once ignited.

Flame resistant shirts and clothing is readily available but can be significantly more expensive than cotton drill. Flame resistant clothing is manufactured and tested to a range of European and North American standards, but in some cases is made of materials that have limited

durability compared to cotton drill. Unless the material is also intrinsically flame resistant, its flame resistance is typically only guaranteed for a limited number of washes.

Clothing compliant with ISO 11611 Protective clothing for use in welding and allied processes - Class 2 is recommended but this would need to be verified by checking labels on the clothing (it should be noted that ISO 11611 Class 1 clothing is only suitable for light duty welding such as with the manual (stick) process and so on).

Class 2 clothing is suitable for higher duty/productivity welding including gas metal arc (GMAW or MIG) and flux cored arc welding. Clothing rated to ISO 11611 has been tested for fire resistance and electrical resistivity to reduce the risk of welders receiving burns or an electric shock. Class 2 should offer greater protection for the welder.

Alternative clothing materials suitable for welders include welders leathers, some synthetics and woollen clothing or undergarments.

This Hotline update covers a specific query encountered during the last few months. Whilst accuracy in welding is critical, it is impossible to report in detail the full circumstances of the query. As such, Weld Australia recommends that further technical advice is sought in relation to specific, individual circumstances.

Pure wool is naturally flame resistant and chars when exposed to a flame. It is unlikely to be tested to ISO 11611 but is safe for use by welders. Assuming that an impervious wool layer can be created over the nylon belt or plastic stoma, there will be a measure of protection. Some people will find that wool irritates their skin and this should be verified in each case.

Welders leathers such as a leather jacket will provide very good protection from spatter and heat and especially so if it has been rated to ISO 11611 Class 2. Such jackets are commercially available in Australia.

There are also alternative jackets made from Proban claiming compliance with ISO 11611 Class 2. Welding hoods/balaclavas made from this material that can help to deflect spatter originating from above the welder during overhead welding are also commercially available. To date, Weld Australia has not tested this material or its durability so cannot comment on its properties beyond its claimed compliance with ISO 11611.

It is expected that in coming months additional clothing and protective gear for welders will become available meeting this ISO standard. It is also anticipated that later in 2024, this ISO standard will be recommended for adoption as an Australian standard once ISO completes its current revision process.

In summary, a range of fire resistant clothing is available for welders, some of which will provide better spatter resistance than others. Welders leathers that are deigned and manufactured to prevent spatter entrapment or penetration etc will provide the welder with excellent protection whilst welding, but should be supplemented by fire resistant clothing underneath.

The jacket should cover the full upper body and torso, including the area of the body impacted by the nylon hernia belt and plastic stoma or colostomy bag. A full length welders leather apron that covers the torso will also provide good frontal protection.

Welding Safety Resources

Weld Australia has a range of free safety resources available, including:

• Fume Minimisation Guidelines: Welding, Cutting, Brazing and Soldering

• Safety Alert: Welder’s Clothing Catching Fire

• Technical Note 7: Health and Safety in Welding

Visit the Weld Australia website to download your free technical resources.

THE CHANGING FACE OF AUSTRALIAN STANDARDS

Australian Standards are living documents. They reflect progresses in science, technology and systems To maintain their relevancy, all Standards are periodically reviewed, with amendments and revised editions published. The last few months have seen several developments, including ongoing reviews into Standards related to welding safety and consumables, pressure equipment, bridges and steel structures.

Pressure Equipment

The revision of AS/NZS 3788 Pressure equipment—In-service inspection has been completed and the standard was scheduled to be published on 28 June. Committee ME-001 has reconstituted the subcommittee responsible for AS 4343 Pressure equipment—Hazard levels and the revision process will commence shortly.

Welding Consumables

Committee WD-002 has commenced the revision of AS 2576

Welding consumables for build-up and wear resistance. Good progress is being made.

Welding Safety

The revision of the AS 1674 welding safety series is well advanced. The initial drafting of AS 1674.1 Safety in welding and allied processes— Part 1 Fire precautions has been completed. Public review is currently underway and will close on 19 June. The standard is used extensively in industry to establish fire preventative measures whilst welding in locations not necessarily designed for hot work.

Separate to this project, Committee EL-019 has commenced the revision of the sister standard AS 1674.2 Safety in welding and allied processes—Part 2 Electrical in

August 2023. Initial drafting has been completed and the draft has been submitting for preparation for public comment.

Associated with these projects is the revision of AS 2812 Welding, brazing and cutting of metals — Glossary of terms by Committee WD-003. Public comments received have resolved and the committee ballot completed. It is due to be published on 28 June.

Bridges

The amendment to AS/NZS 5100.6 Bridge design — Part 6: Steels and composite construction has been completed and was published in

April 2024. The revision aligns the requirements of the standard with the latest revision of AS 4100 Steel structures, AS/NZS 5131 Structural steelwork—Fabrication and erection, and the New Zealand steel structures design standard NZS 3404.1 Steel structures—Part 1: Materials, fabrication, and construction. The revision will resolve known conflicts and anomalies via an amendment.

Steel Structures

Standards Australia has commenced a major revision of AS 4100 Steel structures in May. Committee BD-001 is managing the project. Cognisance will be taken on the relevant amendments to AS/NZS 5100.6.

WD-003’s project to revise AS/NZS 2214 Certification of welding supervisors—Structural steel welding is well underway. The project will see the standard split into parts and renamed.

The existing standard has become Part 1 and has been revised to accommodate welding inspection, similar to the latest revision of AS 1796 Certification of welders and

welding supervisors. Public comment closed in April and comments received are currently being resolved.

Part 2 covers bolting supervisors and inspectors, and has been drafted with the assistance of members of BD-001 and ME-029. As previously advised, the long term intention is to add additional parts to cover the qualification of key personnel relevant to AS/NZS 5131. Public comment closed in April and comments received are currently being resolved.

Committee BD-023 is currently revising AS/NZS 1594 Hot-rolled steel flat products. Formerly managed by Committee MT-001, this standard primarily relates to grades of steel used in hot rolled coil product form but also relates to lighter gauge plate manufactured from hot rolled coil for structural purposes. Public comment closed on 29 May.

ISO Update

ISO TC44/SC10 has completed the revision of ISO 3834 Quality requirements for fusion welding of metallic materials series of standards

primarily taking cognisance of changes to ISO 9001 Quality management systems — Requirements and the 2019 edition of ISO 14731 Welding coordination — Tasks and responsibilities. Parts 1 to 5 inclusive have been published and adopted by Standards Australia as direct text adoptions. Revision of Part 6 of ISO 3834 has been completed and the work is underway to for its adoption in Australia.

TC44/SC10 has also been revising ISO 17660 Welding — Welding of reinforcing steel. This edition is planned to combine the two existing parts into a single document. Work is ongoing.

Similarly, ISO TC44/SC11 has been revising ISO 9606-1 Qualification testing of welders—Fusion welding— Part 1: Steels to combine all 5 parts into the one standard. This will simplify the ongoing maintenance and review requirements for the standards currently published as Parts 2 to 5 of ISO 9606-1. Comments received from the CD draft and ballot are currently being resolved.

AN UPDATE FROM WELD AUSTRALIA’S INDUSTRY GROUPS

Weld Australia’s Industry Groups provide a forum for technology transfer and research and development, linking members with industry and research organisations. Weld Australia works with Technology Network members to ensure they remain diverse and resilient in the ever-changing and increasingly challenging global markets.

WELDING SAFETY COUNCIL

A meeting of the Welding Safety Council was held on 9 April 2024. It kicked off with an update on Australian and international Standards provided by Bruce Cannon (Principal Welding Engineer, Weld Australia).

The recent changes to the Weld Fume Workplace Exposure Limit, which reduced the limit from 5mg/m3 to 1mg/m3 were also discussed.

This change will require a more stringent approach to the implementation of controls during the welding process to achieve the requirements of the new limit. In particular the hierarchy of controls needs to be considered when implementing these controls:

• At source fume extraction

• Good general workplace and workshop ventilation

• Powered Air Purifying Respirators (PAPR)

Weld Australia has made a range of free resources available and established a dedicated phone hotline for enquiries. It seems that most companies are trying to comply with the new regulations.

Andrew Davies (Manager, Technical Industry Networks, Weld Australia) provided an update on the Welding Safety Training Courses. Weld Australia developed two comprehensive online training courses designed to improve safety outcomes across the country. These courses were launched in early March and have been well received by industry. The courses are available via the Weld Australia website or https://weldtraining.online

DEFENCE INDUSTRY NETWORK

The Defence Industry Group met on 10 April 2024.

Russell Lockett (Austal) gave an engaging presentation that provided

an overview of the Austal Group, facilities, range of products, state of orders, and expectations for the future.

Jason Elias (CEO, Precision Metal Group) led an open discussion on local Australian manufacturing in the defence industry, focused on issues and challenges.

The discussions highlighted that one of the major challenges currently facing the defence industry is that of skilled labour, especially the shortage of qualified welders and engineers with a good foundation in hands-on manufacturing.

Another challenge discussed by attendees was that the process of quality, certification, compliance and associated documentation keeps moving and evolving. Welders also need ongoing certification and recertification.

POWER GENERATION INDUSTRY GROUP

The Power Generation Industry Group comprises:

1. Boiler Industry Group

2. Process Safety Industry Group

3. Asset Integrity Board

Process Safety Industry Group

The Process Safety Industry Group met online on 3 April 2024. The theme for the meeting was Management of Change—each member gave a short presentation on this topic.

CS Energy gave a presentation on the technical findings of the Callide Unit C4 incident which occurred on 25 May 2021. This was an analysis and explanation of the sequence of events that lead to the failure of the C4 turbine generator.

Energy Australia gave a presentation of the investigation, findings and learnings of a hydrogen pack leak. This was not a serious incident but gave some very useful learnings.

Stanwell gave a presentation on the process of the management of plant modification requests. Synergy gave a presentation on the risk management of battery energy storage systems.

A new project was also discussed, which will focus on BESS fire management and response.

Asset Integrity Board

The Asset Integrity Board met on 7 March 2024. Representatives from EnergyAustralia, CS Energy, Delta Electricity and Weld Australia were in attendance.

It was agreed during the meeting to expand the group across boilers as well as turbines, and to rename the group the Boiler-Turbine Industry Group. Turbine-related employees of member companies will be invited to the next meeting.

The issues of recruitment, training, developing, mentoring and retaining these critical skills were discussed.

The topic of cyber security was also a focus. Issues with remote monitoring and control of BESSs have arisen for some members of the group.

ISO 81346 Industrial systems, installations and equipment and industrial products – structuring principles and reference designations was on the agenda.

An updated plant labelling system that may be applied to new builds was also discussed. Members advised that existing plant has been labelled in accordance with KKS or other systems and so is not feasible to re-label under a new system. The new system would be appropriate for new builds such a BESS or other renewable plant which are currently being planned by a number of energy generators.

Renewable energy was also discussed, specifically the planned projects around the country. The pros and cons of lithium, phosphine and vanadium batteries were also raised.

Boiler Industry Group

The Boiler Industry Group met on 22 and 23 May at Loy Yang B Power Station in Victoria. This was the first meeting of the newly combined Boiler-Turbine Industry Group, which included presentations for both boilers and turbines.

Of particular note, Toshiba attended and presented on turbine life issues. This was followed by other presentations by on B LP Turbine Rotor Refurbishment (CS Energy), High Energy Piping – Callide B (CS Energy), Boiler Integrity Program (EnergyAustralia), Loy Yang B Unit 1 Reheater Tube Replacement Strategies (Loy Yang B), and Close Proximity Radiography (IRIS NDT).

The meeting also included a site inspection of the Loy Yang B boilers and turbines which was appreciated by all. The meeting was very well attended with 25 participants in person and a further 15 online, from around the country.

FURTHER INFORMATION

For further information or to join one of our Industry Groups, contact: Andrew Davies on a.davies@weldaustralia.com.au or 0438 428 966.

Boiler Industry Group meeting in May

FACE-TO-FACE WELDING SUPERVISOR AS1796 & AS2214

Starts 8 July

A Welding Supervisor qualification expands your career horizons enormously. Both AS 2214 and AS 1796 Certificate 10 meet the requirements outlined in AS/NZS 1554.1 to supervise the welding of structural steel. Similarly, AS 1796 Certificate 10 meets the requirement for a welding supervisor under AS 1210 for pressure vessels.

ENROL NOW

FACE-TO-FACE

Starts 26 August

This face-to-face training runs over a 1-week block in Melbourne. The first 4 days consist of theory and practical training, with the final day a practical exam. The theory exam will be scheduled online the following week. The IWI-B course is a globally recognised IIW qualification that covers general knowledge of welding and inspection.

ENROL NOW

WELDING INSPECTOR AS1796 CERTIFICATE 11

Starts 15 July

The Certificate 11 is an Australian Welding Inspection qualification recently introduced to AS1796, this qualification builds upon the foundation knowledge expected of a Welding Supervisor with a distinct emphasis on inspection activities related to pressure equipment, as well as the documentation associated with this role.

ENROL NOW

FACE-TO-FACE IWI-B TRAINING IN PERTH

Starts 2 September

This face-to-face training runs over a 1-week block in Perth. The first 4 days consist of theory and practical training, with the final day a practical exam. The theory exam will be scheduled online the following week. The IWI-B course is a globally recognised IIW qualification that covers general knowledge of welding and inspection.

ENROL NOW

ONLINE WELDING SUPERVISOR AS2214

Starts 12 August

Welding Supervisors play a vital role in industry, they understand the factors that influence welding quality, how to oversee welders effectively, and the variables that help maximise productivity. The course includes a mixture of prerecorded material, live online lectures, and a variety of other learning resources.

ENROL NOW

ONLINE AS1796 CERTIFICATE 1-9 THEORY

Starts 2 September

An AS1796 Welding certificate is one of the accepted welder certifications. It is used in both structural and pressure equipment Standards. It is by far the most well known and requested welder certification nationally. The course is delivered online over 15 sessions, live via Zoom. Participants can ask questions, in real time.

ENROL NOW

Weld Australia is pleased to announce the launch of a brand new training course in line with the requirements of Welding InspectorAS 1796 Certificate 11. The first session of the course will kick off on Monday 15 July.

The Certificate 11 is an Australian Welding Inspection qualification that was recently introduced to AS 1796 Pressure equipment — Qualification of welders, welding supervisors and welding inspectors. This qualification builds upon the foundation knowledge expected of a Welding Supervisor with a distinct emphasis on inspection activities related to pressure equipment.

The Certificate 11 training is run online over six weeks, followed by a two-day practical training session. The course includes a mixture of interactive online material, live online lectures and in-person training.

Participants will gain an understanding of the roles and responsibilities of a welding inspector, and the comprehensive documentation associated with the role, including:

• Understanding AS/NZS ISO 9606.1 Qualification testing of welders and how to apply it

• Welding imperfections and defects in various materials

• Non-destructive and destructive testing

• Limits of imperfections and acceptance criteria

• Understanding and implementation of AS/NZS ISO 9001 and AS/NZS ISO 3834

• WPQR and WPS

• Welder qualification

The practical training covers:

• Visual examination of weld samples

• Reading and understanding the implications of testing reports, including destructive, radiographic, ultrasonic, liquid penetrant, and magnetic particle

• Documentation verification

This course is designed to equip participants with the skills and knowledge to excel as a proficient welding inspector, ensuring compliance with the latest edition of AS 1796.

Prerequisites

Students must hold an AS 1796 Certificate 10 qualification to meet the requirements for this course.

Please note: Students with an AS 1796 Cert 10 qualification, and an IIW International Welding Inspector - Standard (IWI-S) qualification can apply for the Certification 11 without further training or examinations. Please email qnc@weldaustralia.com.au to apply.

Further Information

For further details, download the Course Schedule, or contact training@weldaustralia.com.au

MEMBERSHIP