Q3 | September 2022 1 Q3 | SEPTEMBER 2022 Official Journal of Weld Australia weldaustralia.com.au WELDING AUSTRALIAN A First for Australian Welding CAgroup invests in robotics for gas tungsten arc welding of lead Page 22 Bridgeman Where social conscious is synonymous with success Page 32
Bridgeman: Where Social Conscious is Synonymous with Success
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Launched in 2020, the BHP FutureFit Academy is part of a new national training program designed to bolster Australia’s skills base and create new career pathways into the mining sector.
Weld Australia would like to congratulate Bruce Cannon (Principal Welding Engineer, Weld Australia) on winning the International Institute of Welding (IIW) 2022 Thomas Medal.
Corrections Victoria has expanded the VET Centre of Excellence model to deliver ISO 9606 certification at Langi Kal Kal prison, with the support of Weld Australia.
Bruce Cannon Wins the IIW 2022 Thomas Medal
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Life After Prison: VET Training and Employment Pathways
Indigenous owned and operated, social conscious is synonymous with success for this Queensland metal manufacturing and construction company.
FEATURES
Weld Australia 2022 Member Survey Results
A First for Australian Welding CAgroup invests in robotics to undertake gas tungsten arc welding of lead in Welding
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Brittany JRSApprenticeHague,Boilermaker,ManufacturingGroup
Weld Australia’s 2022 Member Survey results demonstrate that significant concerns remain for Australia’s welding industry. In particular, fabricators are being forced to turn down work due to a severe shortage of skilled welders.
2022 Welding Excellence Awards
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26 Women
BHP FutureFit Academy
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Australian Welding2 CONTENTS
IN THIS ISSUE
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Weld Australia’s Excellence Awards embody and promote the highest standards of craftsmanship, quality and professionalism. They are a fantastic opportunity to showcase your projects, people and your operations.
Q3 | September 2022 3 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. WELD AUSTRALIA CONTACTS National Office PO Box Macquarie197Park BC NSW 1670 02 8748 weladustralia.com.auoffice@weldaustralia.com.au0100 Chief Executive Officer Geoff Crittenden 02 8748 g.crittenden@weldaustralia.com.au0100 ENGINEERING Victor Blain, Engineering Team Manager 0409 823 v.blain@weldaustralia.com.au991 TRAINING Guy Brooks, Training Manager 0488 743 g.brooks@weldaustralia.com.au322 MARKETING Disha Mistry, Graduate Marketing Assistant 0497 497 d.mistry@weldaustralia.com.au424 MEMBERSHIP David Choudry, Membership Manager 0417 878 d.choudry@weldaustralia.com.au104 QUALIFICATION & CERTIFICATION Deniz Yalniz, Qualification and Certification Team Manager 0487 487 d.yalniz@weldaustralia.com.au170 A Message From Weld Australia’s CEO 04 A Message From Weld Australia’s Chair 06 Inside the Industry Breaking News 11 2022 Welding Excellence Awards 14 Health and Safety 16 Business Essentials 18 Inside Weld Australia An Update from Weld Australia’s Hotline 42 The Changing Face of Australian Standards 44 An Update from the AWTCs 46 An Update from Weld Australia’s Industry Groups 48 Fusion Welding Courses 51 REGULAR COLUMNS BECOME A MEMBER Cover: Women in Welding Haylee Megahey, Apprentice Boilermaker at Bradken. Story on page 20
Australia’s skilled welder shortage has reached critical levels. Industry is already at capacity, with Weld Australia’s members turning away projects because they cannot find enough welders to complete the work. We have known for some time now that Australia will have a shortfall of at least 70,000 welders by 2030. Alarmingly, this projected shortfall of welders does not account for Australia’s move from carbon fuelled power generation to a renewable energy system. To combat this skills shortage, innovative training solutions are required.
We have known for some time now that Australia will have a shortfall of at least 70,000 welders by 2030.
Australian Welding4 FROM THE CEO
Withmarket.aconsiderable
According to the Australian Energy Market Operator’s (AEMO) 2022 Integrated System Plan, for Australia to become a renewable energy superpower, National Electricity Market needs approximately 269 GW of wind and approximately 278 GW of solar—equivalent to 34 times its current capacity of Variable Renewable Energy (VRE).
And, let’s not forget the strain that this is having on welders themselves. With so few skilled welders available, overtime and long hours are the norm. In some instances, this is leading to fatigue, non-compliant welds and rework.
answers were a pipeline of work that extended less than one month (at 28%), one month (19%), and two months (16%).
And yet, the number of welding trade workers in Australia dropped by
It is little wonder that half of survey respondents have a pipeline of work that extends for six months or longer—this protracted pipeline is necessary in the face of these ongoing skills shortages. By way of context, this is a marked increase on Weld Australia’s 2020 member survey results. In the wake of the COVID-19 pandemic, the most common
Amid these skills shortages, employers are also facing increasingly unstable workforces. Employers never know when their staff might be forced into a seven-day isolation period, with COVID-19 case numbers reaching record highs over the last couple of months.
Geoff Crittenden (CEO, Weld Australia)
INNOVATIVE TRAINING MODELS KEY TO AUSTRALIA’S CLEAN ENERGY TRANSITION
None of this is surprising. The Australian Government has projected that, to 2024, the number of job openings for structural steel and welding trades will be above average. In some states, advertised vacancies have shown substantial increases over the last few years; Queensland has seen welding trades workers vacancies increase by 87%, Western Australia saw vacancies increase by 80%, and Victoria saw an increase of 18%.
The results of our 2022 Member Survey indicate that skills shortages have reached critical levels.
being onshored in the wake of international supply chain disruptions, most Australian fabrication companies are so strapped for skilled welders that they are working at anywhere between 30% and 50% of their full capacity. They are being forced to turn down jobs because they simply don’t have the manpower to complete the work. This is having a major impact on production and causing delays throughout downstream industries including building and construction, mining, oil and gas, and manufacturing.
To put this into perspective, construction commenced this month on the MacIntyre Wind Precinct in Queensland. This consists of two wind farms and 180 turbines. This Wind Precinct will generate 1 GW of energy annually. So, if this project is used as a benchmark, Australia
When asked what they are most concerned about, 64% of senior managers cited lack of skilled staff in an extremely constrained recruitment
8% in the course of just five years; from 75,800 in 2014 to 69,600 in 2019. In addition, completion rates of welding apprenticeships, including a Certificate III in Engineering (Fabrication Trade), continue to fall by as much as 23% annually.
volume of work
Alarmingly, this projected shortfall of welders does not account for Australia’s move from carbon fuelled power generation to a renewable energy system.
With Australian industry already desperate for welders, how will this extra demand be met?
Even with international borders opening post-COVID, immigration is not the answer to Australia’s welding workforce crisis. There is no magic pool of international welders from which to draw on—this is a global skills crisis. Australia must develop its own sovereign manufacturing capabilities.
The only way to combat this skills crisis is with innovative ideas—
The situation is much the same in Asia. For instance, according to data released in late 2021 by China’s Ministry of Human Resources and Social Security, 58 of the 100 occupations with the largest shortage of workers were classified as manufacturing roles, including welders. By 2025, the total number of skilled workers in 10 key areas of China’s manufacturing industry will be close to 62 million, with a talent demand gap of nearly 30 million—a 48% shortfall.
In the last two years, BHP’s FutureFit Academy has welcomed over 590 apprentices and trainees, with more than 80% women and over 20% Indigenous learners. The average age is about 30 years old, and most are from regional communities. There have already been over 220 graduates deployed to permanent jobs across BHP’s Australian operations. With strong demand for future intakes, BHP expects to train 2,500 new apprentices and trainees over the next five years.
It is not just the likes of BHP rolling out innovative training programs. A range of Weld Australia members have invested in their own welder training programs. Komatsu, JRS Manufacturing, Maxi-Trans and Precision Manufacturing Group have all established their own schools.
“ While our governments can wish, and hope, and make public pledges about Australia’s transition to renewable energy, we simply do not have the capabilitymanufacturingsovereigntomakethisareality.”
While our governments can wish, and hope, and make public pledges about Australia’s transition to renewable energy, we simply do not have the sovereign manufacturing capability to make this a reality.
innovative training models that engage students and apprentices from the outset and retain them long-term.
Innovative Training Programs
One such innovative training model is the BHP FutureFit Academy. Launched in 2020, the Academy is part of a new national training program designed to bolster Australia’s skills base and create new career pathways into the mining sector. Offering an innovative approach to training, the Academy’s fit-for-purpose maintenance training programs are run in dedicated learning centres in Perth, Western Australia, and Mackay in Queensland.
A Global Perspective
This skills crisis is not unique to Australia. By 2024, the United States is predicting that their workforce will need an additional 400,000 welders. To put this into perspective, that is equivalent to the size of the entire welding workforce in America as of 2019. Similarly, in a recent report released by the European Commission, welders and metal workers rank third on the list of occupations with the greatest workforce shortage.
needs to manufacture and erect 48,420 turbines to generate the 269 GW of wind power required. All this will require a highly skilled workforce.
Unless industry and governments come together now to formulate a plan of attack, when the time comes to manufacture the assets needed for a clean energy transition, the skilled workforce required will simply not exist. There will be no sovereign manufacturing capability.
Q3 | September 2022 5
From day one at the Academy, students are a permanent BHP employee, earning a salary while they’re studying. The purpose-built learning centres feature the latest immersive virtual reality technology— including Soldamatic augmented reality welding simulators—combined with workshop learning designed to provide students with the training they need to competently and safely carry out their work in the field.
platform of the IIW. Weld Australia is the Australian representative member of the ThroughIIW.the work of its Technical Working Units, the IIW’s technical focus encompasses the joining, cutting and surface treatment of metallic and non-metallic materials by such processes as welding, brazing, soldering, thermal cutting, thermal spraying, adhesive bonding, microjoining and additive manufacturing. IIW’s work also embraces allied fields including quality assurance, non-destructive testing, standardisation, inspection, health and safety, education, training, qualification, certification, design and
to develop standards in the field of welding and related processes. IIW’s Technical Database constitutes the world’s largest online resource for welding information available today. The most outstanding papers are published in the prestigious journal ‘Welding in the World’ registered in Thomson Reuters Science Citation Index® since 2009.
IIW international education, training qualification and certification programs for welding personnel and companies are recognised worldwide. The systems developed for education and training are paving the way towards one global education and qualification system for welding personnel. Weld Australia is an IIW Authorised National Body (ANB) and an Authorised Training Body (ATB).
FROM THE CHAIR
industry, educators, students and young professionals from over 51 countries worldwide are all part of the collaborative working
standardising body approved by the International Organisation for Standardisation (ISO)
Thefabrication.IIWisa
Australian Welding6
IIW Annual Assembly
I recently travelled to Tokyo, Japan to represent Australia at the 75th International Institute of Welding (IIW) Annual Assembly and International Conference on Welding and Joining.
THE 75TH IIW ANNUAL ASSEMBLY AND INTERNATIONAL CONFERENCE
An Overview of the IIW IIW is recognised as the largest worldwide network and centre of reference for welding and allied joining technologies. It operates as the global body for the science and application of joining technologies, providing a forum for networking and knowledge exchange among scientists, researchers, industry and educators, and disseminating leading-edge information and best Researchers,practices.
“ The plenary talks given by both a minister and a respected member of the Japanese government, showed the rest of the world how seriously they are taking the need for carbon neutrality and the importance they assign to having a thriving welding industry to develop off shore wind farms and also in obtaining green Hydrogen from Australia.”
David Lake (Chair, Weld Australia).
The Annual Assembly provides an opportunity for IIW Technical Commissions and Working Units to meet. There are currently 18
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The theme of this year’s International Conference was Innovative Welding and Joining Technologies to Achieve Carbon Neutrality and Promote Sustainable Development. The program featured a range of engaging presentations on topics such as welder training, welding automation, laser processes, non-destructive testing, metallurgy, new materials, artificial intelligence, digital transformation, additive manufacturing and more.
The plenary talks given by both a minister and a respected member of the Japanese government, showed the rest of the world how seriously they are taking the need for carbon neutrality and the importance they assign to having a thriving welding industry to develop off shore wind farms and also in obtaining green Hydrogen from Australia.
Weld Australia representatives attended and participated in many of the commissions and have developed contacts from many parts of the world, with Weld Australia having access to the working of all 18 Commissions. The Chair of Weld Australia’s Qualification, Certification and Standards Committee, Doug Hawkes, is the elected board member to the IIW IAB representing Oceania and South Africa, where he has been very active over the last couple of years.
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The 2022 Japan International Welding Show was held in conjunction with the IIW International Conference. Attracting over 100,000 attendees and hundreds of exhibitors, the Show featured exciting demonstrations of the latest welding technology.
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IIW Commissions, each of which is focused on a specific area of interest, from additive manufacturing and power beam processes, through to structural performance of welded joints and pressure vessels, boilers and pipelines.
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I’d also like to congratulate Bruce Cannon (Principal Welding Engineer, Weld Australia) on winning the IIW 2022 Thomas Medal. Bruce was presented with the award at the Opening Ceremony of the Annual Assembly. (For further details, see the article on page 40.)
staff in an extremely constrained recruitment market (see Figure 1). This comes as little surprise, with Australia facing a looming shortage of skilled welders—70,000 additional welders will be needed by the end of the “Withdecade.”aconsiderable
According to Geoff Crittenden (CEO, Weld Australia), “Distributed in June 2022 and completed by approximately 140 companies, our 2022 Member Survey indicates that skills shortages, local content and sustainability remain high on the agenda for the welding industry.”
Given the concern over Australia’s looming skills crisis, it makes sense that 95% of respondents support the concept of free TAFE, increased funding to upgrade TAFE facilities, or both initiatives. Clearly, the welding industry is looking to the government to help increase the supply of skilled labour over the coming years.
Australian Welding8
“When asked what they are most concerned about, almost 64% of senior managers cited lack of skilled
work being onshored in the wake of international supply chain disruptions, most Australian fabrication companies are so strapped for skilled welders that they are working at anywhere between 30% and 50% of their full capacity. They are being forced to turn down jobs because they simply don’t have the manpower to complete the work. This is having a major impact on production and causing delays throughout downstream industries including building and construction, mining, oil and gas, and manufacturing,” said Crittenden.
INSIDE THE INDUSTRY WELD AUSTRALIA 2022 MEMBER SURVEY: RESULTS ANALYSIS Figure 1. As a business owner, or senior manager, which issue are you most concerned about? Lack of skilled labour 63.7% Weak international supply9.1%chains Reliability & affordability of power4.5%supply Inflation & 22.7%costsrising Figure 2. How many months ahead does your pipeline of workLessextend?than1month9.1% 1 4.6%month 2 months 22.7% 3 months4.5% 4 months9.1% 6 Over22.7%months6months27.3%
volume of
It is little wonder that half (see Figure 2) of survey respondents have a pipeline of work that extends for six months or longer—this protracted pipeline is necessary in the face of these ongoing skills shortages. By way of context, this is a marked increase on Weld Australia’s 2020 member survey results. In the wake of the COVID-19 pandemic, the most common answers were a pipeline of work that extended less than one month (at 28%), one month (19%), and two months (16%).
Weld Australia has released the results of its 2022 Member Survey. The results demonstrate that significant concerns remain for Australia’s welding industry. In particular, Australia’s fabricators are being forced to turn down work due to a severe shortage of skilled welders.
Figure 5. What is the size of your business, or the business you work for?
Overwhelmingly, respondents are employed full-time (72%). Another 16% indicated that they are business owners and 9% are either employed part-time or as a sub-contractor. The remaining 3% are retired. At 23%, the majority of respondents have worked for their current employer for over 20 years (see Figure 4).
Figure 3. What is your age?
Industry is also investing in advanced welding technology to help overcome skills shortages. Over 28% of respondents indicated that their company or the company they work for has purchased robots or cobots, and 25% has invested in Industry 4.0 capabilities (see Figure 6). A range of other types of technology was also mentioned, from drones and automated welders, through to various software solutions.
The largest age group was over 65, accounting for 16% of respondents. In line with industry trends, 78% of respondents were over the age of 40 (see Figure 3).
However, SMEs were also well represented, with 16% of respondents confirming that the business they work for has under 10 staff members (see Figure 5).
Despite the skills shortages, local procurement and content targets remain top of mind for the welding industry. 100% of respondents confirmed that they would support Federal and State Government policies to increase Australia’s
Over 51% of respondents work for a business in the fabrication, manufacturing or engineering industry, 12% work for a business in the mining and resources industry, 10% in the education and training industry, and 7% in testing and NDT. The vast majority of these businesses are quite large; 32% of respondents indicated that the company they work for has over 500 staff.
The majority of survey respondents were based in Queensland (at 28%), followed closely by New South Wales (23%), Victoria (19%) and Western Australia (16%).
Figure 4. How long have you worked for your current employer?
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“Our members are also investing in their own welder training programs. BHP, Komatsu, JRS Manufacturing, Maxi-Trans and Precision Manufacturing Group have all established their own schools. While industry appreciates the rollout of government-funded TAFE places, it remains to be seen whether this initiative will translate into high completion rates. Moreover, while encouraging more students into TAFE is always a positive, government spending also needs to focus on resources for TAFEs, teachers and equipment—TAFEs need the right tools to teach this sudden influx of students,” said Crittenden.
The most commonly cited highest level of education was an apprenticeship or vocational training at 30%, followed by International Welding Specialist at 23%, Bachelor Degree at 13% and Masters Degree at Salaries9%.
Survey Respondent Demographics
are relatively healthy compared to Australia’s average wage (of $67,860 per annum); 20% of respondents indicated that their salary is between $100,000 and $125,000, and 17% take home over $150,000 per annum.
Australian Welding10
share of fabricated steel product to at least 75% as part of a joint government-industry plan to grow the manufacturing industry.
Inflation and rising costs were also of concern for approximately 23% of respondents, followed by weak international supply chains (9%) and reliability and affordability of power supply (4%).
Welders are environmentally responsible. 30% of respondents support the target of zero emissions before 2050; 20% prefer cutting emissions by 35% by 2030; and another 17% support cutting emissions by 43% by 2030. In addition, 74% of respondents would support a Federal Government package to help employees transfer from carbon intensive to carbon free industries.
When asked if an electric or hybrid ute was available in Australia at a competitive price would you buy them for your company or employees as fleet cars, 50% of respondents answered in the affirmative. Interestingly, 63% of respondents would buy an electric or hybrid UTE for themselves.
Corporate responsibility remains a growing area of focus for the welding industry. Over 63% of respondents indicated that they have initiatives aimed at improving opportunities for women; 63% promote opportunities for apprentices and trainees; 63% have diversity and inclusion initiatives in place; 59% have mental health and fitness initiatives in place; and 31% have a Reconciliation Action Plan.
“Importantly, whether it is imported or locally manufactured, all fabricated steel erected in Australia must comply with Australian Standards. Weld Australia is committed to ensuring that no Australian lives are lost through an accident caused by noncompliant welding, without causing undue regulatory burden on industry. We firmly believe in quality welding for structural safety,” said Crittenden.
Clearly, Australia’s welding industry is already taking steps to reduce its carbon emissions. While 41% of respondents have already installed
Environmental Sustainability and Corporate Responsibility
Albanese announced more ambitious climate targets. Albanese pledged to cut carbon emissions by 43% from 2005 levels by 2030, up from the previous government’s target of between 26% and 28%. Given these targets, private companies will play a key role, making sustainability a priority for many businesses. As such, our 2022 member survey asked a series of environmental sustainability focused questions.
Figure 6. Has your business, or the business you work for, invested in advanced welding technology? Figure 7. How would you rate the prospects of your business over the next six to 12 months? 18.2%Weak Very27.3%Strong Strong 54.5%
solar panels to supplement power supply, another 53% have installed LED or sensor lighting, 46% have waste reduction programs in place, 46% operate recycling, up-cycling or repurposing programs, and 13% have a net zero carbon plan in place.
Australia is rapidly moving from carbon fuelled power generation to a renewable energy system. In June 2022, Prime Minister Anthony
$4.45 million Invested into Advanced Manufacturing in the Northern Territory
BREAKING NEWS
Austal Australia has delivered the second of eight Evolved Cape-class Patrol Boats (ECCPB’s) to the Royal Australian Navy.
Austal Australia Delivers 2nd Cape-Class Patrol Boat
Territory based manufacturers will soon gain access to a multi-milliondollar advanced manufacturing facility. The facility will house robotic and bespoke automation products and services to support the implementation of technology such as robotic welders, automated pick and pack systems and product inspection
will see Weld Australia member Diverseco and Charles Darwin University (CDU) work closely to develop four new robotic and automation micro credential qualifications tailored to the region and boost local skills and knowledge in advanced processes and machinery for the industry.
The 58m aluminium monohull patrol boat is the second of eight to be delivered to the Royal Australian Navy. The first Evolved Cape-class Patrol Boat, ADV Cape Otway, was delivered in March 2022, following approximately 18 months construction. The six remaining vessels are in various stages of production at Austal’s Henderson, Western Australia shipyard and deliveries are scheduled progressively through to 2024. The Evolved Capeclass Patrol Boat Project (SEA14451) is employing approximately 400 people directly in Western Australia and engaging more than 300 supply chain partners across Australia.
Photo: Austal Australia has delivered the second Evolved Cape-class Patrol Boat. Photo courtesy of Austal.
This announcement is the latest co-investment awarded under the Northern Territory’s Advanced Manufacturing Ecosystem Fund (AMEF), which is administered by the Advanced Manufacturing Growth Centre (AMGC). AMEF will provide almost half a million dollars towards this initiative, giving industry the ability to experience and test the latest in automation technology with the total project representing a $4.45 million investment into the NT’s manufacturing ecosystem.
Q3 | September 2022 11
Austal Limited Chief Executive Officer, Paddy Gregg said the delivery of the second Evolved Cape-class Patrol Boat highlights the critical importance of the vessel as a capability to the Royal Australian Navy, and Australia’s national naval shipbuilding enterprise.
The commitment also enables Diverseco to expand its support services to local manufacturers wishing to advance their operations and improve staff capability by supporting them with access to the latest technology, training programs, design services, equipment implementation, and operations and maintenance activities.
Theservices.project
Photo: Diverseco welding robot.
Diverseco and its project partners will provide on-site technical support and training services to local businesses seeking to adopt advanced technologies in their operations and support these businesses to upskill their staff. The facility will also be available to local businesses to demonstrate these technologies and develop tailored automated solutions for their individual business needs.
Diverseco will support the advancement of NT’s manufacturing industry by leveraging its and CDU’s manufacturing capabilities spanning defence, transport, logistics, agriculture, mining and waste disciplines.
INSIDE THE INDUSTRY
Founded in 1972, this year marks Berg’s 50 year anniversary. Berg has grown from humble beginnings as a single-room operation to a multi-million-dollar Australian-owned and second-generation, family-run business.
In his five decades working at the company, Keith has clocked up just over 109,000 hours, which is the equivalent of 64 years of service for the average person.
Thornton’s clients span oil and gas, power, mining, infrastructure and construction, and include BHP and Rio Tinto, Santos and AGL, John Holland and Lendlease. Established in 1975 from a small workshop making farming equipment in western Victoria, the family-owned business has grown to become one of the leading steel fabricators in Australia.
In front of his colleagues and family, Keith was honoured for his loyalty and dedication by having a warehouse named in his honour, as well as receiving a new Ford Ranger Wildtrak from the company’s founders, Roger and Pam Berg.
Keith became the company’s first employee when he first met Roger Berg in 1972. He was hired as a fitter and turner and worked with Roger out of a Brisbane garage when the company first started.
Photo: Image courtesy of Geelong Manufacturing Council.
Some of the industries that Berg Engineering serves include oil and gas, power, mining, water utilities, rail, defence, civil and general engineering.
Thornton Engineering is expanding into new markets with the purchase of leading electric motor and generator servicing company Bob White Electrix.
Thornton Engineering Buys Bob White Electrix
Australian Welding12
When Keith Pavey clocked in for work at Berg Engineering in Brendale on 19 July, he thought it would just be like any other day. But little did he know his bosses had a surprise double celebration planned to coincide with Berg Engineering’s 50th anniversary and Keith’s 50 years of service.
The company started off making garbage bin axels, but today delivers a diverse range of machining, fabrication, welding and reverse engineering services to major companies across Australia and the Asia Pacific. As the company grew, the business moved into a shed on the northside before outgrowing that and moving into its current premises at Brendale in 1987.
Photo: Keith Pavey with his new Ford Ranger Wildtrak. Image courtesyof Moreton Daily.
This article originally appeared on moretondaily.com.au
BREAKING NEWS
“We’ve just taken it over. I see a lot of opportunity in power generation and I think the business could be more along the scale of Thornton Engineering, with the right investment and people,” said owner David Thornton. “I don’t like businesses being sold to private equity. I don’t like that kind of thing. I am sort of old school, but with very modern equipment. I like industries that make sense, that are really needed, with world’s best equipment.”
This article originally appeared geelongmanufacturingcouncil.com.auon
Berg Engineering Celebrates Two 50 Year Anniversaries
Keith said he was shocked and a little lost for words at the kind gesture. “I wasn’t expecting this at all,” Keith said. “I’m really amazed at what Roger and Pam have done and feeling really proud to work for Berg Engineering – they have always been a great company to work for.”
Learn how to minimise cost and maximise qualifcation usefulness.
Venue: Novotel Perth, 388 Murray Street, Perth Room: Cottesloe Room
The ASME code is the American Society of Mechanical Engineers (ASME) standard that regulates the design, development and construction of boilers and pressure vessels. ASME Section IX specifies the requirements for the qualification of welders and the welding procedure specifications. This three day course will give participants a working knowledge of ASME Section IX, including how to comply with its Therequirements.coursewill be facilitated by Walter J. Sperko, P.E., the President of Sperko Engineering Services, a consulting firm specialising in metal fabrication technology. He has particular experience in piping and pressure vessel fabrication, installation, maintenance and repair. Mr. Sperko is also a past-Chairman of the ASME Welding, Brazing and Fusing Standards Committee IX and a member of ASME Subcommittee III, Nuclear Components.
Registration first day: 7:30am
REGISTER FOR PERTH REGISTER FOR BRISBANE
A review of the welding processes and variables, and basic steel welding metallurgy will be conducted to provide all participants with sufficient background in welding technology to interpret and understand Section IX. The mechanics of using Section IX and how to address its requirements will be explained in a simple, straightforward manner.
For further information, contact: Michelle Bignold (National Manager, Sales and Marketing) on 0437 106 726 or m.bignold@weldaustralia.com.au
• Non Weld Australia Members: $3,960 inc GST
Cost
• Weld Australia Members: $3,610 inc GST
Date: 22, 23 and 24 November 2022
Q3 | September 2022 13
Emphasis will be placed on writing welding procedures so that they contribute positively to the manufacturing process and on qualifying procedures in a cost-effective manner. The requirements for welders and operators will be examined with particular emphasis on minimising the cost and maximising the usefulness of qualifications.
Early Bird Rate:
Course Details
Who Should Attend?
• Non Weld Australia Members: $3,810 inc GST
Please note: in order for the course to go ahead in two locations, minimum attendee numbers must be reached.
• Weld Australia Members: $3,760 inc GST
Course Overview
ASME Section IX Three Day Course
Time will be provided to address individual participant’s problems and concerns. Attendees will receive copies of the course notes covering the course’s content. Attendees must bring a copy of the current edition of Section IX. Multiple choice tests will be given for each section.
This course is intended for people who are involved in writing and qualifying welding and brazing procedure specifications, qualifying welders, brazers and operators, reviewing suppliers procedures, auditing or reviewing in-house procedures and qualifications and estimating jobs which impose the requirements of Section IX.
Need to use ASME Section IX?
Course Time: 8:00am – 5:00pm
Rate After 1 September 2022:
Course time: 8:00am – 5:00pm
Perth Date: 16, 17 & 18 November 2022
Registration first day: 7:30am
Brisbane
Venue: Novotel Brisbane, 38 Cordelia Street, Brisbane Room: Musgrove Room
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 2022 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 1 October 2022.
Company 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:
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:
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 October 2022.
Please note: the online entry form cannot be saved. It must be fully completed in the one sitting.
Project of the Year Award Criteria | Enter Now
• Company of the Year – Fabrication Award Criteria | Enter Now
• Welding Professional of the Year – Welding Supervisor Award Criteria | Enter Now
As such, 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.
This Award recognises people under the age of 25 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.
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Entries must be submitted via the specific online form for each category by 1 October 2022. These forms can be found via the Weld Australia website, by clicking on the relevant red button.
Young Trades Person of the Year Award Criteria | Enter Now
• Company of the Year – Gas & Gear Award Criteria | Enter Now
• Indigenous Company of the Year Award Criteria | Enter Now
How to Enter the Welding Excellence Awards
• Welding Professional of the Year – Welding Coordinator Award Criteria | Enter Now
• Welding Professional of the Year – Welding AwardInspectorCriteria | Enter Now
Welding Professional of the Year
Young Indigenous Trades Person of the Year Award Criteria | Enter Now
This Award recognises the outstanding achievements of a STEM or VET teacher at TAFEs, independent RTOs and private companies. 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 to their profession.
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.
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.
• Melbourne: 1 December at Box Hill Golf Club
This Award recognises indigenous trades people under the age of 25 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.
Ken Trevena Award – South Australia Only Award Criteria | Enter Now
• Sydney: 29 November at Strathfield Golf Club
Further Information
Why Enter the Welding Excellence Awards?
Register Now for the Award Ceremonies
For further information, contact: Michelle Bignold on 0437 106 726 or m.bignold@weldaustralia.com.au
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.
• Brisbane: 24 November at Victoria Park Golf Course
Training and Education Award – Individual Teacher Award Criteria | Enter Now
• Perth: 14 November at Bells Functions
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.
• Adelaide: 17 November at the Terrace Hotel
Training and Education Award – Organisation Award Criteria | Enter Now
The Awards will be presented at events across the country in November and December. Be sure to book your tickets soon to avoid disappointment. The ticket price of just $35 per person includes a two-course meal and drinks. Register now:
WITH THANKS TO OUR SPONSORS
The most effective prevention of injury is to ensure that the laser beam is encapsulated so that no human exposure can occur. For the case of an exposure to the beam, the level of exposure will determine if injury occurs. The level of exposure or irradiance which can be thought of as the border between safe and potentially harmful is called ‘Maximum Permissible Exposure’ (MPE).
To take account of the use of various magnifiers, AS/NZS IEC 60825.14 also refers to a parameter called the “Extended Nominal Ocular Hazard Area” or ENOHA. The extended nominal ocular hazard area is therefore the distance beyond which it
The factors that can contribute to tissue injury and influence the degree of damage from laser beam exposures include:
(a) Wavelength of laser radiation (b) Tissue spectral absorption, reflection and transmission (c) Strength of irradiance of incident laser beam (d) Size of irradiated area (e) Exposure duration (f) Pupil size (g) Location of retinal injury (h) Laser pulse characteristics
The area around a laser installation where the MPEs for the eye can be exceeded is called the “Nominal Ocular Hazard Area”, NOHA. The corresponding distance from the laser exit aperture is called the “Nominal Ocular Hazard Distance”, NOHD. The NOHD depends on the laser power, geometrical laser beam parameters such as the divergence, and the MPE. MPE values for the eye and the skin as a function of wavelength and exposure duration are listed in AS/NZS IEC 60825.14. The standard also contains a number of sample NOHD calculations for a range of geometries and exposure situations.
Potential hazards related to the use of lasers can generally be divided into primary and secondary hazards. The laser beam itself represents the primary potential hazard, as it can affect humans or objects –in the form of raw beam, focused beam, directly reflected beam, or scattered radiation. There are two potential dangers to welding personnel associated with laser radiation: eye and skin damage.
PREVENTING EYE AND SKIN DAMAGE FROM LASER RADIATION
Australian Welding16 HEALTH AND SAFETY
can be deep and cause severe and permanent damage.
Depending on wavelength, damage to either the cornea, the retina, or both, of the eye is possible. Exposure to radiation from a CO2 laser (10.6μm) typically results in corneal damage. The radiation from an Nd:YAG laser, at 1.06μm, is much closer to the visible spectrum (400 to 700 nm) and can be transmitted by the cornea and lens. The lens will focus the laser light on the retina, causing severe and permanent damage to the retina and other intraocular material. This focusing, by the lens of the eye, can cause even low-power diffuse laser light to be focused to a sufficient power density to cause retinal damage. Low-power helium-neon (He-Ne) lasers (0.633μm), often used for alignment purposes, may also present a hazard.
Skin damage is restricted primarily to burns. It should be noted, however, for high-powered lasers these burns
(h) Comfort and ventilation
(k) Peripheral vision requirements
Skin Protection
(j) Strength of materials (resistance to shock)
(l) Any relevant legislation
is safe to use various magnifiers.
(d) Optical density of eyewear at laser output wavelength
(i) Degradation or modification of absorbing media, even if temporary or transient
Laser eye protectors and laser adjustment eye protectors which have been damaged or have undergone a colour change must not be used. Eye protectors are only intended to protect against accidental exposure as the ratings are based on a maximum exposure of 10s (for a continuous wave laser) or 100 pulses (for a pulsed laser). Eye protectors are not intended to be used for looking directly into the beam.
(g) Need for prescription glasses
Further Information For further information and resources on welder health and safety, visit Weld Australia’s Resource Centre and download Technical Guidance Note TGN-SW02: Laser Safety
Q3 | September 2022 17
A method of selecting the laser or laser adjustment eye protector most suited to the hazards associated with the use of a particular laser is given in AS/NZS 1336 Eye and face Specialprotection—Guidelines.attentionhasto be given to the resistance and stability against laser radiation when choosing eyewear for Class 4 laser products.
(c) Maximum permissible exposure (MPE)
(a) Wavelength(s) of operation
(b) Radiant exposure or irradiance
A precaution must be added here –standard safety glasses alone do not provide protection. Any laser eyewear, plain or prescription, must be labelled in accordance with AS /NZS 1337.1 or AS/NZS 1338.1 with information adequate to ensure the proper choice of eyewear with particular lasers. In some laser systems, ultraviolet light may be leaked into the workplace. Thus, the eyewear should provide primary beam protection, secondary radiation protection and also ultraviolet protection.
Where personnel may be exposed to levels of radiation that exceed the MPE for the skin, suitable clothing should be worn. Class 4 laser products present a potential fire hazard and protective clothing should be made from a suitable flame and heat-resisting material. Special attention must be given to resistance and long-term stability against laser radiation when choosing protective clothing for use with Class 4 laser products.
Eye Protection
Information on eye protectors suitable for use with particular lasers and operations together with their required marking is given in AS/NZS 1337.4 Face and eye protection Part 4: Filters and eye-protectors against laser radiation (laser eye-protectors) and AS/NZS 1337.5 Face and eye protection Part 5: Eye protectors for adjustment work on lasers and laser systems (laser adjustment eyeprotectors). The following should be considered when specifying suitable protective eyewear:
(e) Visible light transmission
(f) Radiant exposure or irradiance at which damage to eyewear occurs
As MPE, NOHD and ENOHD evaluations are quite complicated and involved, the laser classification scheme outlined earlier is used for the hazard evaluation process. For instance, for Class 1 lasers, the exposure will always be below the MPE. Class 3B lasers emit radiation which is significantly above the MPE for eye, and for Class 4 also above the MPE for the skin, however, it depends on the beam geometry, set-up and application, if this hazard exists only close to the exit aperture or if it extends over several kilometres.
If you hired your worker through a labour hire or on-hire firm and pay that firm for the work undertaken in your business, your business has a contract with the labour hire firm and they are responsible for pay as you go (PAYG) withholding, superannuation and fringe benefits tax obligations.
• Apprentices • Trainees • Labourers • Trades
both work and recognised training to get a qualification, certificate or diploma. They can be full-time, parttime or school-based and usually have a formal training agreement with the business they work for. This is registered through a state or territory training authority or completed under a relevant law. In most cases
It’s important to note that some workers are always treated as employees, including:
Labour hire firms may be called different names, including recruitment services or group training organisations. They will refer to your business as the ‘host employer’.
If you’re still not sure, you can use the ATO’s Employee or Contractor Decision Tool to work out if your worker is an employee or contractor for tax and superannuation purposes. Simply answer questions about the working arrangement and you’ll generate a report you can keep for your records. If you answer each question accurately and honestly, you can rely on the results.
Australian Welding18 BUSINESS ESSENTIALS
An employee works in your business and is part of your business. A contractor is running their own business. Published by the Australian Taxation Office (ATO), the table opposite outlines six of the factors that, taken together, determine whether a worker is an employee or contractor for tax and superannuation purposes.
UNDERSTANDING THE RIGHTS AND RESPONSIBILITIES OF CONTRACTORS
An employee must be a person. If you’ve hired a company, trust or partnership to do the work, this is a contracting relationship for tax and super purposes. The people who do the work may be directors, partners or employees of the contractor but they’re not your employees.
Labour Hire or On-hire
The Differences Between Employees and Contractors
Apprenticesassistantsandtrainees undertake
Determining whether your workers are employees or contractors is important—it affects your tax, superannuation and other obligations. And, in some cases, penalties and charges may apply if you get the classification wrong. Contractors run their own business and sell their services to others, unlike employees who work in someone else’s business. Contractors generally use their own processes, tools and methods to complete the work. They usually negotiate their own fees and working arrangements, and can work for more than one client at a time.
Companies, Trusts and Partnerships
they are paid under an award and receive specific pay and conditions. You must meet the same tax and superannuation obligations as you do for any other employees.
Businesses that behave this way can often undercut their competitors and obtain an unfair competitive advantage. Businesses also risk receiving penalties and charges, including:
• Not meeting their tax and super obligations
The worker is paid either:
The worker takes no commercial risks. Your business is legally responsible for the work done by the worker and liable for the cost of rectifying any defect in the work.
risksCommercial
• Super guarantee shortfall
• A price per item or activity
The worker takes commercial risks, with the worker being legally responsible for their work and liable for the cost of rectifying any defect in their work.
The worker can subcontract or delegate the work –they can pay someone else to do the work.
The worker has freedom in the way the work is done, subject to the specific terms in any contract or agreement.
It’s against the law for a business to incorrectly treat their employees as contractors. Businesses that do this are illegally lowering their labour costs by:
Control over the work Your business has the right to direct the way in which the worker does their work.
• A commission
• An administration fee
The worker can't subcontract or delegate the work –they can't pay someone else to do the work.
What Happens if Employees are Treated as Contractors?
• PAYG withholding penalty – for failing to deduct tax from worker payments and send it to the ATO
Factor Employee Contractor
• The worker provides all or most of the equipment, tools and other assets required to complete the work
• Additional super guarantee charge of up to 200%.
• Interest charges
In addition to the super guarantee charge – which imposes nominal interest and an administrative charge in all cases on top of the super guarantee shortfall – the ATO can impose additional penalties of up to 200% of the super guarantee charge.
DIFFERENCES BETWEEN EMPLOYEES AND CONTRACTORS
• For the time worked
Basis paymentof
amounts – the amount of super contributions that should have been paid into a complying fund
Ability subcontractto
• The worker does not receive an allowance or reimbursement for the cost of this equipment, tools and other assets.
othertoolsEquipment,andassets
• Super guarantee charge, made up of:
• The worker provides all or most of the equipment, tools and other assets required to complete the work, but your business provides them with an allowance or reimburses them for the cost of the equipment, tools and other assets.
Independence The worker is not operating independently of your business. They work within and are considered part of your business.
The worker is operating their own business independently of your business. The worker performs services as specified in their contract or agreement and is free to accept or refuse additional work.
The worker is paid for a result achieved based on the quote they provided. A quote can be calculated using hourly rates or price per item to work out the total cost of the work.
Disclaimer: this article is for informational purposes only. You should consult a professional for advice that is directly related to your business.
Q3 | September 2022 19
• Denying workers their employee entitlements
• Your business provides all or most of the equipment, tools and other assets required to complete the work, or
For further information, visit the ATO website: https://www.ato.gov.au
I think women should consider Boilermaking as a career path if they are keen on learning new things, and aren’t afraid of getting dirty and
At the moment my job is to learn! I’m about half way through the first year of my apprenticeship at Bradken’s Mining Services workshop in Mt Thorley and I’m really enjoying the experience so far. I work on a lot of different types of projects in the workshop, with the help of the Leading Hands and other tradesmen, but my tasks mostly include welding wear plates to mining size truck trays, excavator buckets and shovel jaws, grinding and small fabrication jobs.
Why do you think women should consider a career in welding?
Haylee Megahey, First year apprentice Boilermaker, Bradken
First year apprentice Boilermaker Haylee Megahey, 19, is one of three new apprentices who joined Bradken’s Australian-based Mining Services team in 2022, working at the company’s Mt Thorley workshop in the historic Hunter Valley mining region of New South Wales.
Can you describe your job?
Photo: Haylee Megahey, hard at work.
What inspired you to choose a career in welding?
Through her younger years, Hayley aspired to be a teacher and so after leaving school she initially gained certification and began working in early childcare. But after a year she started to feel a pull towards something very different and, thanks to an informal introduction to the Boilermaking trade from her partner, she caught the welding bug and hasn’t stopped since.
Celebrating 100 years in operation this year, Bradken has a proud history of supporting fresh tradespeople, and in particular welders, through their apprenticeships and into their new careers. The company has an almost 20 year partnership with established group training organisation MIGAS (Manufacturing Industries Group Apprenticeship Scheme), through which Haylee and Bradken made their connection.
Australian Welding20 INSIDE THE INDUSTRY
I also try to get involved in as many other aspects of the operation as I can, like being on the site safety committee.
Her boss, Mining Services Manager for Bradken, Darryl Pyne, said despite only having been part of the team for six months, Haylee was making the most of every opportunity put in front of her and has made a place for herself amongst her more experienced colleagues.
Bradken has a number of women welders working at its sites around the world, including the ‘A Team’, six highly skilled welders based in Bassendean, Western Australia, who are regarded as the best-of-the-best welders across the company. Haylee is the newest addition to this talented group. She took time out to answer some questions about her welding career so far.
I’ve always had a passion for learning new things and so I knew I wanted to do something that would challenge me. Coming out of childcare I knew I wanted to go down the trade path, something more hands-on as I do much better learning in a more practical ‘doing’ environment, but wasn’t sure which one was right for me.
“For this old boilermaker, seeing Haylee thrive and be interested and curious and hungry to learn the trade makes me very proud indeed. It’s a privilege for us to be hosting someone that knows the value of listening and learning from those around her and really soaks all that knowledge in. Her attitude has
earned her the respect of the whole team and I feel she’s well on her way to becoming an exceptional welder.”
I came across welding through my partner. He’s a welder and would often be working on things at home and suggested I give it a try. So, I did and straight away I knew I had to pursue a career in it.
WOMEN IN WELDING:
A lot of the projects I work on are interesting as most are fairly new to me and each one is different to the next, even if only slightly. I’m really enjoying the fabrication tasks as they’re usually a bit more difficult and more involved and that really interests me.
I’ll admit, at first I was a bit nervous about taking on a mostly male trade and joining an all-male team, but it turns out that was just a fear of the unknown based on an out-of-date idea about what the industry’s like.
I’m inspired by all the welders around
What do you believe is the biggest challenge for the welding industry at the moment?
me like my partner and my Bradken teammates, both tradesmen who are all at different points in their careers and have different tips and tricks to share from their time in the trade, and the other apprentices who are ahead of me and are always keen to show me things. Another person who inspired me is my Dad, who knew the path I wanted to take and supported me the whole way.
What is the most interesting project you’ve worked on?
I’m excited to see what doors my trade will open up for me in the future and hope others like me will consider giving it a go.
Who has inspired you professionally?
We have the potential to create a different energy in the workshop environment, bring a new perspective and new ideas to the table.
My Bradken teammates have given me a lot of support. From the start they’ve been willing to share their knowledge with me and have never hesitated or doubted me when I’ve asked to try something new, making me feel comfortable and confident that this was the right career move for me.
Do you have any advice for women considering a career in welding? I say go for it! Don’t be worried about getting messy, or messing up because that’s part of the learning process. Just give it your all and have fun. Make sure you ask a lot of questions as learning from other people gives you a better understanding of the trade.
How have you found working in a traditionally male-dominated industry?
Photo: Haylee Megahey, a first year Boilermaker apprentice at Bradken.
Q3 | September 2022 21
Everyone at Bradken has been so welcoming and willing to help and I know they want me to become the best tradesperson I can be. All I can say is work hard and we can be just as successful as anyone else in this trade.
I don’t think there’s too many challenges for the welding industry, but I believe the most important one, and the one that provides the biggest opportunity, is bringing more women welders into the trade.
picking up the tools. Being Bradken’s only female apprentice at the moment, I want to encourage other women to think about this trade and about welding in general as an option for them. As women we’re just as capable as anyone else, it’s all about the willingness to learn – you do well at things when you’re passionate about them.
CAgroup traces its origins back to the 1930s. Established in Melbourne, the company was called Consolidated Alloys, and was known as a base metal smelter and refiner. In 1974, Consolidated Alloys was acquired by London-based firm Amalgamated Metal Corporation, and remains a 100% owned subsidiary today.
Established in Melbourne in the 1930s, CAgroup was originally a base metal smelter and refiner. Over the years, the company has grown and diversified into several sectors of operation, namely building solutions, industrial solutions, metals trading and anode solution. Working with major industry players like BHP, Thales and Bunnings, CAgroup continues to evolve with new products and market sectors and remains firmly focused on innovating in line with the needs of their clients—now and into the future. It is for this reason that CAgroup recently invested in an ABB robot, complete with a SMENCO welding arm. In an Australian first, the robot utilises gas tungsten arc welding for lead, rather than the traditional oxy-acetylene process.
According to Sebastian Ortega Galli (Sales Manager, CAgroup), “CAgroup has grown to become a diversified manufacturing and distribution company with sales and distribution centres right across Australia and New Zealand. Our manufacturing site and head office is located at Thomastown in Melbourne. We warehouse and sell a full range of products through our own distribution centres in Melbourne, Sydney, Brisbane and Perth. Over 2,500 products are sold to over 4,000 customers across Australia, New Zealand and around the world. We sell into four distinct market sectors:
CAgroup invests in robotics to undertake gas tungsten arc welding of lead
CAgroup’s Building Solutions team sells a full range of roof flashings, damp proof course products, silicone sealants, insulation foil, brazing alloys, concrete expansion jointing and polythene underlay along with a range of other building products. These are sold to a wide range of both large and small building and plumbing merchants across the country.
FEATURE STORY
Australian WeldingA22
Residential Building, Industrial Manufacturers, Metals Trading and Electrowinning (EW) Anode Manufacture,” said Sebastian.
FIRST AUSTRALIANFOR WELDING
In terms of Industrial Solutions, CAgroup has over 80 years of experience in the manufacture and fabrication of lead based products. Products include solders, fluxes, radiation shielding, window counter weights, leadlight came and plating anodes as well as many other custom designed parts for a diverse range of industries. This includes supply to both the domestic and international
Q3 | September 2022 23
defence industries, the mining industry and the automotive industry.
CAgroup continues to evolve with new products and market sectors
CAgroup utilises the finest primary calcium, tin and lead alloys along their our proprietary TMCR (thermo mechanically controlled rolling) process, which was developed and refined in-house by CAgroup engineers to achieve anode life spans of greater than 10 years.
Rolling mill
Rolled lead anode for copper electrowinning (EW)
When it comes to Metals Trading, CAgroup trades in both prime and secondary metals, and can buy or sell copper, tin, zinc, lead and a broad range of other non-ferrous metals. Their Anode Solutions team provides high quality rolled lead anodes to clients across the globe, as well as recycling services to reduce the amount of scrap metal that would otherwise end up in landfill.
Robotic profiler
Client Focused R&D
Photos (clockwise from top)
A First: Robotic Gas Tungsten Arc Welding of Lead CAgroup recently invested in an ABB robot, complete with a SMENCO welding arm. In an Australian first, the robot utilises gas tungsten arc welding for lead, rather than the traditional oxy-acetylene process.
“We focus on our clients and their needs. Throughout our history, CAgroup has developed many products, for the simple reason that our clients asked us to do so. We’ve worked with many clients to develop products that suit their needs and, in doing so, have developed strong long-term relationships with our clients.”
CAgroup is delivering silver lead anodes to Metalúrgica MET MEX Peñoles plant in Torreón, Coahuila, Mexico.
Under the contract, CAgroup is supplying Jumbo Silver Lead rolled anodes for their main cellhouses. The anodes will be used by Metalúrgica MET MEX Peñoles for recovering and refining
Rolled lead anodes installed in electrowinning (EW) cell (Chile).
Jumbo silver lead rolled anode.
“Finally,delay.”
Accordingzinc.to
Sebastian, “We commenced work on the order from Metalúrgica MET MEX Peñoles prior to the installation and commissioning of our new robotic welder. The timing was perfect—it is the perfect type of project for the robot. The anodes are very heavy but, with the help of the robot, less operators need to be involved in their manufacture. This improves things from a safety point of view. In addition, our productivity improved considerably, as did the quality and consistency,” said Sebastian.
Jumbo anodes packed,ready to be shipped.
“Although lead welding is nothing new, for the last 60 or so years, this has been done using oxy welding. Our new robotic system uses gas tungsten arc welding on lead. This is a brand new technology that no one has used in Australia before,” said Srikanth.
“The robot is installed in the middle of two cells. Both cells feature a jig, with all the components of an anode. While the robot is welding in one cell,
Srikanth Vegi (Quality Manager, CAgroup) agreed. “Companies regularly approach us looking for anodes for new processes. As we have our own mill, we regularly develop these products and then expand our range to supply companies throughout the world. Flexibility and a strong customer focus is what makes CAgroup so
and remains squarely focused on meeting customer demands now and into the future.
we’re always looking to invest in technology. If our clients require something, and we don’t have the in-house capability, we look for technology that can help. At the moment, this approach has seen us investing in robotics,” said Srikanth.
successful. We also pride ourselves on fast deliveries and turnaround times to help ensure that our clients can continue operating without
Australian Welding24
“Our key strengths include lowcost operations, strong brands which are synonymous with high product quality and an extensive and efficient distribution network around Australia and New Zealand. Product development and quality control are supported by our modern in-house laboratory,” said Sebastian.
Silver Lead Anodes for Metalúrgica MET MEX Peñoles in Mexico
For other companies considering investing in robotics, CAgroup has this sound advice. “It’s worth doing. It takes time but there is a good chance that if you have a process, or a step in your process, that you want to improve, robotics is a good possibility,” said Sebastian.
Q3 | September 2022 25
A Long Lead Time
Further Information
busy in the manual cells, we can utilise the robots,” said Sebastian.
our team can load the components in the other cell. In this way, the welding process is continuous. It has resulted in significant productivity improvements in the workshop. Productivity improvements are particularly important when it comes to anodes—we may be producing thousands and thousands of units. We need to reduce our manpower, ensure quality and improve productivity for these types of projects,” said Sebastian.
“We started this project in 2020, working with Scott Automation. We have a good history with Scott Automation—they had commissioned two robots for us previously and were very clear on the project scope, having undertaken something similar for Glencore’s cathode welding process,” said Sebastian.
after the trial,” said Sebastian. “We commissioned the robot early this year and entered production in February. Every time we have a new design, we enlist the help of Weld Australia. We are very happy with the engagement of both Scott Automation (who is more about the equipment) and Weld Australia (who is more about the science of welding).”
Robotic welder.
“We started out with some trials, but the first results were not satisfactory. We knew we needed someone with in-depth understanding and experience in welding. Weld Australia was the perfect partner. Victor Blain (Weld Australia’s Engineering Team Manager – South and West) did some research, and worked with CAgroup and Scott Automation throughout the project. He understood the technical parameters we needed to change
“In addition, the robot is very safe. The operator can only access the cell when it is not in use—we have barriers that stop entry. This means that the operator remains at a safe distance from the welding process at all times. We also have a state-of-theart extraction system to remove the fumes produced during welding.”
Srikanth agreed. “Investing in robotics keeps manufacturing in Australia. It also ensures that you’re producing good quality products locally. Instead of outsourcing manufacturing overseas, and it taking months and months for your delivery to arrive, you can produce better quality products with robotics.”
“In terms of space, the robotic cells are smaller than a regular station for this type of anode. This means that we can have the robotic cell working at the same time as manual welding stations. As such, we can produce different projects in parallel. CAgroup often has three or four major projects underway at any one time, so we need a manufacturing area that is flexible. So, even if our welders are
For further information, visit: cagroup.com.au or caanodes.com
According to Srikanth, the decision to invest in robotic welding technology was driven primarily by a lack of manpower. “We are having a hard time sourcing the manpower for our projects. Investing in robotics gives us the flexibility to produce orders of all sizes simultaneously.”
Brittany Hague, Apprentice Boilermaker,
JRS Manufacturing Group
What do you believe is the biggest challenge for the welding industry?
What is the most interesting project you’ve worked on?
Jump in and have a go!!!
Members of the JRS Manufacturing Group team.
Four years ago, a friend gave me an opportunity to try welding and I found I loved it. At first, I wasn’t confident that I could do it but I’ve jumped in and had a crack and its now my career!!
Why not?! Its fun, its creative and it’s challenging in ways most jobs aren’t.
How have you found working in a traditionally male-dominated industry?
Q3 | September 2022 27
Brittany Hague is a first year apprentice boilermaker at JRS Manufacturing Group. Based in Toowoomba, JRS Manufacturing Group is a steel fabrication and welding company that specialises in plate, pipe and structural steel products for clients in the civil, energy, mining, agricultural, oil and gas industries. Brittany joined the JRS team earlier this year, and is really enjoying a career in the welding industry. Brittany took some time away from the workshop to answer a few questions about her welding career so far.
I think the greatest challenge is finding ways to integrate technology into traditional manufacturing practices to be ready for the future.
What about the biggest opportunity for the welding industry?
Innovating our training models to deliver the next generation of Boilermakers to industry.
Established in 2014 with a small team of five people, JRS Manufacturing Group originally rented a small shed and focused on boilermaking. In the years that followed, JRS grew quickly. The company expanded its service offering, quickly realising that in-house sandblasting and painting capabilities were needed to complement their fabrication services. In 2015, JRS purchased a separate paint shop, which increased their fabrication output. In 2019, with a strong future firmly on the horizon, JRS purchased a much larger workshop. Today, the company boasts a workforce of more than 50 people and is looking to employ a lot more apprentices to handle the company’s expected future growth. Their services encompass pressure pipe fabrication and welding, abrasive blasting and coating, medium to heavy plate fabrication, specialised surface treatments, CNC and general machining and assembly.
In some places I’ve found you have to challenge the perception of what a woman can do in industry and instructions are unnecessarily dumbed down but overall its been positive and welcoming.
WOMEN IN WELDING
Do you have any advice for women considering a career in welding?
Who has inspired you professionally?
What inspired you to choose a career in welding?
Can you describe your job?
Brittany Hague, Apprentice Boilermaker, JRS Manufacturing Group
I’ve recently been able to contribute to the building of the worlds first fully automated mill relining product the RME SKYWAY – it’s exciting to see technology and traditional manufacturing come together.
About JRS Manufacturing Group
Why do you think women should consider a career in welding?
I work as an apprentice boilermaker in a fast paced, dynamic, exciting manufacturing company that specialises in metallics. I work on a lot of complex, geometric, medium to heavy steel products that require grinding, forming, fabricating, welding and testing.
At the moment, it’s the tradespeople I work alongside because they take the time to coach and mentor me so I can improve my skills. I hope to be able to do the same one day for other apprentices.
And, possibly most concerning, once prisoners enter the correctional system, finding their way out can be tough. The Australian Bureau of Statistics latest report showed that prisoners with prior adult
FEATURE STORY
Australian Welding28
Australia’s imprisonment rate also increased by 5% from 205 to 214 prisoners per 100,000 adult population. This rate well exceeds that found across countless nations, from Scandinavia, Western Europe, Canada and the United Kingdom,
VET and rehabilitative efforts are generally successful in reducing recidivism. In fact, there is some evidence to suggest that without rehabilitation, sanctions and incarceration alone may result in increased rates of reoffending.
Geoff Crittenden and Jeff Wanliss
inspect a prisoner’s welding at the Welding Employment Expo
Many prisoners have education and skill levels well below the Australian average. Almost 2 in 3 (63%) prisoners have an education level of Year 8 or below.
through to Iraq, Saudi Arabia, China and New Zealand.
The introduction of VET programs as part of prisoner rehabilitation offers opportunities for prisoners to reduce this disadvantage, increasing the likelihood of successful re-integration into the community and reducing the risk of reoffending.
LIFE AFTER PRISON: VET TRAINING AND EMPLOYMENT PATHWAYS
A recent study confirmed that participation in VET whilst incarcerated helps prisoners to remain custody free post-release. In fact, prisoners who successfully completed VET were 59.96% more likely to remain custody free at two years post-release; and 78.23% more likely to remain custody free at five years post-release.
By Geoff Crittenden (CEO, Weld Australia)
Rehabilitation and Training Programs
imprisonment increased by 5% from 30 June 2020 to 30 June 2021.
As at 30 June 2021, the median age was 35.6 years for all prisoners. When comparing the prison population to the general adult population, prisoners are much younger—2 in 3 (65%) prisoners were under 40, compared with about 2 in 5 (40%) in the general adult population.
All these statistics paint a clear picture: our prison population is rapidly expanding, and is increasingly comprised of younger people and reoffenders. This gives rise to the need for practical rehabilitation and vocational education and training (VET) programs that can help alleviate recidivism.
Australia’s prison population continues to grow at a rate that is four times that of the general population. According to the most recent figures from the Australian Bureau of Statistics, from 30 June 2020 to 30 June 2021, the total number of Australian prisoners increased by 5% to 42,970.
Student *Daine said, “I wanted to take part in this course to not only further my knowledge and experience of welding but to be able to give myself the ability to provide a positive, reliable, and sustainable future for my family.”
“When I am released, I am keen to find as much work as possible in the engineering trade working in the railways, or similar areas that require good welders. I don’t see my life revolving around prison and I want to have real work opportunities in the community when I’m released.”
As part of the program, augmented reality training was introduced to expand the welding skills of the prisoner learners to meet international standards. A welding workshop sits alongside the augmented reality training room so that participants can work on projects to use and practice their welding skills in the physical as well as virtual environments.
According to Andrew Glisson (Teacher, Federation TAFE), “The students all demonstrate potential and are showing excellent aptitude and skill development as we move forward through the course.”
“It has been enjoyable watching the students have ‘light bulb’ moments in their own personal skill development. It has also been rewarding to see a student develop confidence when they discover they are capable of more than they thought.”
To participate in the program, prisoners are invited to submit an Expression of Interest and then selected through an interview process. Up to eight participants can be accommodated in the intensive 14-week program.
VET Centre of Excellence in Welding at HM Prison Langi Kal Kal
Given the proven success of VET programs for prisoner rehabilitation, in 2022, Corrections Victoria expanded the VET Centre of Excellence model to deliver Fusion Welding to ISO 9606 certification standard to complement their Metal Fabrication industry at Langi Kal Kal Prison. Federation University delivers the training program with the support of Weld Australia and on-site prison industry staff.
“I wanted to take part in this course to not only further my knowledge and experience of welding but to be able to give myself the ability to provide a positive, reliable, and sustainable future for my family.”
Q3 | September 2022 29
*Name changed to maintain privacy.
wide report that they have paid employment organised to start within two weeks of release from prison. This can also be exacerbated at times by parole conditions that make full-time employment more difficult to manage.
Gaining and Maintaining Employment
The ability to gain and maintain employment post-release is equally as important as training when it comes to the successful reintegration of former prisoners into the community. And yet, few ex-prisoners are able to find meaningful work.
“ These types of training helpprogramsrehabilitationandaresoimportant.Theygiveprisonerspurpose.Manyoftheprisonershave obviously faced challenges in the past, but, this is a delineation point— it’s like drawing a line in the sand and saying ‘the past is the past’.”
The VET Centre of Excellence model links participating prisoners with prospective employers and preand post-release support service providers. These connections provide prisoners with sustainable pathways to employment and support to reintegrate to society post-release.
Attendees at the Welding Employment Expo at HM Prison Langi Kal Kal.
In conjunction with Weld Australia, Langi Kal Kal Prison recently hosted a Welding Employment Expo to help facilitate connections between prisoners and prospective employers. The Expo was attended by several
Weld Australia members, including representatives from MaxiTrans and Hanlon Industries, as well as Jeff Wanliss (Engineering and Business Development Manager, Keppel Prince). Based in Portland, Victoria, Keppel Prince specialises in the construction, fabrication and maintenance of industrial structures and equipment, ranging from wind farms to bridges.
“I didn’t really know what to expect from the Employment Expo, but the experience was a big eye-opener for me. I was very impressed by the facilities at Langi Kal Kal. The equipment is excellent and in line with industry standards, which helps ensure the prisoners are prepared to walk into any workshop—they’ll be comfortable from day one,” said Wanliss.
Australian Welding30 FEATURE STORY
Prisoners often come from a socioeconomic group that already faces difficulties in gaining employment. They generally have high levels of drug and alcohol misuse, high levels of mental health issues, and poor work histories. Imprisonment adds to this mix, making it even more difficult for prisoners to find a job.
According to the Australian Institute of Health and Welfare fewer than 1 in 4 (22%) of former prisoners national
Further Information
About HM Prison Langi Kal Kal
Situated on the Western Highway at Trawalla approximately 140km west of Melbourne, Langi Kal Kal is an open camp, minimum security protection prison with all prisoners required to work during their stay unless they are over retirement age. As a pre-release prison, Langi Kal Kal specialises in getting prisoners ready for release through on-the job training and employment in a range of industries.
For further information, or if you would like to get involved as a prospective employer, please complete this Expression of Interest Form
“During the tour of the facilities, one of the prisoners produced an industry standard vertical up weld—one of the hardest welds to do. We would have accepted that weld in our workshop. It can be difficult to find potential employees with the skills and experience needed in our workshop. I’d definitely consider employing any of the guys based on the standard of welding they’re doing.”
VET training and employment pathways as part of prisoner rehabilitation could help alleviate some of these skills shortages. However, this will require commitment and collaboration from industry and government—not only to fund VET training in Australia’s prisons—but to help provide secure employment opportunities post-release.
A Successful Future Australia is facing a looming shortage of skilled welders—70,000 additional welders will be needed in the next 10 years. Welders are more in demand than ever with several large-scale, highvalue projects on the horizon, from the Federal Government’s $90 billion Naval Shipbuilding Program, through to major infrastructure projects such as the $16 billion WestConnex project, $12 billion Sydney Metro project, and the $11 billion Melbourne Metro Tunnel.
Welding Employment Expo at HM Prison Langi Kal Kal.
“The level of instruction was top class. The welding supervisor was equipped with a wealth of knowledge and experience, having previous experience as a boilermaker. The level of passion from all the correctional officers was clear. They’re all dedicated to working with the prisoners, bringing out the best in them, and giving them a solid grounding in the skills needed for life.”
“VET and training programs like this one equip prisoners with knowledge and give them practical skills that they can use on release. It is an essential step to ensuring that their future is successful,” said Wanliss.
“These types of training and rehabilitation programs are so important. They help give prisoners purpose. Many of the prisoners have obviously faced challenges in the past, but, this is a delineation point—it’s like drawing a line in the sand and saying ‘the past is the past’.”
Welding Employment Expo at HM Prison Langi Kal Kal.
The land where Langi Kal Kal Prison is located was first settled as a 70,000-acre farming property in about 1838. A substantial farmhouse was built in approximately 1900. After World War II, the land was subdivided and the central area, including the farmhouse, was set aside for prison purposes. The first prisoners arrived in September 1950 and the prison was officially opened in February 1951. In 1965 the prison became a youth training centre, but again became an adult prison in June 1993.
Q3 | September 2022 31
Where social conscious is synonymous with success
According to Managing Director, Adam Sarota, “The last couple of years with COVID-19 have been difficult for everyone and, like many other manufacturing businesses, we’ve had to face a lot of new challenges. We’ve had to adapt and diversify into other areas, and we are really proud of the fact that we’ve managed to diversify our business into different sectors and doubled the business whilst attaining several ISO accreditations, and creating new social and Indigenous life changing initiatives.”
Havingmachinery.beenanExecutive Director
of Bridgeman for over five years, Adam Sarota became an Owner and Managing Director of Bridgeman in April 2021. Adam is a former Socceroo, and a proud Traditional Owner and Yidinji man. Subsequently, Jade North joined Bridgeman as an Owner and Managing Partner. Jade is also a former Socceroo, Olympian, NAIDOC Sportsperson of the year, current Co-Chair of Football Australia’s National Indigenous Advisory Group and a proud Indigenous man from Biripi Country.
also expanded into new areas of operation, with its entities now encompassing Bridgeman Manufacturing, Bridgeman Building Group, and Bridgeman Defence, Government and Infrastructure. In addition, sustainability, governance and environmental planning have been paramount through the creation of an executive team with significant and diverse experience that continues to drive Bridgeman’s evolution.
Social conscious is synonymous with success for Queensland metal manufacturing and construction company, Bridgeman. An Indigenous owned, operated and Supply Nation certified company, Bridgeman prides itself on its commitment to the community, as well as its highly experienced staff and leadingedge capability. The company works with Traditional Owners to engage with the community, and with Australian Government agencies, to improve employment and training outcomes for Indigenous People across Australia.
Bridgeman has been delivering end-to-end solutions in Queensland and across Australia for more than 25 years. Originally founded in 1997 as a metal manufacturing company, Bridgeman has transitioned into one of Australia’s most trusted and respected multi-faceted solutions providers. With a presence in Brisbane, Townsville and Cairns, Bridgeman boasts an advanced manufacturing facility of over 2,700m2, which is equipped with the latest
Since the new ownership of the company commenced, Bridgeman has increased its staff numbers from 40 to 90 employees, including 20 apprentices and 11 Indigenous employees. The company has
BRIDGEMAN
Australian Welding32 FEATURE STORY
“Our company operates across the primary areas of metal manufacturing solutions and construction. We are compliant with all relevant accreditations and ISO certified and have the ability to provide a multifaceted range of solutions which deliver quality, cost effective, and
Adam Sarota and Jade North.
“Bridgeman’s expertise is unrivalled, whether it’s manufacturing, engineering, drafting or fully customised design and manufacturing, including galvanising, powder-coating, anodising, and state-ofthe-art laser cutting,” said Adam.
timely results to our clients, across sites of all sizes and scopes through a single point of contact.”
As an Indigenous owned, operated and Supply Nation certified company, Bridgeman is committed to ensuring that they provide leadership, support, opportunity, and encouragement to Aboriginal and Torres Strait Islander peoples and the broader community.
Q3 | September 2022 33
“We aim to demonstrate an increased Indigenous participation beyond traditional levels and provide more advanced roles for Aboriginal and Torres Strait Islander people through various initiatives,” said Managing Partner, Jade North.
“Our goal is to set the benchmark for Indigenous participation and inspire the Indigenous business community in helping to break down stereotypes and unconscious bias. Bridgeman continuously liaises and works with Traditional Owners on a range of community engagement matters, including cultural protocols and to seek advice on recognition and acknowledgment of Traditional Owners within specific “Weregions.”also
INDIGENOUS OWNED AND OPERATED
work alongside other Australian Government Agencies, such as the Department of Seniors, Disability Services and Aboriginal and Torres Strait Islander Partnerships (DATSIP), to facilitate the alignment of businesses and employment and training outcomes for Indigenous Peoples. Bridgeman proudly has Indigenous Employment and Procurement First Policies to encourage greater social and economic benefits within the communities in which we work.”
“We work across all metals including, stainless steel, mild steel, aluminium, brass and copper. Bridgeman has in-house welding operators qualified to AS/NZS 1554.6 and AS/NZS 1554.l. Our team includes Weld Australia qualified welding supervisors (AS1796 Cert 10), and an International Welding Specialist (IWS).”
“One of our key strengths is our capability to adapt and diversify when and where needed. From minor refurbishments to major construction projects, we pride ourselves on our capability and capacity to provide flexible solutions, over and above the scope requirements. Our priority is the health and safety of our people, our clients, contractors, and our community,” said Adam.
This program targets Indigenous and Non-Indigenous high school students, providing real-life learning opportunities for students by mentoring and supporting them through the transition from high school to work life. “Bridging the Gap offers pathways post school and most importantly, provides kids with the inspiration and drive to transition from school to the real world. We assist in closing the gap of intergenerational welfare and long-term unemployment by providing support and mentoring by key people and senior members within our business to help students gain confidence, reach their full potential and achieve success in their chosen field,” said Jade.
Womeniniative.inConstruction
Pathway.
Futures Program
Bridgeman also partners with companies on selected projects allowing them to share the journey and help improve the livelihood and future for Indigenous and underprivileged people.
“Our Futures Program focuses on training and retaining Australian apprentices and trainees for the long term. It enables Bridgeman to create and develop our future workforce. Apprentices and trainees work alongside our qualified tradespeople who assist with on-the-job training and allows them the opportunity to build new skills in a hands-on learning environment. Working with our Bridgeman experts in their trades helps develop invaluable skills and experience in a varied environment,” said Jade. As a result, Bridgeman currently employs 20 full-time apprentices across their operations.
They have created the Bridgeman Yarning Circle, a unique Indigenous supply chain network that provides companies with genuine, pre-qualified, accredited and compliant Indigenous companies. Bridgeman’s ‘Multiplier’ goal—designed to create meaningful change through tangible outcomes— is to convert every $1 contracted to Bridgeman into $3 within the Indigenous business community.
Australian Welding34
Career Transition Program
SOCIAL INITIATIVES ENHANCING THE LIVES OF QUEENSLANDERS
Kickin With A Cuz
One Mob Initiative
“We are working to create as many opportunities for Indigenous businesses within our supply chain as possible and working with our non-indigenous supply chain partners to create more opportunities for Indigenous people and businesses within their supply chains. This process is creating real opportunities and genuine outcomes which is really pleasing but only the start for us,” said Adam.
FEATURE STORY
Bridgeman was recently awarded the 2022 Dickson Small Business of the Year Award by Hon Peter Dutton MP, in recognition of their Outstanding Service and Leadership for the Indigenous Community. Some examples of Bridgeman’s social initiatives that enhance the lives of Queenslanders are outlined below.
Bridgeman’s One Mob Initiative (OMI) was developed to engage and provide positive educational and work experiences for Aboriginal and
“Bridgeman created our Career Transition Program to assist former professional athletes, service men and women and people with disabilities who are struggling to
Bridging the Gap
Torres Strait Islander Peoples. OMI builds a pathway for those seeking to pursue tertiary education and employment, particularly vulnerable and disadvantaged Indigenous.
transition into the mainstream workforce. We understand the unique challenges and hardships people face when transitioning from one career to another. The goal of the program is to build confidence and enhance skills and knowledge through practical experience, mentorship and support,” said Jade.
“We proudly support the recipients of this initiative with vocational and financial support to assist with this journey. We see the significance and draw on the skills, capability and unique life experiences that Aboriginal and Torres Strait Island Peoples can bring. We want the forefront of our business to drive inclusiveness and diversity. We currently employ 11 Indigenous full-time employees through our One Mob Initiative,” said Jade.
Bridgeman currently employs three full-time employees via this program.
For further information about Bridgeman and their programs visit: bridgeman.com.au
• Kickin’ with a Cuz: created by Jade North, to teach young Indigenous and under privileged children a viable pathway to make better life choices
As a result, Bridgeman has developed a four step system that sees the company involved in prevention and rehabilitation of both past and current offenders.
• Prime Minister’s Veteran’s Employment Program: providing employment opportunities to Veterans leaving the Australian Defence Force
Bridgeman employs three women via this pathway, with one studying project management.
• Cairns Safer Streets: Adam Sarota is an active Indigenous Ambassador encouraging young people and their families to take part in activities together
Women in Construction Pathway Bridgeman is dedicated to providing and creating career opportunities to boost female participation within the construction industry.
Q3 | September 2022 35
• Givit Foundation: Jade North is an active Indigenous Ambassador for Givit which provides support to Indigenous and Torres Strait Islander Peoples who are experiencing hardship
“Our Women in Construction Pathway Program assists women in their professional growth and ongoing success in our company where we appreciate the distinctive qualities they can bring to Bridgeman and the construction industry. The pathway has been designed to provide more opportunities for females in front-line delivery roles where the program offers apprenticeships, tertiary education, and internal promotion opportunities along with trade-specific courses such as project management,” said Jade.
Further Information
Working with Correctional Centres is deeply personal for Bridgeman’s Owners Adam Sarota and Jade North. They are passionate about providing opportunities for those who are going through or facing hardship, particularly past offenders.
Bridgeman’s recent bunk bed and cell furniture project created 17 new full time employment positions of which 23.5% were Indigenous, 17.6% were past offenders and 23.5% were newly created apprenticeships.
Bridgeman has successfully manufactured and installed over 2,700 bunk beds and cell furniture in the last five years alone in live Correctional Centres including Lotus Glen, Townsville, Brisbane, Maryborough and Wolston Correctional Centres. Projects include Bridgeman’s current 827 bunk bed and cell furniture rollout program for QBuild.
Bridgeman also supports the following initiatives:
Bunk Beds Boost for Jobs, Safety and Offender Rehabilitation
Preparing Australians for a career in mining
FEATURE STORY
BHP’s FutureFit Academy seeks to forge new territory in the way the company prepares their people for a career in mining. Launched in 2020, the Academy is part of a new national training program designed to bolster Australia’s skills base and create new career pathways into the mining sector. Offering an innovative approach to training, the Academy’s fit-for-purpose maintenance and production training programs are run in dedicated learning centres in Perth, Western Australia, and Mackay in Queensland.
• Production: Students complete a Certificate III in Surface Extraction Operations to equip them to be trained, competent and authorised as a Production Operator.
From day one at the Academy, students are a permanent BHP employee, earning a salary while they’re studying. The purpose-built learning centres feature the latest immersive virtual reality technology combined with workshop learning designed to provide students with the training they need to competently and safely carry out their work in the field.
In the last two years, BHP’s FutureFit Academy has welcomed over 590 apprentices and trainees, with more than 80% women and over 20% per cent Indigenous learners. The average age is about 30 years old, and most are from regional communities. There have already been over 220 graduates deployed to permanent jobs across BHP’s Australian operations. With strong demand for future intakes, BHP expects to train 2,500 new apprentices and trainees over the next five
The Academy offers the following pathways:
and these results are testament to the strength of the BHP FutureFit Academy’s program and its focus on a supportive culture and developing career pathways,” said Michelle.
“When first establishing the BHP FutureFit Academy, we set out to dream big and think differently. Our goal was to develop an inclusive learning environment where students and leaders would feel welcomed and supported. Two years later, we are seeing greater retention
Photo: Soldamatic augmented reality welding simulators are student-focused, allowing individual students to progress at their own pace. Welding apprentices learn and understand welding procedures and techniques through a more interactive training method, gaining hands-on experience in a controlled, safe environment. Augmented reality transforms training from boring theory and text books into high-quality interactive experiences that capture the imagination.
• Maintenance: Students complete specific modules to a Certificate II level to equip them to be trained, competent and authorised to perform a range of preventative maintenance tasks as a Heavy Diesel Maintenance Associate or Mechanical Fitter Maintenance Associate.
FUTUREFIT ACADEMY
Fitting, Mechanical Fitting, Fabrication and Conveyor BeltSplicing (Polymer Fabrication), with new Auto Electrical and Electrical trades coming in the 2023 financial year.
• Trade Apprenticeship: Over 24 months students earn a full trade qualification and the skills to perform preventative maintenance, diagnostics and repairs. BHP is offering apprenticeships in Heavy Diesel
Gibson (Head of Learning and Development, BHP),
• Traineeships are offered over 12 months in either:
Australian WeldingBHP36
Accordingyears.toMichelle
Academy programs are nationally accredited and supported by BHP’s partnerships with Central Queensland University (CQU) Australia and North Metropolitan TAFE (NMTAFE), Western Australia.
welcomed students from all walks of life such as Lisa Berwick at our Perth Academy, who is a 49-year-old mother of three with no prior mining experience. Lisa now works on BHP shutdowns after graduating from a 12-month maintenance traineeship with FutureFit Academy,” said Laura.
Welding apprentices learn and understand welding procedures and techniques through a more interactive training method, gaining handson experience in a controlled, safe environment. With zero risks involved, apprentices can respond to realistic scenarios without pressure or fear of injury. Augmented and virtual reality
The FutureFit Academy in Perth offers training programs in fabrication. Students commence their training using Soldamatic augmented reality welding simulators.
the Academies are not just for school leavers. We have
“Our FutureFit Academy national training program is designed to create exciting career pathways into the mining sector. We offer mining apprenticeships and traineeships, backed by nationally recognised “Importantly,curricula.”
Augmented Reality Welder Training
According to Laura Tyler (Chief Technical Officer, BHP), “We are an industry that offers a diverse range of rewarding career opportunities that suit any passion or skill set. But it is not always easy to gain the skills to get in the door.”
“ When first establishing the BHP FutureFit Academy, we set out to dream big and think differently. Our goal was to develop an inclusive learning environment where students and leaders would feel welcomed and supported.”
Jimblebar, Western Australia
What does a typical day look like as a FutureFit Academy student at CQUniversity (CQU) Mackay? We start every day with a pre-start meeting and safety share. This ensures that we identify things from yesterday that could be done better - or safer - and plan out what we might face today. Safety is a major focus and everyone wants to be sure you go home in the same condition you arrived in. Every day is a joyful experience and our trainers and supervisors are always there to help. No question is too silly and no question goes unanswered. Everyone here wants to drive you in the right direction and help you achieve and succeed
Australian WeldingGet38
to Know FutureFit Academy Student Rachael Almond
Tell us about your journey so far with the FutureFit Academy? I was blown away when I found out I was accepted into the FutureFit Academy. It was like winning the lotto! My journey has been amazing with the greatest thing being the support provided to every student. An example of this is late last year on New Year’s morning my son lost his house and his belongings in a house fire. It was incredibly sad and my fellow students, teachers, superintendents and the people in the office reached out to provide support. You’re not just a number at the FFA!
What do you like to get up to when you’re not studying?
Before I relocated to Mackay, I was from Sydney where I harboured a passion for cars. I enjoy working on cars with my dad and restoring the old classics like mustangs, XY falcons and everything in between. As long as it sounds tough and has the horsepower! I have a soft spot for animals, my horse Apollo, and my dogs Johnny Cash and Ruby. My partner and I recently brought a caravan and plan on exploring North Queensland on our days off.
When she’s not restoring classic cars, Rachael Almond is studying to become a Mechanical Fitter at BHP’s FutureFit Academy. Rachael talks about her journey so far, the support she’s received since joining the FutureFit Academy, and her excitement for the future.
What’s been your highlight so far? Making things! If you had asked me 12 months ago to make a drill gauge I would have replied with “a what?” Yes, I can now actually make a drill gauge from a flat piece of steel. I enjoy tool time as I love pulling things apart and putting them back together.
Why did you join the FutureFit Academy? I joined the FFA for the opportunity! I’m 39 years old and no one gets a fresh start in a career as an apprentice new to industry trade at 39! I joined for my future, to try something different, and to go somewhere I’ve never been before in my career.
Indigenous Employment Target Reached Ahead of Schedule
In Western Australia, the Indigenous employment rate is higher than the national average – increasing from 9.2% in 2019 to 10.5% in 2021. Of the 231 apprentices and trainees currently in training at BHP’s Future Fit Academy in Welshpool, which provides heavy diesel mechanics and mechanical fitters for BHP’s iron ore operations in Western Australia, 20% are Indigenous.
interactions, support in literacy and numeracy, Indigenous support and access to library resources.
BHP President Minerals Australia Edgar Basto said BHP was committed to creating a diverse and inclusive workforce and supporting the local communities in which it operates.
In April 2022, BHP achieved its national Indigenous employment target of 8% three years ahead of
“Creating more opportunities for Indigenous people, particularly in the Pilbara and other local communities in which we operate, is an important focus of BHP. Combined with our commitment to accelerated training programs, I am proud that we are providing more opportunities for Indigenous people. Reaching this target ahead of schedule is a great achievement for the whole team but our commitment doesn’t end therewe know there is plenty more work to be done,” said Edgar.
This is supported by BHP’s partnerships with CQUniversity (CQU) and North Metropolitan TAFE (NMTAFE), who offer students weekly support sessions with face-to-face
Further Information For further information about the BHP FutureFit Academy visit: bhp.com.au
Q3 | September 2022 39
“Our commitment to the Indigenous community—from employment, engagement with traditional owners and Indigenous businesses—is
vital to our ongoing and sustaining relationship with Indigenous and Traditional Owner communities.”
training is enabling future welders to acquire the skills and the selfconfidence they need before moving into real-world workshops.
Bowen Basin, Queensland
South Flank, Western Australia
BHPschedule.hasa targeted Indigenous recruitment campaign, which includes a tailored application process to take into account the cultural needs of applicants. The Academy attracts more Indigenous individuals into education through the proximity of training centres to local communities, a holistic curriculum specially designed for new to industry people, and the inclusion of sessions dealing with culture, capability and life skills.
The BHP FutureFit Academy recently took home the bronze award in the World Federation of Technical Colleges and Polytechnics (WFCP) Awards for Excellence alongside its partner training organisations CQUniversity and North Metropolitan TAFE (NMTAFE). Recognised in the top three on the world stage out of over 100 nominations for its contribution to Indigenous Education, this is a phenomenal achievement for the BHP FutureFit Academy.
FEATURE STORY
Australian Welding40
BRUCE CANNON WINS
Manager in February 2016. His duties include the revision of key technical literature as required, peer reviewing of technical reports, and engagement with standards organisations including attendance at relevant ISO meetings. Further details of Bruce’s involvement in standards is outlined below.
Bruce Cannon has made an exceptional contribution to the Australian welding industry over the last 40 years. He has helped to ensure that welding quality standards are paramount, improving safety both for welders, as well as members of the general public. Since 2004, he has been instrumental in the direct adoption of over ten ISO standards.
AS/NZS 1554 Series
Weld Australia would like to congratulate Bruce Cannon (Principal Welding Engineer, Weld Australia) on winning the International Institute of Welding (IIW) 2022 Thomas Medal. Bruce was presented with the award at the Opening Ceremony of the 75th IIW Annual Assembly of the International Institute of Welding (IIW) in Tokyo. Established in 1997, the Thomas Medal is awarded to an individual who has been involved in IIW and ISO international standards activities for over 10 years, and is recognised by their peers as having actively promoted international welding standardisation.
A Career in Welding Bruce commenced employment
From 1993 to 1995, Bruce was seconded to Weld Australia (then the WTIA) as its welding engineer, providing technical support to the welding industry.
In July 1995, Bruce returned to BHP Steel, continuing to be involved in specialist weldability testing, resistance welding, weld monitoring, hot tapping, and customer support. He was a guest lecturer at the University of Wollongong for International Welding Technologist (IWT) and Engineer (IWE) students, and liaised with various research groups. Bruce’s work in Australian standards continued and in April 2001, he was appointed as Chair of committee WD-003 Welding of structures. In 2015, Bruce retired from BlueScope and joined Weld Australia as its Technical Publications
His involvement with ISO commenced in 2001 as Chair of the Australian and New Zealand standards committee WD-003 Welding of steel structures. He has also been the Australian representative for several other Standards Committees, including Terms and Definitions (WD-001), Health and Safety (WD-004), Weld Testing (WD-006) and Steel Structures
In(BD-001).thesevoluntary positions, Bruce has liaised with Pacific Rim countries, reviewed countless standards and other documentation, advising Standards Australia accordingly. In particular, Bruce’s review of ISO 9606-1 Qualification testing of welders –Fusion welding led to much of it being adopted in Australia within AS 2980 in 2004, and New Zealand in 2007.
Arising out of the secondment and following his appointment as Chair of WD-003, it was apparent there were issues with the understanding of the AS/NZS1554 series and in particular, the qualification of welders was problematic. Bruce used his position to collate questions arising from industry and implement changes into the standards, as well as explanations in Technical Note 11 to further assist users. One major challenge he has managed is the use of dumped steel
THE 2022INSTITUTEINTERNATIONALOFWELDINGTHOMASMEDAL
An Exceptional Contribution
Chair of WD-003
In 1994, Bruce became a representative on a number of standards committees, including Welding of Structures (WD-003), Terms and Definitions (WD-001), Health and Safety (WD-004), Weld Testing (WD-006) and Steel Structures (BD-001). In 2001, Bruce was appointed as Chair of Committee WD-003 and a number of its subcommittees—a position he currently holds.
with BHP in 1977 after graduating with a Batchelor of Applied Science (Metallurgy) from what is now Federation University. Early in his career, he worked in areas such as mechanical testing, metallography and marketing before joining BHP Steel’s welding development group in 1985. He was involved in the welding and weldability testing of steels, weld repairs, electroslag roll reclamation, weldability of quenched and tempered steels, quality management and technical advice.
AS/NZS ISO 9606.1
3. AS/NZS 2980 allowed for portability of qualifications, a
concept adopted by some independent inspectors and training organisations.
Recognising that AS/NZS ISO 9606-1 is here to stay, Committee ME-001 agreed that AS/NZS ISO 9606.1 be incorporated within AS 3992. As the drafting leader for the 2020 revision of AS 3992, Bruce ensured that AS/NZS ISO 9606.1 was given full recognition within the pressure equipment industry. It is anticipated that in a future revision of AS 3992, welder qualification will likely refer to AS/NZS ISO 9606.1, simplifying the welder qualification process.
contaminated with boron.
Q3 | September 2022 41
In 2016, with the short list of tenders for the various Federal Ship Building Programs all European based, Bruce recognised that the tenders would most likely mandate the use of ISO 9606-1 for welder qualifications. Accordingly, he submitted a project to Standards Australia to adopt ISO 9606-1 as AS/NZS ISO 9606.1. The project was accepted and the standard was published in 2017. To facilitate the adoption and use of
The innovations introduced to AS/NZS 2980 and the AS/NZS 1554 series proved revolutionary and of great benefit to the welding industry:
AS/NZS 2980:2007 was well ahead of its time. Being aligned with ISO 9606-1, it paved the way for ISO 9606-1 to be introduced in Australia in 2017.
In 2017 and 2018, Bruce attended three committee meetings in relation ISO 9606-1 and, at the Miami 2018 meeting, provided first hand feedback to the committee on Australia’s experiences with the standard. He remains a member of working groups on ISO 9606 at ISO, presenting an Australian perspective on this important standard.
AS/NZS 2980
AS 3992
Left: Bruce Cannon is presented with the Thomas Medal in Tokyo by Dr Rick Polanin, President of AWS.
Top: L to R: Doug Hawkes, Bruce Cannon and David Lake (Chair, Weld Australia).
2. When published, AS/NZS 2980:2007 was approximately 90% aligned with what is now ISO 9606-1.
1. A table of welder qualification positions (both standards) was included that was identical to the then ISO 9606-1.
Photos
Bottom: The winners of the 2022 IIW Awards. Third from the left: Bruce Cannon.
AS 2980:1987 had the weakness that it could not be used for the GTAW process. In 2003, Bruce reviewed the content of the then ISO 96061 and prepared a draft to align the requirements of AS 2980 with ISO 9606-1 and give cognisance to ISO drafts in circulation. A problem that Australia, USA and Canada identified at the time was the ISO draft was aligned with European thinking. Bruce recommended that Australia vote to support the position taken by the USA and Canada. He actively worked with the USA to assist in the production of a workable draft that could be considered for adoption in Australia. A standard was eventually produced that achieved consensus in 2012.
AS/NZS ISO 3834
AS/NZS ISO 9606.1, Bruce submitted project proposals for the adoption of key referenced testing and other ISO standards, all of which were accepted and have since been published.
In 2017, Bruce travelled to Berlin to present a request on behalf of Australia to the subcommittee for an interpretation on the status of ISO 3834. It was ruled to be a factory production control system. As a result of his work, the Bridge Code (AS 5100 series) was modified to mandate ISO 3834 conformance by fabricators, and more recently, it was mandated within AS/NZS 5131. There are now over 100 companies certified to ISO 3834.
AS/NZS 5131 and AS 4100 Bruce was heavily involved with the development of these ground breaking standards.
the question, it will depend on who is requesting that the examination take place, be it part of the client specification, whether a NATA endorsed report may be required, or if it is for internal use by the fabricator as part of their quality management system. It should be noted that with the publication of AS/NZS 17637 Non-destructive testing of welds - Visual testing of fusion-welded joints, Standards Australia withdrew AS 3978. We generally advise enquirers as follows.
Australian Welding42 INSIDE WELD AUSTRALIA
Ifcourse.thefabricator is either compliant or claiming compliance with either AS/NZS 5131 Structural steelworkFabrication and erection and/or AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials, the fabricator is required to define requirements for (in-house) inspection before during and after welding including visual inspection of welds. The standards do not define who has to perform this task but does require them to be competent. Reference to Clause 5
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: www.weldaustralia.com.au/hotline.
AN UPDATE FROM OUR HOTLINE
Whilst some will say the answer is obvious, Clause 7.3 of AS/NZS 1554.1 requires the inspector to conduct the visual examination in accordance with AS 3978 Non-destructive testingVisual inspection of metal products and components. The complication arises when Non-Destructive Testing (NDT) personnel compliant with visual testing qualifications consistent with AS 3978 undertake such examinations rather than the welding
Toinspector.answer
For in-house visual examinations, AS/NZS 1554.1 is silent on who is qualified to perform this visual examination. It is not uncommon for the welding supervisor to perform this task, which is consistent with their AS/NZS 2214 Certification of welding supervisors - Structural steel welding training.
In some cases, a welder may be trained and tasked with inspecting their own work and signing off on this. Requirements may vary depending on what options have been defined by the fabricator as part of their quality management system. Depending on the nature of the work being undertaken, persons undertaking the visual examinations of welds may find it beneficial to attend Weld Australia’s IIW International Welding Inspector – Basic (IWI-B) welding inspection
Weld Australia is occasionally asked for an opinion on who can perform a visual examination of welds. This is a question that periodically arises when structural welds are to be examined to the requirements of AS/NZS 1554.1 Structural steel welding - Welding of steel structures at the completion of welding.
Notecontract.that
If the client asks for NATA endorsed visual examination reports of welded joints, then the person performing the inspection will most likely need to be compliant with AS ISO 9712. The fabricator should be aware that NDT technicians with NATA endorsement for visual examinations (VT) are accredited by NATA to provide a supplementary visual examination report in conjunction with the NDT method for which they are accredited.
For example, if performing a magnetic particle examination, the technician will perform a basic visual examination of the welded joint prior to performing the magnetic particle examination and, report appropriately on any surface imperfections observed. The extent of the visual examination though may extend beyond the specific weld length subjected to the magnetic particle examination. Weld sizing and other assessments typically performed by welding inspectors fall outside the scope of the NATA endorsed supplementary visual examination.
For Australia, this means that, for example, a AS/NZS 2214 qualified welding supervisor or a suitably qualified welding inspector (e.g. see Clause 7.2 of AS/NZS 1554.1) would conform with this recommendation as would a person with a visual examination qualification consistent with AS ISO 9712, but as per industry practice it does not preclude a suitably trained welder performing this task unless the client specifies otherwise in the
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.
of AS/NZS ISO 17637 recommends that the visual examiner be qualified to either ISO 9712 Nondestructive testing — Qualification and certification of NDT personnel (AS ISO 9712) or at an appropriate level in the relevant industry sector.
Q3 | September 2022 43
in this discussion, it is important to clarify that any person performing visual examination of welds claiming conformance with AS ISO 9712 requires specific welding-related knowledge and skills for this industry sector.
Committee WD-002 met in March 2022 to review Australia’s suite of ISO-based welding consumable standards. Projects have been initiated to revise the GMAW and FCAW suite of standards, including a proposal to supersede AS 4882 Shielding gases for welding with ISO 14175 Welding consumables — Gases and gas mixtures for fusion welding and allied processes.
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 an urgent review into Standards related to rubber hoses for welding, cutting and allied processes, and ongoing reviews into Standards related to pressure equipment and steel structures.
qualification (published in June 2020), and amendments have been prepared to address the issues raised. Public comment on the proposed amendments closed on 15 July 2022 and are now being
INSIDE WELD AUSTRALIA
schedule and the initial draft has been completed and submitted for preparation for public review.
of AS/NZS 3788
Pressure equipment—In service inspection is progressing to
A project was also initiated to adopt the GTAW consumable standard ISO 636 Welding consumables — Rods, wires and deposits for
As previously reported, users have reported a number of issues with the revised AS 3992 equipment—WeldingPressureandbrazing
CHANGING FACE OF AUSTRALIAN STANDARDS
Welding Consumables
tungsten inert gas welding of non-alloy and fine-grain steels — Classification to complete the GTAW suite of standards. The intention is to supplement and retain the existing AS/NZS 1167.2 Welding and brazing — Filler metals Part 2: Filler metals for welding. Public comment on all proposed adoptions and revisions has now been completed.
A proposal has been submitted and accepted by Standards Australia to revise AS1674.1 Safety in Welding and allied processes—Part 1 Fire precautions. The standard is used extensively in industry to establish fire preventative measures whilst welding in locations not necessarily designed for hot work. The project
Australian WeldingTHE44
Pressure Equipment
Committee ME-001 has completed the revision of AS 1796 Certification of welders and welding supervisors, and it was published on 24 June 2022.
Welding Safety
Thereviewed.revision
Bridges
Parts 1 to 5 inclusive have been published and a project request has been submitted to Standards Australia to adopt the latest revisions. As Part 6 is being revised to become an ISO standard in lieu of a technical report, consideration for adoption in Australia will be some years away.
or d.mistry@weldaustralia.com.au
ISO Update
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. A DIS ballot has been held and comments are currently under review. The
Q4 | December 2021 45 For further information, contact
The revision of AS/NZS 5100.6 Bridge design — Part 6: Steels and composite construction is well advanced. The objective of the revision is to align the requirements of the standard with the latest revision of AS 4100 Steel structures and the New Zealand steel structures design standard NZS 3404.1. The revision will resolve known conflicts and anomalies via an amendment.
is intended to clarify what is meant by the term ‘hot work’ and include provisions to assist small business and sole traders. Associated with this project is a proposal to update AS 2812 Welding, brazing and cutting of metals — Glossary of terms. Kickoff meetings for both projects are currently in the early planning stage.
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. The next meeting of the working group is scheduled for September 2022. Disha 02 8748 0100
Mistry on
Q3 | September 2022 45
Did you know that Weld Australia produces a comprehensive range of technical resources? We have Technical Notes on topics as diverse as the weldability of steels, welding of aluminium and quenched and tempered steel, flame cutting, control of lamellar tearing, and minimising corrosion in welded steel structures. When it comes to Guidance Notes, you’ll find resources dedicated to weld defects, welding fume mitigation and an overview of recent changes to standards such as AS/NZS ISO 9606-1 and AS/NZS 2980. Best of all, some of these resources free for anyone to download, some are only discounted or free for certain member types. All resources can be purchased by non-members and all member types, with rates tiered by member type. Visit the Weld Australia website to download your free technical resources.
Weld Australia’s Technical Resources
sub-committee TC44/SC10 met on 24 May 2022 to progress these projects and is due to meet again in October 2022.
ISO TC44/SC10 has commenced the revision of ISO 3834 Quality requirements for fusion welding of metallic materials series of standards primarily to take cognisance of changes to ISO 9001 Quality management systems — Requirements and the 2019 edition of ISO 14731 Welding coordination — Task and responsibilities
INSIDE WELD AUSTRALIA
Australian Welding46
The first tranche of the program was rolled out in the Bathurst region in January 2022. The second tranche of training took place in late February 2022 for high schools in Temora, West Wyalong, James Fallon, Shepherds Park and Junee.
In April 2022, Weld Australia commissioned another two Soldamatics for each of Cobar High School, Bourke High School and Willyama High School in Broken Hill. We also rolled out teacher training for the machines.
AN UPDATE FROM THE AWTCs
Advanced Manufacturing School Outreach Program
to students in Years 10-12 studying Manufacturing and Engineering, and Industrial Technology. Based on the success of the first pilot program, the NSW Department of Education ordered a further 20 simulators for another 10 high schools in regional areas.
Weld Australia has worked with partners around the country to secure State and Federal Government funding for the establishment of Advanced Welder Training Centres (AWTCs). Using the state-of-the-art Soldamatic augmented reality welding simulator, the training delivered at the AWTCs quickly qualifies welders to the only industry Standard in the world that is accepted in both Europe and America: ISO 9606-1 Qualificationtestingofwelders–Fusionwelding. This Standard is the minimum requirement for working on rolling stock, defence and infrastructure projects, which are crucial to onshore Australian manufacturing and a stronger national economy.
This will enable the program to be rolled out across another 14 high schools. The schools include Bateman’s Bay, Camden Haven, Dubbo, Evans, Great Lakes College, Gunnedah, Heathcote, Nowra, Macksville, Morisett, Mount View, Muswellbrook, Vincentia and Whitebridge. Weld Australia is looking forward to working with the schools on implementing the program, commissioning the Soldamatics, and rolling out ‘train the trainer’ courses.
The first pilot commenced at the beginning of Term 1 in 2021. The simulators were used to teach welding
A Short History of the Program
In 2020, Weld Australia proposed an Advanced Manufacturing School Outreach Program to the New South Wales (NSW) Government. The Program received their support, with funding provided through the Department of Education’s Vocational Education and Training Program for Secondary Students.
As a result, 32 augmented reality welding simulators were deployed in a pilot program in 16 schools across the state. The schools ranged from the Wagga Wagga, Lake Illawarra and Dapto high schools in southern New South Wales, to the Gorokan and Kurri Kurri High Schools in the Lower Hunter region.
Weld Australia’s Advanced Manufacturing School Outreach continues to go from strength to strength. The New South Wales Department of Education recently invested in additional Soldamatic augmented reality welding simulators.
Weld Australia’s Student and Apprentice Membership is free for high school students, as well as students and apprentices completing a welding related vocational training course with an RTO. As a Student or Apprentice member you’ll receive:
• The machine is amazing. The students are learning skills we cannot teach in a practical sense. We absolutely love it. The best learning tool I have seen in a long time!
• Access to our Job Board and Member Directory
JOIN NOW
• Excellent program accompanied with excellent training and backup support for the VR welders.
• Discounts on some products and services
• Invitations to events, presentations and site tours
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• All students have found the VR welders a positive way to learn basic welding skills.
MEM 2.0 Learning Resources
Just some of the feedback from teachers includes:
According to Michael Pitt, (National Manager Education and Training, Weld Australia), “We are creating a set of national resources mapped to the national MEM training package, so that learning resources for trade students are consistent across the country. This will help ensure consistent training, regardless of where in the country students undertake that training. The new resources are completely online and accessible via phone, mobile device or computer. This will allow students to access learning at the time, place and pace that suits them best. We are very excited about the project and are already seeing some great results.”
Weld Australia recently circulated the new learning resources to members of the National TAFE Consortium. The feedback was extremely positive. As a result, South Metropolitan TAFE in Fremantle, Western Australia is running an official pilot using the new units of competency and online resources. Once again, the feedback received from students and lecturers alike has been extremely positive. Weld Australia will continue working closely with TAFEs nationally on further development and uptake of the resources.
• Australian Welding (quarterly magazine)
Weld Australia is making significant progress with the national Metals and Engineering online learning resources project. Weld Australia is working with TAFEs across the country through the National TAFE Consortium to create excellent online resources.
FREE WELD AUSTRALIA STUDENT MEMBERSHIP
• Weld Connect (monthly e-bulletin)
• Regular industry updates and news
Photo: Power Generation Industry Group meeting attendees.
The Power Generation Industry Group 1.comprises:BoilerIndustry Group
POWER GENERATION INDUSTRY GROUP
2. PG9 Project
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.
AN UPDATE FROM WELD AUSTRALIA’S INDUSTRY GROUPS
CS Energy gave a presentation on the dry out and preservation procedures following the major turbine incident at the Callide C4 unit which occurred on 25 May 2021. This process was subjected to a wide range of conditions, issues and constraints arising from the turbine incident which required actions well beyond
Meetings of the Power Generation Industry Group were held in the offices of CS Energy (Brisbane) over 22 and 23 June 2022. A huge vote of thanks to CS Energy who provided excellent facilities, catering and support for the IT systems required to manage the meetings and online attendees.
4. Asset Integrity Board
Energy Australia gave a presentation on layup practices for wet and dry storage of boilers. These practices had been developed at the Mt Piper Power Station covering a number of plant requirements, scenarios and layup durations.
Wayne Hill (Principal Engineer Boilers and Pressure Parts, EnergyAustralia) spoke about an investigation into post
3. Process Safety Industry Group
Boiler Industry Group
There were four meetings held over two days. The meetings covered a wide range of subject material with many highly detailed presentations.
Australian Welding48 INSIDE WELD AUSTRALIA
A summary of each of the meetings is outlined below.
normal operating conditions and CSrequirements.Energyalso provided an overview of a failure in a reheater cross over tube at Kogan Creek Power Station. The root cause was found to be excessive weld root concavity on one of the connecting welds. These welds were undertaken at the time of manufacture through a robotic welding process. The implication was that all welds would have the same fault.
Les Sabo (Managing Director, Uneek Bending) provided an overview of Uneek Bending, which specialises in the bending of tubes and other types of steel. Les also discussed the Acoustic Gas Temperature Measurement System (AGAM) which has been developed by Germanbased Bonnenberg & Drescher. This system uses an array of acoustic transmitters and microphones to measure time differences between sending and receiving and so accurately determine the temperature of flue gases and similar. This is particularly applicable to boiler flue gas exit ducts.
With 35 people in attendance, the meeting was opened by Geoff Crittenden (CEO, Weld Australia). Geoff provided an industry update, touching on the nation-wide shortage of skilled welders and the MEM2.0 Learning Resources that Weld Australia is developing in conjunction with TAFEs. Geoff also detailed the issues related to wind tower manufacture and the import of towers considered to be non-compliant with Australian Standards. Weld Australia is calling for local manufacture and compliance with Australian Standards.
A number of issues were raised, from skills shortages, process safety, welder certifications, chartered
• Throttling of outlet dampers
The database is currently well developed and populated. The logistics for access and procedures for future qualifications and certifications are issues being addressed. PG-9 project members conducted a progress meeting.
Ian Rawlings (Chief Mechanical Engineer, CS Energy) gave a presentation on a near miss incident that occurred on the Callide B2 precipitator inlet duct. Operational conditions caused the dust loading in the duct to accumulate and overload one of the duct supports. The duct did not suffer a failure of the support but was considered to be a near miss.
Industry Group members then discussed general safety incidents and learnings. The first incident was an issue with a vertical 9m duct that ran from the top of a boiler to an air heater. A crack had developed in the duct, and an expansion joint was found to be locked up due to a build up of ash. In addition, constant load hangers were found to be out of adjustment. A major failure could have occurred if the crack had developed.
The meeting concluded with a discussion of current issues and future directions over the next five to 10 years. The discussion focused on the current market and transition towards the closure of coal fired power stations.
Process Safety Industry Group
With over 30 people in attendance, Geoff Crittenden opened the meeting. This was followed by an open discussion around baseline audits.
Wadechange.Underhill
(CS Energy) gave an update on the progress of implementing process safety at CS Energy. A rigorous program of training is being undertaken across the entire CS Energy organisation, including a separate training package aimed at company leaders. While establishing the systems is easy, the implementation of training and cultural change is hard.
• Gas velocities in ducts
The Power Generation Number 9 Project (PG-9) is being conducted within the Boiler Industry Group. The objective of the project is to develop a database of certified weld procedures which will then be accessible by the project members. The project is funded and managed by the members.
outage boiler tube leaks after major unit outages. One possible scenario was debris which can accumulate in boiler tubes and orifice plates leading to flow starvation and tube failure. This led to a discussion on the use of rice paper during boiler tube weld repairs and the need to use the correct type of paper for draft reduction during weld repairs.
PG9 Project
engineers, and the need for process safety to be accompanied by cultural
• Maintenance of precipitators
• Process safety risks to be fully assessed in conjunction with health and safety risks
HRL is currently working on a project to review flexible operations for Power Generation Industry Group member power stations. This mode of operation is extremely important, particularly as the industry is transitioning towards net zero carbon by 2050 and phasing out coal fired power stations. HRL’s presentation focused on how a process for flexible operations may be implemented.
Ryan James (Director, OXT Group) spoke on the topic of risk assessment, focused on improved performance monitoring, and risk control within a commercial environment. Ryan emphasised that process safety cannot succeed without leadership, or cultural change.
There were many learnings from this incident, including:
DEFENCE INDUSTRY NETWORK
cranes and lifting equipment are often over looked, but need ongoing maintenance and certification. A near miss was discussed which emphasised the need for ongoing maintenance and Finally,certification.theProcess
Safety Good Practice Guide is nearing completion but requires final editing. This is to be undertaken by a smaller committee
An issue which occurred with the controls on some newly installed tanks was then reviewed. There was a mismatch on the valve identification on the vessels. Testing was carried out on components only and the mismatch was not identified. This underscored the importance of
Tallawarra switchyard transformer failure was raised as a prime example of a catastrophic Monorails,failure.
Membership of the Defence Industry Network will be free of charge for all Weld Australia Premium Corporate Members. Just some of the benefits include: networking with others in the defence industry, addressing technical
Weld Australia is pleased to announce that it has signed a Memorandum of Understanding (MoU) with the Australian Industry and Defence Network Together,(AIDN).WeldAustralia and AIDN will collaborate on matters related to their members’ commercial participation in defence projects with particular reference to fabrication and advanced Tomanufacturing.achievethese objectives, Weld Australia and AIDN will engage in joint events and activities, provide advice and communications on the development and management of a Defence Industry Network and undertake joint promotional activities.
For details, contact: Andrew Davies (Manager Technical Industry Networks) on 0438 428 966 a.davies@weldaustralia.com.auor
A range of other issues was discussed, from skills shortages, aging plant, failure modes, and the use of non-destructive testing.
and presented at the next meeting.
Interested in Joining?
Asset Integrity Board
As a result of COVID and a certain amount of industry turbulence, the Weld Australia Defence Industry Network experienced a hiatus. It’s now back—bigger and better than before. The Defence Industry Network will focus on companies who are either already operating in the defence supply chain, or have ambitions of joining. Our aim is to ensure that contractual commitments to Australian Industry Content and Indigenous Participation are honoured.
The Asset Integrity Board members discussed high level issues affecting each of the companies, with a focus on flexible and low load operations. The transition from coal will not happen overnight. It will take time and require specialist knowledge in areas like BESS, pumped storage, wind and hydrogen. All members agreed that mentoring and skills development were of the utmost importance.
and welding issues, discussing supply chain issues and solutions and accessing Weld Australia training, resources and specialist personnel.
thorough testing of all aspects of Thetanks.TransGrid
Australian Welding50
INSIDE WELD AUSTRALIA
The next incident raised was the discovery of asbestos-looking material around some thermocouples during boiler maintenance. The asbestos register indicated that asbestos had been removed in the area, but did not detail the particular level and location of where the asbestos had been removed. The key takeaway from this incident was that staff need to be trained to be aware of asbestos.
Weld Australia will organise and facilitate all meetings, with agendas and areas of interest driven by members. Areas of Proprietary or Confidential Information will be recognised and appropriately managed by all participants.
Further Information
• Interpret and apply AS/NZS ISO 9606 for fusion welding processes
• Identify welding processes, safe welding practices and use of hand and power tools
FURTHER INFORMATION
• Simulate fusion welding processes using augmented reality equipment
• Bundaberg Campus: 118 Walker Street, Bundaberg West Tasmania Tasmanian Minerals and Energy
13tasminerals.com.auCouncilWellingtonStreet, Burnie Victoria Box Hill 465boxhill.edu.auInstituteElgarRoad, Box Hill Bendigo TAFE 23bendigotafe.edu.auMundyStreet,Bendigo Federation University Lydiardfederation.edu.auStreetSouth, Ballarat
• Nambour Campus: 91 Windsor Road, Burnside
EXPERIENCED WELDERS
Q3 | September 2022 51
• Townsville (Trade Centre Bohle) Campus: 763 Ingham Road, Bohle
TRANSITION WORKERS
To be awarded a certificate for the Course in Fusion Welding to AS/NZS ISO 9606 for Transition Workers, you must successfully complete seven units of competency (four core and three elective). Core units:
To be awarded a Statement of Attainment for the Course in Fusion Welding to AS/NZS ISO 9606 for Experienced Welders, you must successfully complete three units of competency (one core and two elective). The core unit is: Interpret and apply AS/NZS ISO 9606 for fusion welding processes.
For further information, contact: training@weldaustralia.com.au
There are two fusion welding courses that adhere to ISO 9606 Qualification testing of welders on Training.gov.au. This is the authoritative source of nationally recognised training and Registered Training Organisations (RTOs). These two courses were developed in Victoria in 2018 and use augmented reality welding simulators as a key component of the training.
ACT Canberra Institute of Technology Street, Fyshwick
81cit.edu.auMildura
• Cairns Campus: Gatton, Newton, Eureka and, Wilkinson Streets, Manunda
• Ashmore Campus: Benowa Road & Heeb Street, Ashmore
Enrol in a fusion welding course through any Advanced Welder Training Centre below.
ENROL IN A FUSION WELDING COURSE TODAY
• Perform fusion welding procedures to meet the procedures of ISO 9606-1 (Steels – carbon steels)
• Toowoomba Campus: 100 Bridge Street, Toowoomba City
Queensland TAFE tafeqld.edu.auQueensland
Securing the Future of
IndustryWeldingAustralia’s
Australian Welding52 weldaustralia.com.au | office@weldaustralia.com.au | +61 2 8748 0100
