Australian Welding |September 2020 by Weld Australia

AUSTRALIAN 1

WELDING

Q3 | September 2020 Official Journal of Weld Australia www.weldaustralia.com.au

Australian Welding: September 2020

Weld Australiaâ&#x20AC;&#x2122;s Value Proposition

Weld Australia is the peak industry body, representing the welding profession in Australia.

Our members include individuals and companies in almost every facet of Australian industry, making a significant contribution to the economy.

Weld Australia is the Australian representative member of the International Institute of Welding (IIW).

Our mission is to represent the interests of our members and safeguard the public.

We do this by ensuring the integrity of in-service welds, and promoting the use of best practice technology and quality systems.

HowWeld WeldAustralia AustraliaDelivers DeliversValues Value to How to Members Members Network

Learning

We provide a network for the exchange of ideas and the sharing of resources.

Technology Transfer

We facilitate technology transfer from research institutions and overseas markets.

We deliver pathways for learning.

Technical Solutions

We offer specialist technical solutions on all welding and materials related issues.

Voice

We are the voice of industry to promote awareness of welding to decision makers.

Certification We are an internationally accredited certification body.

Weld Australia Contacts National Office

Qualification & Certification

Editorial Submissions

Building 3, Level 3, Suite 5 20 Bridge Street Pymble, NSW 2073 (PO Box 197 Macquarie Park BC NSW 1670) T: +61 (0)2 8748 0100 E: office@weldaustralia.com.au

Paolo Corronca T: +61 (0)438 012 099 E: p.corronca@weldaustralia.com.au

Sally Wood T: +61 (0)434 442 687 E: sally@wordly.com.au

Chief Executive Officer

Marketing & Advertising

Geoff Crittenden T: +61 (0)2 8748 0100 E: g.crittenden@weldaustralia.com.au

Donna South T: +61 (0)2 8748 0130 E: d.south@weldaustralia.com.au

Training Guy Brooks T: +61 (0)2 8748 0150 E: g.brooks@weldaustralia.com.au

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

Contents: September 2020

Contents

Australia’s First Double Helix Bridge Now Open

Berg Engineering: Investing in the Future of Manufacturing

About Weld Australia A membership-based organisation, Weld Australia represents Australia’s welding profession. Our primary goal is to ensure that the Australian welding industry remains locally and globally competitive, now and into the future. Weld Australia is the Australian representative of the International Institute of Welding. Visit: www.weldaustralia.com.au.

DJM Fabrications Poised for Expansion

Baker & Provan: Aussie Manufacturing at its Finest

A Message From Weld Australia’s Chair

A Message From Weld Australia’s CEO

Inside the Industry Breaking News The Impact of COVID-19 on the Welding Industry Tips for Managing Cashflow Post COVID-19 The Changing Face of Australian Standards Welding Electrical Safety Australia’s First Double Helix Bridge Now Open Minprovise: Continuous Improvement for Quality Outcomes Berg Engineering: Investing in the Future of Manufacturing Baker & Provan: Aussie Manufacturing at its Finest A Guide to the Adoption of ISO Standards in Australia Coregas & BlueScope Process Safety: The Start of the Journey DJM Fabrications Poised for Expansion Inside Weld Australia An Update from Weld Australia’s Hotline An Update from Weld Australia’s Industry Groups The Benefits of Online Training NSW Set to Pilot School Outreach Program Member Directory

Cover: Australia’s First Double Helix Bridge Now Open. For further information, see the article on page 20.

8 12 14 16 18 20 26 28 30 32 34 38 40

42 44 46 47 48

Australian Welding: September 2020

A Message From Weld Australia’s Chair “

We know that the industry is facing uncertainty and challenges in the wake of the COVID-19 pandemic. This is particularly true for many members in Melbourne and Victoria, where Stage 4 restrictions have been in place. Weld Australia is here to support and assist you, wherever we can.”

David Lake Chair, Weld Australia

On behalf of the Weld Australia Board of Directors and the entire Weld Australia team, I would like to send a message of support to all of our members. We know that the industry is facing uncertainty and challenges in the wake of the COVID-19 pandemic. This is particularly true for many members in Melbourne and Victoria, where Stage 4 restrictions have been in place. Weld Australia is here to support and assist you, wherever we can. If you need help or advice, please reach out. If we cannot help, then we will do our best to put you in touch with someone who can. As our Chief Executive Officer, Geoff Crittenden, has communicated on numerous occasions now, that Weld Australia’s aim is to help ensure that every single one of our member firms, as well as individual members, have jobs when all this is over. As members of the Weld Australia community, we need to work together to help each other and to make the best of the situation that we possibly can. The more we work together, the better the outcome can be for the industry as a whole. To help support members, our existing LinkedIn Group is now focused on the challenges of the COVID-19 pandemic. The Group is an open platform for the

welding industry to collaborate and support one another, discuss particular struggles, and learn how other businesses are coping. If you’re not already a member, be sure to join our LinkedIn Group. We have also established a COVID-19 Resource Hub which contains a raft of information from reputable sources, including Federal bodies such as the ATO, FairWork Ombudsman and Safe Work Australia, as well as all the state governments. Weld Australia Initiatives Weld Australia responded rapidly to the changing market conditions presented by the COVID-19 pandemic. At all times, the Weld Australia team has focused on ensuring that we are providing the resources and services that our members need most. Weld Australia facilitated its first national series of virtual town hall meetings. These virtual events provided a way for regular event attendees to continue coming together despite COVID-19, and made the Weld Australia community more widely accessible to those members who aren’t able to make in-person events due to work and family commitments, or the travel required. This new initiative was designed to help us reach out to members, and for members to come together and talk about the challenges facing their businesses and the industry

In addition, Weld Australia has facilitated several informative and engaging webinars over the last couple of months. These webinars have delved into topics such as Welding Electrical Safety, Process Safety: The Start of the Journey, EN15085: Railway Applications - Welding of Railway Vehicles and Components, and ISO 15607 to ISO 15614: Qualification of Welding Procedures. We have several other webinars and virtual workshops on the horizon. I encourage all members to take a look at these events, and attend where possible. The value and level of technical and practical information presented at all these events is of a very high quality.

Lasting Connections

THE BEST FOR THE BEST.

Don’t forget: Always put on protective clothing before starting to weld!

at large. The feedback received from members throughout the meetings has been very interesting and valuable.

Weld Australia’s 2020 Annual General Meeting Weld Australia’s 2020 Annual General Meeting (AGM) took place in late June. With social distancing restrictions in place to mitigate COVID-19, this was the first time that Weld Australia has held its AGM virtually. The virtual format proved successful, making the AGM more accessible to members who would usually be unable to attend due to interstate or long-distance travel. During the AGM, Chris Brugeaud was elected as a new Director. With over 15 years industry experience, Chris is the Chief Executive Officer and co-owner of SSS Manufacturing and IR4. Richard Fowles, who retired by rotation in accordance with the Constitution of Weld Australia, was also re-elected as a Director. Richard is a strategic marketing manager for BOC with extensive experience in manufacturing and as an assessor for AS/NZS ISO 3834. Having been appointed to a casual vacancy on the Board of Directors in December 2019, Geoff Crittenden was also elected as a new Director. Roger Griffith retired as a Director of Weld Australia, with his term expiring in accordance with the Constitution. I would like to take this opportunity to thank Roger for his valuable contribution to the Board since 2008. I look forward to working with all of Weld Australia’s Directors over the year ahead. 73rd IIW Annual Assembly The International Institute of Welding (IIW) recently held the 73rd IIW Annual Assembly. It was the first time that the Annual Assembly has been hosted online. The event proved to be very interesting and provided an opportunity to hear from some of the global welding industry’s leading experts.

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Australian Welding: September 2020

A Message From Weld Australia’s CEO “

Welders build the very world in which we live. However, it’s not just the pervasive nature of the welding process that makes it so essential—welding is also vital to the strength of Australia’s economy.”

Geoff Crittenden Chief Executive Officer, Weld Australia

Welder training in Australia is outdated. The TAFE curriculum has remained relatively unchanged since 1998. TAFE has been required to teach courses such as fabrication, in which the welding modules are of varying degrees of complexity, and are usually optional. This has not produced welders that are skilled or qualified to the levels needed by industry, especially within the defence sector. Young welding apprentices enter the workforce without the requisite skills or knowledge. Generally speaking, TAFE graduates cannot read a welding procedure, set up a welding machine, or weld according to Australian Standards. Released in June 2019, the latest version of the Manufacturing and Engineering training package (MEM 2.0) differs very little from the previous versions (released in 1998 and 2005). In fact, many of the units and much of the content remains identical to the 1998 version. Not surprisingly then, MEM 2.0

bears no relation to what is actually required by industry. It ignores the huge technological advancements and changes that will continue to occur in Australia’s engineering and manufacturing industries. The course still devotes significant time and energy to oxy-acetylene welding, which is rarely used today. The future of Australian industry in a post-COVID-19 world cannot rely on regurgitating a curriculum that is 20 years old. The MEM 2.0 Training Package The only real differences in the MEM 2.0 training package are a significant increase in prerequisites, and the addition of over 2,000 hours of mandated workplace practice. Both of which will impose significant restrictions and burdens on students, industry and TAFE. Significantly Increased Prerequisites The significant increase in prerequisites in MEM 2.0 will eradicate any modicum of flexibility for students, industry and TAFE. Course duration will be extended, increasing both the delivery costs for TAFE and course costs for students.

With extended courses, completion rates are likely to drop, with students expected to complete a greater number of theory-based, nonpractical units before having the opportunity to learn the hands-on practical skills in which they are most interested. For TAFEs, delivering courses in a meaningful way will be hampered by the additional prerequisites, and there will be little opportunity to deliver short, sharp micro credentials. The table opposite looks at a typical unit of competency and demonstrates how the prerequisites have grown. Prescribed Workplace Practice MEM 2.0 mandates a workplace practice component of over 2,000 hours. This will place a considerable burden on employers, who have to ensure that students are able to meet this requirement. Over 90% of manufacturing firms in Australia are classified as Small to Medium Enterprises (SMEs), which are comprised of fewer than 19 employees. These businesses are unlikely to have the capacity to

A Message from Weld Australia’s CEO sufficiently monitor the workplace practice requirements, and may deter businesses from employing apprentices. This situation will be difficult enough for apprentices, but is likely to be even more challenging for transitional workers hoping to train up and enter manufacturing and engineering. In essence, welders will be required to be employed in industry before they can successfully gain their formal qualifications. The Skills of the Future The implementation of MEM 2.0 by Australian TAFEs is due for completion by the end of 2020. Before this happens, industry must voice its concerns. Welding curriculum must concentrate on the skills that will be essential to the future of industry. These skills must be focused on advancements such as automation, robotics, artificial intelligence, big data, and advanced manufacturing processes. It is these skills that will see

Australian industry continue its push into high-quality, complex, smallbatch manufacturing. The Federal Government must revise MEM so that the curriculum teaches skills such as programming, operating and maintaining robots, co-bots and welding machines integrated with artificial intelligence. It must include units that teach students how to analyse and leverage big data. It must delve into concepts such as Industry 4.0 and additive manufacturing. The TAFE welding curriculum must be revised so that it meets industry demand now, and into the future. It cannot be bogged down by excessive prerequisites, mandated workplace practice that employers simply cannot deliver, and training in skills that just aren’t relevant to industry anymore. While many of the state governments have backed this vision, and invested in Advanced Welder Training Centres around the country, TAFEs still need real support from the Federal Government. TAFEs do

not need more free apprenticeship programs. They need funding from the Federal Government so that they can invest in the necessary cuttingedge technology and equipment required to teach a forward-looking curriculum focused on the skills of the future. Our young people need to acquire complex, high order technical knowledge and skills. They need robust, deep and transferrable qualifications that provide a strong base for life-long learning and skill development. They need a TAFE system that is properly funded with curricula focused on the future. How to Get Involved If you support Weld Australia’s position that the MEM 2.0 training package is inadequate for the needs of industry, apprentices and TAFEs, we encourage you to write to the Hon Steve Irons MP, Assistant Minister for Vocational Education, Training and Apprenticeships via am.irons@employment.gov.au or PO Box 1060, East Victoria Park, Western Australia, 6981.

Typical Unit of Competency in MEM and the Growth of Perquisites MEM 1998

MEM 2005

MEM 2.0

MEM 5.7a

Manual heating and thermal cutting

MEM05007C

Perform manual heating and thermal cutting

MEM05007

Perform manual heating and thermal cutting

MEM 5.12A

Perform routine manual metal arc welding

MEM05012C

Perform routine manual metal arc welding

MEM05012

Perform routine manual metal arc welding

MEM 5.15A

Weld using manual metal arc welding process

MEM05015D

Weld using manual metal arc welding process

MEM05015

Weld using manual metal arc welding process

MEM 9.2A

Interpret technical drawing

MEM09002B

Interpret technical drawing

MEM09002

Interpret technical drawing

MEM 18.1A

Use hand tools

MEM18001C

Use hand tools

MEM18001

Use hand tools

MEM 18.2A

Use power tools/hand-held operations

MEM18002B

Use power tools/hand-held operations

MEM18002

Use power tools/hand-held operations

MEM05051A

Select welding processes

MEM05051

Select welding processes

MEM12023A

Perform engineering measurements

MEM12023

Perform engineering measurements

MEM05052A

Apply safe welding practices

MEM05052

Apply safe welding practices

MEM13015

Work safely and effectively in manufacturing and engineering

MEM14006

Plan work activities

MEM16006

Organise and communicate information

MEM11011

Undertake manual handling

MEM12024

Perform computations

Australian Welding: September 2020

Breaking News Local Partnership Delivers World Leading ‘Smarts’ to Shipbuilding A partnership involving industry and academia is to invest more than $4 million in research to develop world-leading manufacturing technologies to the Hunter Class Frigate Program. Australia’s Innovative Manufacturing Cooperative Research Centre (IMCRC), the University of South Australia (UniSA) and BAE Australia’s shipbuilding business, ASC Shipbuilding, are joining forces to fund data visualisation research that will prepare Australian industry for a future driven by digital innovation.

The research will shape the development of digital manufacturing (Industry 4.0), improve shipyard planning and add unique data analytics and problemsolving capacity to the Hunter program, which will deliver nine world-leading anti-submarine frigates to the Royal Australian Navy. The Hunter Class Frigates will be the world’s first bow-to-stern digitally designed anti-submarine warfare frigates, and each ship involves highly complex supply chains. According to ASC Shipbuilding Continuous Naval Shipbuilding Strategy Director, Sharon Wilson,“Digital shipbuilding is all about connectivity – not just within the physical and digital shipyard but with our supply chain and customer – and the research will support everyone and every single part and product on the Hunter program to be connected. Together we’re creating a first-of-its-kind digital environment through the entire ship design and construction to improve productivity, quality and safety outcomes in the shipyard, and underpin growth and longevity in the naval shipbuilding industry in Australia.”

Image: (L to R): Dr Wolfgang Mayer (Senior Lecturer, UniSA), Dr Andrew Cunningham (Lecturer, UniSA), and Dr Anastasia Kuusk (BAE Systems).

Strategic Defence Partnership to Secure Hundreds of Australian Jobs Thales and the Australian Government have signed a decade long contract worth more than $1 billion that guarantees the Australian manufacture and supply of strategic munitions to the Australian Defence Force (ADF). This contract demonstrates that Australia’s sovereign defence industry is vital to delivering a capability advantage to the ADF. The continued long-term partnership between Thales and the ADF reinforces the Government’s commitment to maintaining a world leading, competitive and safe domestic munitions manufacturing capability in Australia. Thales continues to build long-term relationships with hundreds of Australian suppliers, building Australia’s self-reliance and the capability of the broader Australian manufacturing sector. Thales’ recent supply chain study, with AlphaBeta Advisors, proved that there is a strong correlation between Sovereign Industry Capability and benefits flowing to Australian suppliers. In 2019, Thales spent $113 million with its Australian suppliers for munitions and small arms, supporting 414 direct jobs in the supply chain. This contract will enable Thales to secure more than $450 million in export and non-ADF orders over the coming 10 years, demonstrating Australia’s world leading munitions manufacturing capability. The Group has invested more than $20 million in research and development, and $25 million in capital infrastructure over the last 10 years at the Benalla and Mulwala facilities and will invest further to develop new and world leading products for the Australian Defence Force.

Image: Thales has signed a $1 billion contract for the manufacture and supply of munitions to the Australian Defence Force. Image courtesy of Thales Australia.

Inside the Industry: Breaking News

Steel Research Hub Wins $28 million in Funding The Federal Government recently announced an additional $5 million in new funding for the University of Wollongong-led, ARC Research Hub for Australian Steel Innovation (Steel Research Hub). The Steel Research Hub will be funded for five years (2021-2025), and will be led by Dr Paul Zulli. Minister for Education, the Hon Dan Tehan, announced the funding as part of the ARC’s Industrial Transformation Research Program, which brings together the best and brightest researchers, scientists and engineers from higher education and industry to drive innovation and improve global competitiveness in key industries. In addition to the ARC funding, the Steel Research Hub’s eight industry partners, BlueScope Steel, Liberty Primary Steel, Infrabuild, ArcelorMittal, Bisalloy, Weld Australia, Australian Steel Institute and Australian Industry Group will contribute another $13.9 million in cash and in-kind support. The University of Wollongong, together with RMIT University, Australian National University, Swinburne University of Technology, University of Newcastle, Deakin University, University of Sydney, University of New South Wales and Monash University, will contribute a further $9.5 million cash and in-kind support. The total funding for the Steel Research Hub is $28.4 million. The overarching goal of the new Hub is to support the transition of Australia’s steel manufacturing industry to a more sustainable, competitive and resilient position, based on the creation of new, higher value-added products and more advanced manufacturing processes.

Bisalloy Signs MoU with Australian Defence Contractors Bisalloy has signed a memorandum of understanding (MoU) with Axiom Precision Manufacturing and K-TIG to jointly develop a sovereign capability in welding for the Australian Defence Industry. Development of an Australian sovereign capability in the welding of specialist defence steels will allow Australian industry to maximise its participation in upcoming Defence procurements, such as the LAND 400 program, that will see the Australian Defence Force’s existing Australian Light Armoured Vehicle and M113 Armoured Personnel Carrier fleets replaced with new vehicles that deliver improved levels of firepower, protection and mobility. Bisalloy Chief Executive Officer and Managing Director, Greg Albert said, “Bisalloy have a long history of successfully collaborating with partner companies to develop new and innovative solutions in steels. Our capabilities extend far beyond product supply, it extends to technical and product development assistance. As such, we are committed to offering our customers everything they need for future success.” K-TIG Chairman, Stuart Carmichael, said, “We are delighted to be expanding into the Defence market and partnering with Axiom Precision Manufacturing and Bisalloy Steels, two established Australian Department of Defence contractors. K-TIG will be responsible for the development of a keyhole TIG welding process for high carbon steels typically used in the defence industry”.

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Australian Welding: September 2020

Breaking News ASC and Partners to Pioneer Additive Manufacturing for Submarines Australia’s dedicated submarine sustainment organisation, ASC, is collaborating with Australia’s national science agency, CSIRO, and DMTC Limited, to pioneer the use of additive manufacturing for the repair of Collins Class submarines. The partners have joined forces to further develop ‘cold spray’ technology for repairing damaged metal surfaces, to enable the future in-situ repair of submarine components. Successful development of the cold spray technique for this specific maritime application will allow Australian submarines to remain at sea for longer, without the need to dock for lengthy repairs. Cold spray is an additive manufacturing and repair method that uses a stream of supersonic gas to accelerate metal powder particles at a surface, building up a dense deposit. The innovative process occurs below the melting temperatures of the metals involved, which avoids damaging the structural integrity of the components and surrounding area. ASC Chief Executive Officer, Stuart Whiley, said, “It’s vitally important for ASC to be on the cutting edge of submarine sustainment innovation, to continually improve Australia’s submarine availability to the Royal Australian Navy service. The use of additive manufacturing for the repair of critical submarine components, including the pressure hull, will mean faster, less disruptive repairs for our front line Collins Class submarine fleet.” The two-year project seeks to deliver breakthroughs in submarine repair and cost-of-ownership reductions for the Royal Australian Navy, through expert contributions from industrial and research partners.

AMGC’s New Prefab Innovation Hub to Boost Jobs and Economy A new Innovation Hub is set to supercharge Australia’s prefabricated building industry, potentially creating thousands of new jobs and adding up to $30 billion to the economy. The Federal Government has provided $2 million to the Advanced Manufacturing Growth Centre (AMGC) to fund and manage the new hub, following a feasibility study. AMGC Managing Director, Dr Jens Goennemann, said that the Prefab Innovation Hub will build new capabilities in the manufacturing industry and construction sector. “This Prefab Hub will connect recognised research institutions and industry bodies that have experience in this area to form a network of Prefab Innovation Labs across Australia,” Dr Goennemann said. “The purpose of these labs is to help drive skills, accelerate adoption of new technology, formulate regulatory proposals, identify new procurement pathways, and recommend new funding mechanisms – all to support a burgeoning prefab construction industry.”

The two halves of the first Arafura Class OPV coming together to form a complete hull. © Commonwealth of Australia 2020

Weld Australia and Gotcha4Life Team Up to Help Build the Mental Fitness of Australia’s Welders Suicide is the leading cause of death for Australians between 15 and 44 years of age, and men are three times more likely to die by suicide than women. Workers in construction and other trades—including welding—are even more at risk. Tradies are 70% more likely to die by suicide than their behind-the-desk counterparts.

fitness is a complex issue and there is no one simple solution. However, it’s clear that Australian tradies, including welders, need more support. The statistics around suicide and tradies are frightening, and we recognise how important it is for us to take a leadership role in helping to spread awareness and education in the welding community,” said Crittenden.

This means that every second day an Australian tradie takes their own life. Despite these alarming statistics, mental health definitely isn’t something that tradies talk about at smoko or after knocking off.

“It’s vital that we work together, that we back one another, and that we remove the stigma associated with mental health issues. Remember: it’s OK not to be OK,” said Crittenden.

Weld Australia and Gotcha4Life believe that, together, they can strengthen the emotional muscle to help build strong social connections, which in turn develops the resilience required to deal better with the challenges that life throws at us.

Gotcha4Life is a not-for-profit foundation that believes in the concept of Prevention through Connection, and raises awareness of the importance of identifying a close friend in life, someone you can speak openly and honestly to when times are tough.

Gotcha4Life’s Founder, Gus Worland, explains, “Gotcha4Life’s vision is focused on a society where people are open, honest and supportive in their relationships and comfortable to express themselves when they are not ok. A society in which everyone has a Gotcha4Life mate who they can open up to and rely on no matter what.”

Gotcha4Life enables this connection by funding educational workshops and training programs that build mental fitness in individuals and communities across Australia, to enable strong, open and binding relationships. To do this, Gotcha4Life partners with programs like Tomorrow Man and Tomorrow Woman, Man Anchor and Rural Outreach Counselling to help build emotional muscle in communities across the country. For more information about Gotcha4Life, visit: https://www.gotcha4life.org

“Weld Australia’s commitment to building this mental fitness amongst their members ties in perfectly with our aspirations and we’re so excited to be partnering,” said Worland. According to Weld Australia’s Chief Executive Officer, Geoff Crittenden, Weld Australia has made supporting the mental health and wellbeing of its members and the wider welding community a priority, particularly in the wake of the COVID-19 pandemic—partnering with Gotcha4Life was a natural extension of this. “Weld Australia is proud to partner with Gotcha4Life. Mental

The Negative Impacts of the COVID-19 Pandemic While a loss of income was reported by almost half of survey respondents (at 47%), Australian welders and fabricators are facing a range of negative impacts and challenges caused by the COVID-19 pandemic. The most common challenges are outlined below.

47% Loss of income

26%

32%

Staff working reduced hours

Increased business continuty risks

Decline in employee morale

23%

26%

Staff laid off or stood down

29%

Difficulty sourcing materials

Increased costs

The Impact of CO Welding In

As the peak body representing the welding ind supporting our members and the wider industry Itâ&#x20AC;&#x2122;s important then that we understand how th COVID-19 pandemic, including the impact it is employees. To gain a better understanding, Weld senior business leaders. The data collected will he industry in the wake of COVID-19. The findin

23%

Impacts on Em

Workforce instability

With the majority of responden COVID-19, it makes sense that of respondents indicated all of with another 39% indicating tha

21%

Loss in Income When it came to quantifying the loss in income, responses varied considerably. Companies reported having lost anywhere from $200,000 right up to $50 million already, with forward estimates of future losses as high as $100 million for one company.

15%

58% Postponed work

The Cause of the Negative Impacts

15%

41%

Overwhelmingly, the cause of the negative impacts experienced by welders and fabricators was linked to disruptions in their pipeline of work. Other major causes included interstate travel bans (38%), restricted site access (38%), disruptions and changes to working environment (35%), and social distancing (35%).

39%

Uncertain forward order book

Disruptions in the Pipeline of Work

How many of your employees have been negatively affected by the impacts of COVID-19?

38% Lack of new work & tender opportunities

The Type of Employees Impacted the M

The type of employees most impacted by the COVID-19 (48%), followed by middle management (39%) and the

29% Cancelled work

48% 39%

The Positive Impacts of the COVID-19 Pandemic

30%

Site Workers

Contractors & Subbies

While 20% of respondents reported that their business had not experienced any positive impact as a result of the COVID-19 pandemic, not everything was bad news. Some welding and fabrication businesses reported several positive impacts, particularly around improved internal processes and procedures.

Workshop Floor

41% Improved processes & procedures

29%

26%

Opportunities to innovate

Built a better team culture

Secured new clients

Middle Mngmt

Impact of COVID-19 on the Mental Healt

When asked about the impact of COVID-19 on the mental pandemic had taken its toll. Business owners felt that 48% while 30% of business owners themselves admitted experie

48%

Diversified products or services

Increased orders or work

5% Increased demand

18%

General Workforce Negatively No impact

Increased income

Positively

18% 15%

Other

Government Support Surprisingly, while most welding and fabrication businesses have been negatively impacted by COVID-19, only 33.3% have accessed federal, state or territory government economic stimulus packages or financial support. Of those who did access government support, JobKeeper was the most common.

OVID-19 on the ndustry

dustry, Weld Australia is committed to y throughout this very challenging time. he welding industry is experiencing the having on you, your business, and your d Australia recently distributed a survey to elp guide Weld Australia’s support for the ngs of the survey are outlined below.

66.6%

Have not accessed any government support

72.7%

Are not likely to access any government support in the future

33.3%

Have accessed any government support

27.3%

Are likely to access government support in the future

mployees

nts reporting negative impacts as a result of employees also experienced negative affects: 21% their employees had been negatively affected, at most employees had been negatively affected.

45% 41%

Why Companies Have Not Accessed Government Support The most common reason provided by respondents as to why they haven’t accessed funding was that they didn’t need any financial support (45%), followed by the fact that their business did not meet the eligibility criteria (41%).

All employees

A few employees

Most employees

9% 5%

I don’t need support

I do not meet criteria

Other

Too confusing

Some employees

What Sort of Help Do You Need from Government? No employees

Most

9 pandemic were those on the workshop floor en site workers (30%).

“Recognise the true value in Australian made production. Local production must still be competitive, but assign a value analysis in improved logistics, service and quality versus imports. Don’t make assessments just on lower dollar rate.” “Increase import tariffs on welded/fabricated products to ensure that Australian welding businesses can offer products and services at competitive prices when compared to overseas. Ensure a mandatory large percentage of welding and fabrication works for all contracts are to be completed by Australian owned and operated businesses.”

“Assist Weld Australia with the implementation of industry regulations which would minimise those operating in an industry where many products have the potential to fail if not completed the correct weld specifications or process, potentially leading to defective products which can also lead to injury or death of members within the community depending on their purpose or use.”

24% 18%

s s

Senior Mngmt

15%

Support & Admin Staff

No Impact

What Sort of Help Do You Need from Weld Australia?

th of the Workforce

health of their workforce, it was clear that the of their workforce had been negatively impacted, encing negative mental health impacts.

33% 18%

Business Owners No impact Negatively Positively

18%

30%

Other

“Lobby for greater support of local Australian manufacturers.” “Trade related industry opportunities, like a database of displaced apprentices.”

“Weld Australia can play an important role by emphasising the importance of manufacturing to government and other stakeholders.” “Weld Australia can help enforce Australian Standards, promote local manufacturing, and make engineering business actually meet some mandated licencing model like electricians, and plumbers.”

Australian Welding: September 2020

Tips for Managing Cashflow Post COVID-19 In the wake of the COVID-19 pandemic, small to medium businesses are facing financial fragility, caused by a decline in consumer demand as restrictions continue. The full extent of the pandemic may not yet be known, but it is already having an impact on almost all industries, including the welding and fabrication sector. In the coming months, ensuring positive cashflow will be essential.

Gavan Ord, Manager of Business and Investment Policy at CPA Australia, said the widespread impacts of COVID-19 are unprecedented. “Most businesses have had their cashflow impacted by the restrictions imposed to control the spread of COVID-19,” said Ord. “Usually smaller businesses have less fat in their cash position and can find it more difficult to raise extra cash, therefore they tend to feel cashflow pressures sooner than larger businesses.” According to Ord, there are some simple techniques for businesses to focus on – review, change and plan – to manage cashflow and support the organisation into the future. Review The first step to achieving a positive cashflow should be to take a step backwards and understand the overall situation. A weekly cashflow

forecast provides a constant review of a business’ current financial position. If the business does not have an accounting software, an accountant can assist with this review.

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After the initial financial assessment, businesses should conduct a ‘whatif?’ analysis to measure how certain events like further restrictions or reduced projects after a lockdown may impact cashflow.

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After these two steps have been completed, a suite of other steps can be conducted to improve a business’ cashflow position, including: • Focusing attention on sales that are paid at the point of purchase or paid early • Quickening the collection of outstanding debts, including following up with debtors before the due date rather than waiting until the debt is overdue • Reducing stock orders, particularly stock in low demand

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Seeking an extension to any payment terms with suppliers Considering introducing an up-front deposit requirement for critical items required by customers Focusing on marketing products that are more likely to be sold quickly.

While there is government assistance, and banks and some suppliers are offering payment deferrals, Ord said the importance of constantly reviewing cash on hand is paramount for the future. “While taking advantage of those deferrals can improve your cashflow in the short term, the amounts owed still have to be repaid at a later date. Be sure that you can repay those debts in a few months’ time – you don’t want to set yourself up for a bigger cashflow problem,” said Ord. When conducting an analysis of the

Inside the Industry: Business Essentials

current cashflow, seek to minimise existing costs by reviewing cost structures and overheads. Change Once an initial review has been completed, small businesses should change processes where appropriate. Unlike large-scale businesses, smaller organisations may not have the flexibility to seek materials from other suppliers. Supply chain management and changing logistics may also need to be considered in the review stage and altered if there is an over reliance on certain materials from one manufacturer. “An increased focus on supply chain risk potentially opens up new opportunities for local manufacturers,” Ord said. Small businesses should also consider how to leverage their expertise into other areas where there is high demand and move some parts of the business online where appropriate. Matthew Prouse, Head of Industry at Xero, said that despite the economic impacts of COVID-19, there are also opportunities for small businesses. “The resilience and flexibility of small

businesses is also creating new opportunities for small businesses to innovate and provide new services,” Prouse said. Businesses should consider changing operating processes to ensure that they are running as efficiently and effectively as possible during the pandemic. “Keep an eye on the changing needs of your customers and be open to further adapting your business,” Prouse said. Data collection in the review stage should also shine a light on business performance to provide an indication for areas of improvement and how to meet key performance indicators in the future. Prouse said building a timeline that focuses on the high-value tasks is also an important step for returning strength to operations. Plan As existing work dries up or becomes completed, new projects are required. However, the COVID-19 crisis may have altered the routine of a constant workflow for some manufacturing organisations. Ord suggests taking actions if orders are drying up, and planning for a new

normal, which could include: • Increasing marketing spend • Discounting products • Contacting key customers to see if they have work • Moving more of the business online to communicate with customers • Thinking outside the box and assessing whether undertaking different work that is in high demand is viable. “It is important to keep on top of your forward orders so that you can act early if your orders dry up,” Ord said. Ord said businesses should not expect to come out of this pandemic in the same way that they went in. “The business they have after COVID-19 will be different to the business they had before the pandemic. Businesses that get on the front foot and spend time thinking and planning their future are much more likely to succeed on the other side of the crisis.” Similarly, Prouse said there is support available to help small business owners during this difficult time. “Work with your accountant to have a clear cashflow forecast in place. Find out when any debt is payable, reduce unnecessary spending, and recast your budget to reflect the new reality,” he said.

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Keep an eye on the changing needs of your customers and be open to further adapting your business.”

~ Matthew Prouse, Head of Industry at Xero

Australian Welding: September 2020

The Changing Face of Australian Standards Australian Standards are living documents. They reflect progresses in science, technology and systems. To maintain their relevancy, all Standards are periodically reviewed, with amendments and revised editions published. The last few months have seen several developments, including ongoing reviews into standards related to pressure equipment, steel structures, welding of structures, non-destructive testing and pipelines.

Pressure Equipment As previously reported, the revision of AS/NZS 3992 Pressure equipment—Welding and brazing qualification was completed late in 2018. The standard was published as AS 3992 on 9 June 2020.

Steel Structures As previously reported, committee BD-001’s work on updating two of its standards, AS/NZS 5131 Structural steelwork - Fabrication and erection, and AS 4100 Steel structures, has been completed.

Welding of Structures Preparation of a public review draft of the revision of AS/NZS 1554.2 Structural steel welding—Part 2: Stud welding (steel studs to steel) has been completed and was released for public review in July 2020.

Committee ME-001 has also commenced the balloting of the latest revision of AS 2592 Boilers— Safety management and supervision systems. Once work on this standard is resolved, it will allow the project proposal on the revision of AS/NZS 3788 Pressure equipment— In‑service inspection to be finalised and submitted to Standards Australia.

The changes to the standards were published on 14 August 2020 and 21 August 2020 respectively. The revision removed fabrication requirements from AS 4100 and referenced AS/NZS 5131 in lieu. AS/ NZS 5131 was accordingly amended to satisfy Australian Building Codes Board requirements as a secondary reference in the Building Code of Australia.

As previously indicated, the draft has taken cognisance of the relevant ISO standards, and to this end, ISO 13918 has been adopted as AS/NZS ISO Welding - Studs and ceramic ferrules for arc stud welding for stud materials, providing for the use of stainless steel studs and studs for wear applications. Pipelines Committee ME‑038 has revised AS/NZS 2885.2 Pipelines—Gas and liquid petroleum Part 2: Welding with a modified public review draft closing for public comment and committee ballot in January 2020. The revised standard was published in May 2020. Part 3 of AS/NZS 2885 Pipelines—Gas and liquid petroleum Part 3: Operation and maintenance has also been revised and public comment that have been received are being resolved.

For further information about Australian Standards, simply contact Weld Australia on +61 2 8748 0100. Weld Australia members can also utilise our Hotline, available via our website: www.weldaustralia.com.au

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Inside the Industry: Australian Standards

ISO Adoptions A number of welding related ISO standards have been recently adopted by Australia. These were ISO 14731 Welding coordination – Tasks & responsibilities, ISO 6947 as AS/NZS 3545 Welding positions, and SA/SNZ TR ISO 15608 Welding— Guidelines for a metallic materials grouping system. ISO 5173 Bend tests has also been adopted as AS/NZS 2205.3.1, superseding AS 2205.3.1 and AS 2205.3.3. All were published in June 2020.

ISO Update ISO TC44/SC10 has commenced the revision of the ISO 3834 Quality requirements for fusion welding of metallic materials series of standards, primarily to take cognisance of changes to ISO 9001 and the 2019 edition of ISO 14731. The next meeting is scheduled for October 2020. Similarly, ISO TC44/SC11 has commenced the revision of ISO 9606-1 Qualification testing of

welders—Fusion welding—Part 1: Steels with the intention of combining all five parts into the one standard. This will simplify the ongoing maintenance and review requirements for the standards as parts 2 to 5 of ISO 9606-1 are in need of revision. The initial meeting was held in April 2020 and a number of follow‑up meetings have been held with the committee meeting again on 27 August 2020. Australia is participating in the revision process on both ISO sub-committees.

The Australian Welder Certification Register (AWCR) was developed and is managed by Weld Australia. It provides a national framework for qualifying and testing welders to International Standard AS/NZS ISO 9606-1, and provides a raft of benefits for welders and industry alike.

Go to www.awcr.org.au Click on ‘Click Here to Register’ Click on ‘Create An Account’ Enter your contact details Verify your email address Login and complete your profile

AWCR

Australian Welder Certification Register

+61 2 8748 0100 | www.awcr.org.au | awcr@weldaustralia.com.au | www.weldaustralia.com.au

Australian Welding: September 2020

Welding Electrical Safety Safety is a critical consideration for any welding project. Welding is a safe occupation when proper precautions are taken. But, if safety measures are ignored, welders face an array of hazards which can be potentially dangerous, including electric shock and electrocution. Weld Australia recently hosted a webinar on Welding Electrical Safety, during which experts shared insights on safety in the welding industry, and learnings from past catastrophes.

Weld Australia CEO, Geoff Crittenden, opened the online event, where he spoke about the importance of the Welding Safety Council (WSC), which has been in operation for two years. “The focus is to provide a pathway to a safer welding workplace, set clear expectations on what is required, and training,” Crittenden said. The purpose of the WSC is to provide an exchange between industry leaders and legislative authorities to address issues in the sector, and work together to identify solutions for future practice. It is underpinned by the vision of eliminating loss of life or injury that may come as a result of welding. Research into Welding Fatalities David Hisey (Welding Health and Safety Advisor, Canadian Welding Bureau) joined the webinar from Canada. He shed light on welding safety, drawing on over 30 years of data and research. Hisey shared the details from 24 welding fatalities

“Prevention is only going to happen when you put education and regulation together.” David Hisey (Welding Health and Safety Advisor, Canadian Welding Bureau)

across Australia, New Zealand, Canada, China and the United States, and three injuries from an electrode shock-study. The average age of the welders involved in the research study was 31.9, which Hisey believes is old enough to assume that they can be classified as experienced. “A welder who is 30 years old has probably been welding for a few years,” Hisey said. The study discovered that 22 of the 24 deaths took place in a hot and wet environment, where the humidity was high, in comparison to the two deaths and one injury where conditions were cool and dry. All 24 victims in the study had suffered from upper body electrode circuit contact, including eight who suffered electrode contact in the head, neck or face. It is important to note that the study did not measure whether it was raining outside and

the welder was under a shelter. “The environment certainly appears to be a factor,” Hisey said. Clearly, humidity and rain increase the likelihood of injury or death when welding. “If you want to weld when it’s raining you have to be prepared to die and I don’t know if your boss wants that happening,” Hisey said. Hisey also said 90 per cent of welders in a recent Canadian survey reported that electrode shock is a ‘normal part of the job’. This seems true in Australia as well, with close to one-third (32 per cent) of participants indicating that they had experienced an electric shock from a welding power source while on the job. “Prevention is only going to happen when you put education and regulation together,” Hisey said. Carl Hussell, a Consultant at Quantec Safety Solutions, also joined the webinar to share his expertise. Hussell shared the findings from a 2011 Coronial Inquest after

Inside the Industry: Health & Safety

the death of Daniel Morris. Morris, who was 23 at the time, suffered from electrocution while working as a production supervisor for a labour hire company in Townsville. He was using a Liquidarc 245 welder, which was attached to a three phase lead and plugged into a switchboard. The Coroner found that Morris’ colleagues found him shaking after he was sitting on the metal hopper with his legs hanging down while he was welding. Inspectors from the Electrical Safety Office (ESO) concluded that the equipment had no faults. However, the conditions on the day of Morris’ death were humid. These humid and sweaty conditions greatly increased the conductivity of his skin, ultimately leading to his death when he came into contact with the electrode. Sharing the findings of the investigation, Hussell reminded attendees about the importance of welding in a safe environment and understanding the dangers. “The welding was done in a shed and the sun was beaming through,” he said. Environmental Standards Welding under unsafe conditions— like extreme heat or wet weather —is a risk, which is underpinned by national safety and regulatory measures. Standards Australia defines three welding environments:

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Category A: where the welder cannot contact the workpiece or a live part of the circuit, and the risk of an electric shock or electrocution by arc welding is low and normal work practices can continue Category B: where there is an increased risk of the welder contacting the workpiece or other parts of the circuit. This may take place where the surrounding temperature is less than 32°C or the welder is performing tasks in a cramped position Category C: where low body impedance of the welder, and a greater risk of the welder contacting the workpiece of the circuit leads to a significant risk of electric shock or electrocution.

Morris was welding in circumstances that brought the environment within a Category B or C at the time of his death. The Coroner’s Inquest also determined that Morris did not have the necessary training to perform ‘hot work’ activities like welding. Health and Safety Emeritus Professor John Norrish from the University of Wollongong specialises in materials welding and joining. According to Norrish, “The current that can flow through the heart is impeded by the clothing that the operator is

wearing, skin contact and internal body impedance.” Small increases in sweat and dampness reduce the impedance of the clothing and skin resistance exposing the welder to the risk of a severe electric shock, or worse. Norrish also explained the differences between voltages. “At 25 volts, 95 per cent of the population would have a body impedance of around 6,000 Ohms. At 75 volts across the body, the impedance has dropped to around 3,500 Ohms.” Bruce Cannon (Technical Publications Manager and Principal Welding Engineer, Weld Australia) also shared his thoughts on the importance of safety in the industry. “It’s crucial to note that if the welder fitted with a pacemaker feels unwell, cease welding immediately and seek medical assistance.” Cannon also touched on additional safety requirements that are specific to welders with a pacemaker. “When I was taught to weld, I was taught to wrap the cable around me, don’t do that if you’ve got a pacemaker.” Seven per cent of webinar attendees either had a pacemaker, or had worked with a colleague that had a pacemaker. Of those people, a further seven per cent reported that welding had interfered with the operation of the pacemaker.

Australian Welding: September 2020

Australia’s First Double Helix Bridge Now Open The Lachlan’s Line pedestrian and cycleway bridge opened to the public in June 2020. Believed to be the first of its type in the world, the eye-catching, bright blue double helix bridge twists and turns over one of Sydney’s busiest motorways to connect a new residential and mixed-use development, a major business precinct, and a metro station.

The $40 million Lachlan’s Line pedestrian and cycle bridge is a firstof-its-kind—an organic, double helix bridge. It connects Landcom’s new Lachlan’s Line Residential Precinct on its western extremity, to the North Ryde Commercial Sector and Metro Station on its eastern extremity. Bold and bright blue, the bridge is a striking visual landmark, as well as a busy active transport connection. The bridge has transformed access to the Lachlan’s Line site, which

is bounded by one of Sydney’s busiest intersections, that of the M2 Motorway and Delhi Road. Commissioned by Landcom (the New South Wales Governments’ development agency), the Lachlan’s Line bridge project was delivered by a joint venture between Daracon Group and Arenco, designed and engineered by Arup and KI Studio, and fabricated by Weld Australia member, S&L Steel.

The Design At 178m in overall length, the Lachlan’s Line bridge is a variable diameter helical steel truss bridge, curved in plan. As reported by This is Construction, it is the first double helix bridge in the world to have a variable diameter, which increases in size over the supports (where bending moments are higher) and narrows midspan (where moments are lower). These eye-catching

Australia’s First Double Helix Bridge Now Open

curves and unique features were not designed purely for looks, but were required to meet the site constraints. “The double helix and sinuous design was actually derived from the structural parameters, not primarily for aesthetics, as it may first appear,” said Andrew Johnson (Principal and Project Director, Arup). The bridge alignment – defined by the minimum feasible length and pier locations - dictated a sinuous structural form. The use of curved plate fabricated box sections was also more than an aesthetic choice: it enabled each side of the section to be optimised with different plate thickness, responding to section and structural demand, which simply would not have been possible with tube sections. It also means that each of the steel plates is no thicker than required at any point, reducing steel consumption, as well as excess weight throughout the structure.

“The curved, fabricated box section construction elevates helix design and fabrication to a new level, combining sharper surfaces with fluid geometry, enabled by Arup’s digital approach through both design and delivery phases,” said Johnson. The diameter of the bridge was adjusted to achieve greater structural depth at locations of higher demand, as opposed to increasing material use at a shallower depth. Robust

materials and finishes, the use of closed structural sections and smooth connections between elements minimises maintenance and ensures long-term durability. The Arenco Daracon Joint Venture was responsible for the novated design and construction of the new bridge. According to Phil Douch (Engineering Manager, Arenco), “We novated the design from Landcom at 85 per cent, which was undertaken

by Arup for the structural works and KI Studio for the architectural features.” The Fabrication Of all the 3,600 steel plates used to fabricate the 335 tonne structure, no two are alike – every piece of steel has a different curvature, and the helix varies 2.3m in its diameter in relation to the structural demand. Every member is unique in shape and plate thickness. This made for a complex fabrication project for Glendenning-based steel fabricator, S&L Steel. Fabricated from 350 tonnes of locally produced structural mild steel and 170 tonnes of high grade imported Duplex 2205 stainless steel, the bridge comprises four segments, with a maximum span of 50m. The substructure comprises reinforced concrete abutments and three piers, each in turn supported on bored reinforced concrete piles. Bridge approaches to both ends are landscaped and paved, all in keeping with the free-flowing theme of the structure. The steel superstructure consists of 78 chord members, 160 diagonal members and 82 connecting

Australian Welding: September 2020

nodes (320 members in total), creating a singular longitudinal truss arrangement. The fabrication of each member required individual cutting to size and bending of approximately 4,000 flat steel pieces prior to welding to form the individual box shaped members. Over the course of approximately 100,000 manhours, S&L Steel completed approximately 14km of welding. According to Javier Lorenzo (Director, S&L Steel), given the unique nature of the project, it posed some challenges for S&L Steel. “Early on, our biggest worry was getting the radius of each piece correct. That was difficult for us, but we worked out a strategy that allowed us to maintain the shape of the box as we built and welded it. All the pieces had to be rolled, and sometimes during welding, pieces lose their shape. To overcome this, we had to hold down the pieces with smaller jigs.” The Trial Assembly Prior to the on-site erection, members for each segment were trial assembled in S&L Steel’s workshop using specially designed support jigs, tack welded in position and surveyed to verify dimensional accuracy. “We have a lot of space in

our yard. In fact, I believe we have one of the largest fabrication facilities in Sydney. This affords us the ability to undertake large-scale projects such as Lachlan Bridge. For this project, we felt that the more work we could do in our workshop, the more advantages it would afford the siteworks. So, we basically replicated the entire site and bridge in our yard prior to erection. The only thing we didn’t do in our workshop was fully weld the bridge,” explained Lorenzo. “The purpose of the trial assembly was to ensure all the pieces fit together exactly. This was particularly important, given that no two pieces on the bridge are the same. If we’d craned a piece into position on-site, and then it didn’t fit, we’d have had to re-crane it the following night, causing major delays.” Douch was equally as adamant about the importance of the trial assembly. “The trial ensured that we had all the tolerances correct. Everything was cloud point surveyed, and the segments were all joined to make sure they aligned with one another. This was all completed in the precambered state, through models. When we did the trial assembly in the workshop, we had three fully

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Of all the 3,600 steel plates used to fabricate the 335 tonne structure, no two are alike – every piece of steel has a different curvature, and the helix varies 2.3m in its diameter in relation to the structural demand. Every member is unique in shape and plate thickness. This made for a complex fabrication project for Glendenningbased steel fabricator, S&L Steel.” Workshop assembly works.

Australia’s First Double Helix Bridge Now Open

assembled units. All of these units were checked, surveyed and ticked off, before being broken down into pieces and then transported to site,” said Douch. From there, the segments were dismantled, grit blasted and painted for delivery to the purpose-built site fabrication facility. There, they were reassembled using the same support jigs that S&L Steel relied upon during the trail assembly, and then fully welded while again being surveyed for dimensional conformity. All of the decking elements were fabricated entirely off-site, prior to delivery and fixing into each segment. Paint touch-up was completed concurrently, and tensile stainless steel mesh protective screens enveloped the external form. As one segment was completed, S&L Steel began the adjoining segment, replicating the same process, while ensuring the splice connections between adjoining segments matched perfectly. The Lifting Process Arenco undertook extensive planning with the New South Wales Government’s Transport Management Centre for all four segment installations to understand and mitigate the effect each would have on the Sydney traffic network. The key objectives were the absolute minimisation of impacts on traffic and the community. Traffic engineers prepared detailed analyses to assess projected traffic queuing and compare potential traffic detours. This process was a balance between traffic optimisation and mandatory construction aspects, including personnel safety and bridge installation complexity. Using limited road closures, the four individual bridge segments were successfully erected into position using a single crane lift methodology. The heaviest lift was Segment Two with a gross lifting weight of 135 tonnes involving a 600 tonne crawler crane and closure of both Delhi Road and the M2 Motorway.

Diagonal being assembled in jig.

Assembley of node with pier connection. .

Segment assembly on-site. .

Segement One being prepared for erection. .

Assembly of Segments One and Two on-site. .

According to Douch, “When Arenco took on the project, the design didn’t have any way of being lifted into place. So, in the early stages, we worked out how we were going to lift it. We agreed on four segments, each with four lifting points.” “All the lifts were completed over weekends and at nights to minimise the amount of time roads were closed,” said Douch. Segment Two, which was largest segment weighing in at 110 tonnes, was erected on 28 December to capitalise on the quieter traffic over the Christmas and New Year period. Even then, Arenco worked to ensure that the M2 was closed for as short a period of time as possible.

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You just have to look at the design—the first reaction is always ‘wow’. We knew it was going to be hard work, but now that the bridge is finished, it’s clear that it is an iconic project. People are going to wonder how we managed to build it for years to come.”

Australian Welding: September 2020

“During the lift of Segment Two— which was the largest segment— the M2 was only closed while the segment was slewed over the motorway. Throughout the set up and pack up of the crane, the motorway remained operational. We originally planned to close the M2 for 40 hours, but only needed to close it for 15 hours in the end,” said Douch. The Erection S&L Steel was heavily involved in the erection process. “Our job was to transport each segment approximately 300m from the site shed to the site. The segments were gigantic to be travelling along a road – it was quite an impressive sight. On most jobs, we would have transported the segments from our factory in Rooty Hill to the construction site but it simply wasn’t possible for this project,” said Lorenzo. “The segments had an 8m radius, which meant they were too large to transport along the M7 Motorway— they would have knocked out all the overhead bridges. That’s why the decision was made early on to build a workshop on-site, so we could finish the job over there.” Each segment was lifted out of an assembly jig at the on-site factory, and onto transport frames. “The transport frames suspended the segments, almost like a mini crane lift itself. Then the segments were

transported into position to be lifted by the crane,” said Lorenzo. As Douch explains, the lifts themselves were no mean feat. “When we lifted the segments, because of their unusual shape, we used a synchronised lifting system. This was a bit like a hydraulic jack at the end of each segment. We were then able to rotate the segments as we picked them up from the transporter—tilting them from the horizontal position to match the grade of the bridge.” “A lot of the segments had to be lifted higher or lower than the last to suit the site constrains. For instance, Segment Two clashed with Pier Two, so it was lifted in higher at one end and then rotated into place,” said Douch. Lorenzo explained further. “When Segment Two was craned into position, because of the shape of the structure, it forced the end of Segment One to point up into the air. The segment didn’t rest in its final position—it flexed. The crane had to be fitted with hydraulics so that segments could be manipulated while in mid-air—twisted and tilted so that the two connecting plates of the pieces fitted exactly,” said Lorenzo. Once each segment was erected, it was bolted onto the adjacent segment, and sat on a pier as a temporary support. It was only then

Australia’s First Double Helix Bridge Now Open

Far Left: Lachlan’s Line bridge will be a striking visual landmark, as well as a busy active transport connection, for years to come. Left: Erection of Segment One takes place. Below: Segment Four is lifted out of the transport frames.

that the crane could be released, all the joints welded, and the bolted sections cut off, so that the segment was fully self-supporting. The Outcome The end result is a truly remarkable feat: bold and bright blue, Lachlan’s Line bridge will be a striking visual landmark, as well as a busy active transport connection, for years to come. As such, it is little wonder that the project stakeholders were so keen to be involved. Lorenzo’s enthusiasm and excitement was clear. “You just have to look at the design—the first reaction is always ‘wow’. We knew it was going to be hard work, but now that the bridge is finished, it’s clear that it is an iconic project. People are going to wonder how we managed to build it for years to come.” “As soon as I saw the design, I went looking for projects and bridges that are similar. There’s a similar bridge in Singapore, but when you look at it in detail, the Lachlan’s Line bridge is considerably more difficult. The bridge in Singapore is constructed using rolled members—we had to fabricate physical boxes.” “There are other helix bridges all around the world, but Lachlan’s Line is snake shaped – it’s like a worm, where it gets fatter and skinnier. There is simply no other bridge in the world like it,” said Lorenzo.

Australian Welding: September 2020

Minprovise: Continuous Improvement for Quality Outcome Headquartered in Perth, Minprovise is a specialist products, engineering and services company that provides expert support to the mining, oil and gas and construction industries. The company boasts an excellent reputation for outstanding quality, performance and safety initiatives, as well as exponential growth over the last 12 months. Minprovise recently achieved certification to AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials.

According to Tony Sutton (General Manager, Minprovise), “Graham Townsend opened Minprovise in 1994 as a specialist company in crushing and screening for the mining industry. Over the next few years clients asked Graham to supply labour, which he did. In 2009 he launched the award winning Dugless 900 automated digging and cleaning unit capable of safely maneuvering under low conveyor sections and other inaccessible places. By 2010, Minprovise employed approximately 50 people.” “In 2015, the mining industry went through a downturn and work started to drop off, so Graham considered what the next phase for the company should be,” explained Sutton. “It was then that we started providing additional fixed part

maintenance on crushers with our team of expert tradespeople.” It turned out to be the right decision. Today, Minprovise boasts workshop facilities that cater for the most complex repairs, refurbishments, maintenance shut downs, engineering, fabrication and the supply of mineral processing equipment. The company boasts an 8,000m2 undercover workshop in Welshpool, with a 10-tonne overheard crane to support the work they do in the shut down and project maintenance field. “In November 2019, we opened a 1,000m2 workshop in Karratha enabling us to service the north-west like never before, and just a few weeks ago, in July 2020, we opened offices in Port Hedland,” said Sutton.

Minprovise now has a team of over 200 full time and 500 part time employees. The company has enjoyed exponential growth over the past 12 months, establishing a project services division and expanding their capabilities to include corrosion control (using wet and dry abrasive blasting techniques), and scaffolding specialist divisions. Minprovise also partners with original equipment manufacturers (OEMs) to supply equipment, parts and products that are complimentary to their suite of services. When asked to explain this growth, Sutton emphasised that the success of Minprovise rests on two key elements: the right team of people and the ability to consistently produce high quality work. “I was taught years ago that if you do it right, the work will come to you. Minprovise has proved this to be true.” Minprovise places a very heavy emphasis on not only having the right people, but on looking after them and making sure they have the right training and support they need to succeed. “We’ve been involved with the education of apprentices in Western Australia for the last 14 years and have a very strong background in training. Minprovise currently has 22 apprentices in its workforce, and we work hard to ensure that we’re building up the skillset of the next generation of welders and tradespeople.”

Minprovise: Continuous Improvement for Quality Outcome

AS/NZS ISO 3834 Certification Minprovise recently achieved certification to AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials. “There are a lot of companies that like to think they do a lot of things very well, but it’s not until you put the disciplines in place and undertake a process such as certification to AS/NZS ISO 3834 that you truly know whether you have quality management and assurance right,” explained Sutton. While having already achieved high quality levels, Minprovise identified that processes like consumables management needed further attention. “Factors like consumables management have been key for us. Prior to undertaking certification, our welders would put a roll of wire on their machine, and roll it out. The next morning, our welders would come in and continue with the same roll of wire on the same machine.” “Now, at the start of their shift, all welders have to sign out a roll of wire that they sign back in at the end of their shift. When considering traceability, these quality processes soon become a culture that continues throughout the organisation,” said Sutton.

Left: Just some of Minprovise’s high quality above ground fuel tanks. Right: One of Minprovise’s welders works on an above ground fuel tank. Far Right: Gantry signage fabricated by Minprovise for Main Roads Western Australia.

A Culture of Continuous Improvement Every job and every department contributes to the Minprovise culture of continuous improvement and their approach to certification. “You must have leaders within the team who can do more than police processes and protocols, they really need to mentor other staff through the new processes so that safety and quality become embedded in the company culture,” said Sutton. New Opportunities AS/NZS ISO 3834 certification has presented new opportunities for Minprovise, including significant fabrication work for a defence project that is currently underway. “Our AS/NZS ISO 3834 certification made us eligible to meet the criteria the client was chasing,” said Sutton. “If you are a large mining or oil and gas company, or an infrastructure utility like Main Roads Western Australia, our AS/NZS ISO 3834 certification endorsed by an independent third party like Weld Australia, goes a long way—it’s a very strong industry endorsement.” “For instance, a couple of years ago, an overhead gantry fell on a car in Melbourne – that’s the type of work we’re in. We recently fabricated a number of overhead gantry signs for

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The Standards and requirements become the way your company completes all tasks— all day, every day.”

Main Roads Western Australia over the Tonkin Highway.” “From a reduction of risk perspective for the end user, road authorities need to know that the company performing the work for them is performing it correctly. Where public safety is concerned, and people’s lives could be at risk, quality is paramount,” said Sutton. For other companies considering certification to AS/NZS ISO 3834, Sutton has some sage advice. “You have to adopt the Standard as a whole. You can’t treat it as an addon to your organisation. It needs to be what your entire team eats, sleeps and breathes. The Standards and requirements become the way your company completes all tasks— all day, every day,” said Sutton.

Australian Welding: September 2020

Berg Engineering: Investing in the Future of Manufacturing Queensland manufacturer, and Weld Australia member, Berg Engineering is set to expand their operations and create new jobs following the recent award of $160,000 for the purchase of advanced manufacturing equipment under the Queensland Government’s Manufacturing Hubs Grant Program. This follows Berg’s own investment, in March 2020, of over $4 million to acquire and house state-of-the-art Titan SC 40/50-4HY Double Column Vertical Boring and Turning Mill.

Berg Engineering has built a reputation for excellence on the back of two generations, and more than four decades, of Berg family passion. Founded in 1972, Berg has grown from a single room operation into a multi-million dollar business. According to Rod Clarke (International Welding Technologist and Group Welding Coordinator, Berg Engineering), “Berg engineering has been in existence for almost 50 years. We have humble beginnings; our founder initially started out with a manual lathe in his family home. Today, we have workshops in Brisbane and Gladstone, with clients throughout Australia, the Pacific Islands and South East Asia.” “Berg boasts a broad range of offerings, which we deliver to all sorts of industries, from alumina, mining and power, through to oil

Above: On-site welding at a Gladstone site. Right: Duplex stainless steel repairs using Berg’s newly commissioned TIP TIG machine.

and gas, rail, water infrastructure, and many more. There is no sector we haven’t worked in at some stage throughout our 50 year history,” said Clarke. With over 7,000m2 of factory space and 23,000m2 of external laydown, Berg currently has a 100 person strong workforce across its two sites. Their multi-discipline workforce includes capabilities across engineering, estimating, NDT, welding, fabrication, fitting, and valve and pump repair and maintenance. Berg also offers NATA endorsed NDT facilities and hydro-testing facilities. “With machining, fabrication, welding and reverse engineering services, we have extensive experience in welding, including the welding of exotic materials, and in providing material change options and wear solutions to the market.”

“We combine high-end welding with high-capacity machining all under one roof. The advantage for our clients is that they only have to deal with one project manager. This makes the engineering process more cost-effective for the client and provides a less stressful experience in that their asset is only managed through one workshop,” said Clarke. Manufacturing Hubs Grant Program Berg Engineering recently received $160,000 from the Queensland Government’s Manufacturing Hubs Grant Program to purchase advanced line boring equipment. With this equipment delivering higher accuracy and finer cuts, it will help Berg grow their operations and create new jobs. Berg Engineering’s Owner and CEO Derek Berg said, “Thanks to this

Berg Engineering: Investing in the Future of Manufacturing

Berg’s Titan SC 40/50-4HY Double Column Vertical Boring and Turning Mill.

funding, we can take our line boring capability to the next level and seek to enter new markets like defence, energy and mining. This equipment is part of our plan to transition to advanced manufacturing from its traditional practices, which is the direction we, and the entire industry, need to take.” The new equipment adds a lot larger scale to Berg’s on-site business. The company can now machine much larger items than it could previously. “With this new line boring equipment, we have a greater presence onsite, particularly mine sites. The equipment will attract larger items, which then require machining and welding in our workshop, necessitating the use of our newly upgraded Titan equipment,” said Clarke. “The new equipment is fitted with laser measuring and recording equipment as well, which gives us the ability to generate high-quality, extensive reports for clients at the end of each job.” “This new capability has already created another five to 10 full time local jobs in the Gladstone area, and we only see that number increasing,” said Clarke. A Titan Investment The Queensland Government grant award follows a significant investment by Berg to increase the capability of their Gladstone workshop. In March 2020, Berg invested over $4 million to acquire and house the state-of-the-art Titan SC 40/50-4HY Double Column

Plasma Transfered Arc Welding (PTAW) process depositing cobalt based hardfacing.

Vertical Boring and Turning Mill. “The introduction of the new Titan to our operations reflects our optimism about the strength and resilience of the market over the coming years,” said Berg. “It significantly broadens our service offering, complementing our specialised welding sciences division and the on-site machining and shutdown division.” “With increased torque and maximum load, and a maximum outer diameter of 5.3m available, we are now able to manage operations that were previously beyond our capabilities. From a business perspective, it positions us to capitalise on new opportunities with existing and prospective customers,” said Berg. Originally produced in Europe to service the nuclear and defence industries, the acquisition of the Titan positions Berg to serve the emerging needs of defence contractors, traditional power providers and hydro-electric power stations in the 5m+ diameter machining space. Of significance, the Titan allows Berg to better service the ever-developing Southern Bowen Basin and the wider mining industry as a whole. Believed to be the largest machine of its kind in the Central Queensland region, the Titan measures an impressive 17m x 11m x 10m and has a 5m swing diameter and 41 tonne Lathe Chuck. It also has a controlled C-axis and a pusher for turning tool holders and one

for mounting SK 50 boring and milling tool holders; with each side equipped with a 12-unit tool magazine. The machine is housed in Bergs’ purpose-built new facility which includes a 50 tonne overhead crane and 20m height under crane. The Future of Industry Clarke believes wholeheartedly that it is essential Australian industry adopts advanced manufacturing capabilities. “Manufacturing has been on the decline in Australia for a long time—advanced manufacturing technology is the key to turning the industry around. For welding, I believe additive manufacturing is the way of the future. There are still some issues to resolve within the process itself, but as time goes on, there will be significant cost benefits derived by the end user,” said Clarke. “The biggest opportunity for the welding industry is moving towards supporting the Australian Defence Force. There are lots of opportunities available if your business is willing to upgrade its quality management systems and internal processes to meet the demands of defence and international standards.” “This is something that we’re gearing up for ourselves at Berg Engineering. We’re undertaking ISO 3834 [Quality requirements for fusion welding of metallic materials] certification at the moment, and investigating the German DIN 2303 [Welding and allied processes - Quality requirements for production and maintenance companies for military products] certification as well.”

Australian Welding: September 2020

Baker & Provan: Aussie Manufacturing at its Finest Established in 1946, Baker & Provan is one of the leading defence industry suppliers in Australia. Based in Western Sydney, Baker & Provan specialises in manufacturing, fabrication and support. Baker & Provan recently teamed up with global defence giant, Thales to manufacture Modular Cylindrical Array frames for use on the Royal Australian Navy Collins Class submarines.

Western Sydney based manufacturer, Baker & Provan has partnered with Thales to manufacture Modular Cylindrical Array (MCA) frames, ready for use on Royal Australian Navy Collins Class submarines. Located in St Mary’s, approximately 40km west of Sydney’s central business district, Baker & Provan was established in 1946 by two returning World War Two veterans, Arthur Baker and Don Provan. The friends purchased an optical profile grinder and started business as proficient toolmakers. By 1975, the business had shifted its focus from toolmaking to Computer Numerical Control (CNC) and conventional machining, fabrication, project work and machine

“

Baker & Provan... were put through a robust vetting process and not only came out more cost effective than overseas suppliers, their product was also in many ways superior. They are also helping contribute sovereign industrial capability on a key Underwater Systems program.”

Michelle Richard (Director Regional Procurement Centre, Thales)

building, increasing their client list substantially in the process. Looking to future proof the business, Baker & Provan continued to achieve quality accreditation and ISO certification, ensuring it could work on ever more complex and diverse projects. A History in Defence In 1989, Baker & Provan—now fully owned by the Baker family after co-founder Don Provan moved into farming—began its first of many contracts with Defence, and the defence industry, manufacturing slewing arm davits for the Royal Australian Navy. Less than a decade later, in 1998, Baker & Provan partnered up with Thales to provide nonmagnetic cranes for the Huon

Class Minehunter Coastal ships. Throughout the 2000s, Baker & Provan designed and manufactured cranes, davits and winches for a number of ship classes, becoming the principle supplier of this equipment to the Royal Australian Navy with, at the peak, 45 systems in service that were originally manufactured, and then maintained, by Baker & Provan. From this base, Baker & Provan moved into servicing a range of other equipment on Royal Australian Navy vessels including fin stabilisers and steering gear, anchoring and mooring equipment, doors, lifts, elevating platforms, thrusters and propulsion lines. The company then branched out further to support projects on both the ANZAC and FFG vessels.

Baker & Provan: Aussie Manufacturing at its Finest

It then cemented itself as a quality manufacturer within the maritime space by producing the control surface and hydroplane shafts for the Collins Class submarines. “While we serve a range of sectors from rail to mining, we’re no strangers to Defence and Defence Projects account for a large part of our business,” said Malcolm Cazier (Business Development Manager, Baker & Provan). SEA 1439: Upgrades to the Collins Class Submarines Director Regional Procurement Centre at Thales, Michelle Richard, said that when Thales went looking for potential suppliers as part of the SEA 1439 upgrades to the Collins Class submarines, there was a perception that Australian suppliers didn’t have the capability to produce the Huon Class Minehunter Coastal ship frames. “Baker & Provan proved that theory wrong,” Richard said. “They were put through a robust vetting process and not only came out more cost effective than overseas suppliers, their product was also in many ways superior. They are also helping contribute sovereign industrial capability on a key Underwater Systems program.” Cazier says that the core values at the heart of Baker & Provan is what keeps the business moving forward and has it succeeding on projects like the Huon Class Minehunter Coastal ship frames for Thales. “We value teamwork, passion, honesty, accountability and of course, safety here,” Cazier said. “And we are committed to providing quality training to our apprentices and tradespeople. We have 65 staff and we value each and every one of them.” To date, over 70 apprentices have gained their trades at Baker & Provan since it opened its doors, and it even has a dedicated area set for its apprentices to train in. “We take training very seriously,” Cazier said. “It’s beneficial to everyone to

keep these trades alive, and with more projects like this one with Thales, it all helps to build that strong, diverse workforce of the future.”

Above (Top): Inside Baker & Provan’s facilities in St Mary’s, approximately 40km west of Sydney’s central business district.

Troy Stephen, Director Underwater Systems at Thales, said it was important to select a supplier that Thales could trust.“The Collins Project is an extremely important project for Thales and we wanted a partner we could rely on for the manufacture of this highly complex component.”

Above (Below): Collins Class submarines HMAS Collins, HMAS Farncomb, HMAS Dechaineux and HMAS Sheean in formation while transiting through Cockburn Sound, Western Australia. Collins Class submarines are an essential part of Australia’s naval capability, providing a strategic advantage in terms of surveillance and protection of our maritime approaches. Image courtesy of the Department of Defence. © Commonwealth of Australia 2020

With the first of the frames having successfully passed final dimensional checking, manufacture of the following sets is now underway.

Left: Baker & Provan has partnered with Thales to manufacture Modular Cylindrical Array (MCA) frames, ready for use on Royal Australian Navy Collins Class submarines.

Australian Welding: September 2020

A Guide to the Adoption of ISO Standards in Australia Standards are voluntary documents that set out specifications, procedures and guidelines that aim to ensure products, services, and systems are safe, consistent, and reliable. To ensure they keep pace with new technologies, Standards are regularly reviewed by Standards Australia technical committees. During the review process, International Standards may be adopted as Australian Standards, but only where technically feasible and reasonable to do so, after careful consideration by the relevant Australian experts.

Government policy is that International Standards (also known as ISO Standards) be adopted where relevant, technically feasible and reasonable to do so, and only after consideration by the relevant Australian experts. According to Standards Australia, “The policy of Standards Australia is to base Australian Standards on International Standards to the maximum extent feasible and to apply the requirements of the World Trade Organisation (WTO) Agreement on Technical Barriers to Trade (known as the WTO TBT Agreement) as a benchmark.” “The principal benefit to Australia of basing Australian Standards on the equivalent International Standards is the benefit to the Australian economy by facilitating the international exchange of goods and services.” ISO Standards also have the advantage that once published, they are reviewed by the drafting

committee every five years. At this review, the Standard is either reconfirmed or submitted for revision. This process ensures that the ISO Standard remains current.

groups provide the technical content to write the Standard. These working groups report to the technical committee on the scope and timeliness of the work.

The Process of Developing Australian Standards The process used by Standards Australia to develop Standards includes six steps:

4. Public Comment: This stage ensures that the broader community has an opportunity to review the content and direction of the document prior to its completion. Drafts are available to the public for comment for nine weeks. All comments from the public are considered in detail by the technical committee and, if necessary, further drafting is undertaken.

1. Project Proposal: Any proposal to develop, revise or amend an Australian Standard can be raised by the Australian community. The proposal is required to go through Standards Australia’s project prioritisation and selection process. 2. Project Kick-Off: Once a proposal has been approved, it is assigned to a technical committee. Standards Australia holds a kick-off meeting with the technical committee to discuss the approved project scope, draft tasks, timeframes, and monitor project progress. 3. Drafting the Standard: Working

5. Ballot: The committee votes affirmatively or negatively on the final draft. To be considered, negative votes must be accompanied by technical substantiation. For a Standard to be published, consensus must be reached. 6. Publication: The Standard is ready for publication once final approval is given by, or on behalf of, the Standards Development and Accreditation Committee (SDAC).

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Government policy is that International Standards be adopted where relevant, technically feasible and reasonable to do so, and only after consideration by the relevant Australian experts.”

A Guide to the Adoption of ISO Standards in Australia

The Benefits of Standards Standards mean better value for all. They ensure the quality and consistency of products and services, giving businesses and consumers greater peace of mind. Below are just some of the benefits afforded by Standards. Boost confidence: Thanks to standards, businesses and consumers can feel confident that the products and services they use are safe, reliable and fit-for-purpose.

How to Get Involved If you believe that the adoption of a particular International Standard will not be beneficial to Australian industry, or needs to be modified for local conditions, it is important to participate in the ‘Public Comment’ phase of the process. Be sure to submit your views directly to Standards Australia and their technical committees. Weld Australia’s Principal Welding Engineer, Bruce Cannon, sits on many of the welding-specific technical committees and is in the perfect position to advocate on behalf of industry. Weld Australia publishes an article in every edition of its quarterly magazine—Australian Welding detailing the relevant Standards activities to help keep industry informed. Adoption of International Welding Standards in Australia The adoption of ISO 9606-1 for welder qualification in Australia has been under consideration since 2004. However, the adoption of ISO 9606-1 only occurred in 2017 once objections from Australian experts were considered and resolved. Australia is directly involved in the revision of this ISO Standard and comments are being considered (and accepted) by ISO. Similarly, Australia only adopted ISO Standards related to welding consumables once objections from Australia and many other Pacific Rim countries were resolved by

ISO. A number of these adoptions were modified adoptions of the ISO consumable Standards due to technical issues with the content. The ISO Standards that are most likely to be adopted in Australia in the near future are those in areas such as weld testing (the AS 2205 series, for example) and NDT. Many of the Australian versions of the weld testing and NDT Standards are over 20 years old, and were actually based on ISO Standards when first drafted. However, time and technology have moved on, and Australia no longer has the resources to keep these Standards current. When it comes to structural and pressure equipment welding, many of Australia’s practices are based on those of North America. This is likely to continue. In this area, ISO Standards are based around incompatible European practices and the development of cohabitation standards is challenging. Australia’s welding practices are also intimately linked to our design Standards, which are based on local requirements. Whilst there are some ISO inclusions, these are quite limited. In some situations, ISO (European based) requirements can be unnecessarily complex and in these cases, ISO Standards are inevitably not considered for adoption. For further information, visit: https://www.standards.org.au

Enhance innovation: Standards are a launch pad for new ideas. They can be created, evolved or discarded according to the changing world. New standards are developed to reflect the latest technologies, innovations and community needs. Give products a competitive edge: In the eyes of consumers, products that comply with Australian Standards offer added value. International Standards give Australian exporters an instant competitive advantage when moving into overseas markets. Reduce barriers to international trade: Regardless of where a product is made, standards mean it can be sold and used around the globe. Opening new doors to international trade, standards help Australian businesses compete globally. Reduce red tape: Standards assist with harmonisation across Australia’s laws and regulations. They offer an alternative to regulation, reducing business costs and decreasing red tape, but still providing security for businesses and consumers. Help businesses thrive: Standards are central to Australian business. They make business transactions simpler and more efficient, assisting with risk mitigation and compliance. Source: https://www.standards.org.au

Australian Welding: September 2020

Coregas & BlueScope:

A Symbiotic Relationship of Operational Excellence Located in the heart of BlueScope’s Port Kembla steelworks, the Coregas world-class Air Separation Unit (ASU) is one of the largest production facilities of its kind in the Southern Hemisphere. Not surprisingly then, Coregas is one of the largest oxygen, nitrogen and argon producers in Australia—supplying to over 60,000 customers around the country—and owns the largest merchant hydrogen production plant in Australia. With an impeccable reputation for operational performance, Coregas supplies enormous volumes of oxygen to BlueScope for use in the steelmaking process at their Port Kembla steelworks. Of the 1,400 tonnes of oxygen that Coregas produces every day, 1,350 tonnes is used by BlueScope. The symbiotic working relationship enjoyed by Coregas and BlueScope is one that spans over 60 years and is defined by best practice performance and reliability, and safety excellence. According to Dave Bell (General Manager Manufacturing, BlueScope), “We are delighted with our relationship with Coregas. Oxygen is a vital raw material in the steelmaking process, and Coregas provides us with a timely supply of the large quantities we require.” “In turn, the Coregas facility uses processed air from our blast furnace and cokemaking operations to produce oxygen, argon and nitrogen. We are very pleased and proud that these gases are able to be used throughout hospitals in New South Wales,” said Bell.

Right: BlueScope is responsible for more than $2 billion in sales of locally produced steel each year. An integrated steelmaking operation, BlueScope’s Port Kembla steelworks cover 760 hectares, directly employ around 3,000 people, and have a production capacity of approximately 2.6 million tonnes of steel per annum. The Port Kembla steelworks are the largest manufacturer and supplier of flat steel in Australia by volume. They also manufacture slab, hot rolled coil, thin strip and plate products.

How the Coregas-BlueScope Collaboration Works Converting Processed Air into Argon, Nitrogen and Oxygen The coke ovens and blast furnace at the BlueScope Port Kembla steelworks produce hundreds of thousands of tonnes of by-product gas, which is used to produce steam. In turn, this steam drives compressors that produce processed air, which is then supplied to Coregas. Utilising its state-of-the-art air separation technology, Coregas produces argon, nitrogen and oxygen. Air separation is based on the principle that gas is converted into liquid at different temperatures. Air is comprised of 78% nitrogen, 21% oxygen and 1% argon, and a number of other minor constituents, such as neon, xenon, carbon dioxide. Coregas processes the air supplied by BlueScope in five steps to extract these vital molecules: 1. Filtration: The processed air supplied by BlueScope contains impurities. As such, the air is purified through a filter to remove any unwanted particles. 2. Ambient Air Compression: The air is compressed to 6 bar in preparation for separation. 3. Purification: To prevent ice forming during the cooling phase, carbon dioxide and water are removed from the compressed air. 4. Cooling: The purified air is then cooled to -173°C, preparing the air closer to the liquefaction temperature.

Coregas & BlueScope: A Symbiotic Relationship of Operational Excellence

The Coregas ASU at BlueScope’s Port Kembla Steelworks.

5. Distillation: The cooled air is fed into the Coregas distillation tower, which operates at approximately -196°C (a cryogenic temperature). Nitrogen (in both gas and liquid form) is extracted from the top of the column. Oxygen (in both gas and liquid form) is collected near the base of the column.

Coregas uses this high-temperature steam (700°C to 1,000°C) to produce hydrogen from a methane source, such as natural gas. When placed under pressure (between 3 to 25 bar) in the presence of a catalyst, the methane reacts with the steam to produce hydrogen, carbon monoxide, and a small volume of carbon dioxide.

This liquified gas can then be used for a wide range of applications, from welding and scientific analysis, through to environmental monitoring and medical purposes.

Unlike fossil fuels, hydrogen does not generate carbon dioxide when it is burnt. Instead, hydrogen’s only byproduct is water, which dramatically reduces the impact on global warming. Affordable, clean hydrogen is the holy grail of environmentally sustainable power supply.

Converting Steam into Hydrogen for Clean Energy BlueScope generates two main fuels during its steelmaking process: coke oven gas and blast furnace gas. Much of this fuel is reused within the steelmaking process, such as in the hot strip mill, or to power the furnace itself. However, BlueScope uses any excess fuel to make steam, which is then supplied to Coregas to convert into hydrogen for clean energy.

Coregas produces high purity hydrogen for use in applications such as metal cutting and welding applications, as well as laboratories. Working with leading vehicle manufacturers such as Hyundai, Coregas also supplies hydrogen to hydrogen car and bus schemes across the country.

Why Oxygen is Essential to the Steelmaking Process In every heat, or batch, of steel that BlueScope makes, they use approximately 13,500 normal cubic metres of oxygen. This is equivalent to five and half Olympic swimming pools full of pure gaseous oxygen. This oxygen must be of an extremely high purity—99.5% pure—supplied at a high flow rate. Oxygen purity is essential in the steelmaking process; the more pure the oxygen, the better quality the steel. Oxygen is used in the steelmaking process to reduce carbon content. Molten iron contains approximately 4.5% carbon, whereas steel, such as that used to manufacture BlueScope’s COLORBOND® roof sheeting, has only about 0.05% carbon. Oxygen is blown through a water-cooled steel lance or pipe at a rate of 55,000 normal cubic metres per hour, which is equivalent to twice the speed of sound. This creates a thick foamy slag that is critical to ensuring the steel has the correct carbon content and chemical composition. With their Port Kembla steelworks operating constantly 24 hours per day, it is essential that BlueScope has access to the constant, reliable supply of high purity oxygen delivered by Coregas.

Australian Welding: September 2020

“

We are delighted with our relationship with Coregas. Oxygen is a vital raw material in the steelmaking process, and Coregas provides us with a timely supply of the large quantities we require.” ~ Dave Bell (General

Manager Manufacturing, BlueScope)

National distribution by Coregas from Port Kembla.

A History of Operational Excellence and Safety Success The first Air Separation Unit (ASU) at the Port Kembla steelworks site was purchased by BlueScope (known as AIS at the time) from Linde in 1962. Long since demolished, this ASU was a captive plant, which mainly supplied oxygen to the steelworks. With the advent of the more modern Basic Oxygen Steelmaking processes, BlueScope purchased a second ASU from Linde in 1972, which has since been decommissioned. In 1976, an argon column was added to the plant, which was the catalyst that saw the establishment of Linde Gas in Australia. With the argon column in operation, Linde Gas was able to purchase excess argon, oxygen and nitrogen from BlueScope. The third, and existing, ASU was commissioned in 1989. It has a production capacity of up to 1,450 tonnes per day of gaseous and liquid oxygen, gaseous and liquid nitrogen, and liquid argon.

continuous improvement, value, and customer service, it is little wonder BlueScope made the decision to extend their contract. Since Coregas assumed management of the ASU, the site has never experienced a major breakdown. The superior engineering design of the ASU delivers optimal performance and unbeatable reliability, during both day-to-day operations and planned maintenance shutdowns. A typical, industrystandard maintenance shutdown for a complex of this kind lasts two to three weeks. At the Coregas complex, just 96 hours are required.

operation included a lack of redundancy in nitrogen compression, an extended timeframe for ASU overhauls, and reduced back-up system capacity. To overcome these drawbacks, Coregas undertook several measures to ensure all necessary fail-safes were in place, installed a larger back-up system, and invested in additional equipment.

The site also boasts 15 years free from Lost Time Injuries (LTI), demonstrating the exceptionally stringent adherence to health and safety standards. In 2014, Air Products undertook a rigorous assessment of the Coregas Cryogenic Plant and Bulk Production Complex and declared it a “worldclass facility and best-in-class operations”.

BlueScope granted an initial ten-year contract to Coregas in 2004 for the management of the ASU, and then extended the contract for another ten years until 2024. In 2007, a nitrogen liquefier with a capacity of 200 tonnes per day was installed at the Coregas facility to support the company’s merchant growth.

All this operational excellence is delivered in the most cost-effective manner possible; to achieve optimal operating margins, Coregas demonstrated to BlueScope that a single ASU was all that was necessary, and that the configuration would be safe and reliable.

With Coregas committed to

At the time, the potential vulnerabilities of a single ASU

The Coregas ASU at Port Kembla.

Supervision, Inspection and Qualification Services

Now Available Remotely In the wake of COVID-19 restrictions, Weld Australia has developed a new procedure to carry out welding inspection and supervision services, as well as qualification of welding procedures and personnel—remotely. The procedure has been developed in accordance with IAF (International Accreditation Forum) guidelines. All services are carried out with the cooperation of a competent person on-site, utilising videoconferencing and video recording for record keeping purposes. If you need help with remote welding inspection, supervision or qualification services—we’re here to help. All you need do is call Paolo Corronca (National Manager Engineering) on 0438 012 099. www.weldaustralia.com.au

engineering@weldaustralia.com.au

Australian Welding: September 2020

Process Safety: The Start of the Journey Process safety is about managing the integrity of operating systems by applying safer design principles, engineering and disciplined operating practices. Its objective is preventing incidents with the potential for a loss of control of a hazardous material or energy. In turn, this prevents severe consequences like fire, explosion or toxic effects, which may ultimately result in loss of life, extensive property damage and environmental impact. Weld Australia recently hosted a free webinar that delved into this topic, providing attendees with practical advice from industry experts.

Eighty-seven per cent of people identified ‘process safety’ as a term used in their workplace at a recent webinar event hosted by Weld Australia, but less than half (47 per cent) said it is only managed in some areas of their organisation. CEO of Weld Australia, Geoff Crittenden, hosted the free webinar, where five experts from Weld Australia’s Power Generation Industry Group discussed the importance of managing safety in highly technical environments. Process safety focuses on managing the integrity of operating systems, and handling hazardous substances through the application of safer design principles, engineering and operating practices. Its core objective is to prevent and manage incidents with the potential for a loss of control of a hazardous material,

which leads to a loss of life, property or environmental damage. A failure to meet process safety requirements could lead to catastrophic consequences as seen historically through the 1986 Chernobyl Nuclear Disaster, or more recently at the Coolaroo Recycling Plant Fire in Victoria. “Infamous process safety incidents have shone a light on the importance of process safety management,” said Lara Kayess, Manager for Asset Management at Auercon. Speaking at the webinar, Kayess said the first step to start the journey in process safety management is to find leaders in the organisation “who can support you and collaborate with you to implement those process safety measures”.

While traditional concepts of process safety include oil, gas and chemical incidents, the concept extends to a variety of operating systems like the Thunder River Rapids Ride incident on the Gold Coast, which led to four fatalities. “The Dreamworld incident in 2016 was a classic process safety incident, which changed the game,” Kayess said. Process safety is underpinned by workplace legislation or industry practice and International Standards such as ISO 55000 Asset management and ISO 31000 Risk management. Who is Responsible? Ralph Villarosa, the Engineering Leader at Energy Australia, believes that process safety is a team effort. “Everyone in the business has a role to play,” said Villarosa. Villarosa shared Energy Australia’s process safety journey, which is 18 months into its implementation. “Process safety requires a cultural shift in mindset. It’s very much about developing forward thinking plans based on risk and vulnerabilities.” Villarosa discussed the challenges of transforming process safety from an ‘extra’, to its embedment like other business-as-usual activities, and the power of knowledge in driving that change. “It’s not limited to the power industry. There is a wealth of knowledge and expertise in this country,” said Villarosa.

Process Safety: The Start of the Journey

The lead engineer also discussed the importance of process safety and upholding Australian and International Standards in all aspects of the welding industry. “Welding is all about joining components, in joining components there are Standards,” he said. Senior Manager for Process Safety at AGL Energy, Ryan James also presented at the webinar about the challenges of implementing process safety at an organisational level. James said “change management’s really hard”, but described the importance of measuring operations through self-assessments, incident reporting, audits and the achievement of key performance indicators. “People, process, plant and performance are the systems that control the hazards,” James said. AGL Energy has a process safety framework that outlines these steps for increased process safety, particularly given the nature and safety risks associated with coal power generation sites. “Ultimately the goal is to prevent major incidents,” James said. How to Measure Safety Villarosa, from Energy Australia, also shared his insights on the benefits of conducting a bowtie assessment – a risk assessment evaluation that uncovers the casual relationships in high risk scenarios. The assessment can also identify where new or enhanced controls may be worthwhile through an analysis of

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the causes and consequences of an incident.

cheese holes and resulting in a catastrophe.

For example, a fire could occur as the result of an electrical fault, which is defined as the ‘source’. The electrical fault and the fire itself could lead to financial loss for the company, which are the ‘consequences’.

Ian Rawlings (Manager, Boilers at CS Energy) shared this process safety framework with attendees at the webinar when referring to a catastrophic pulveriser failure at the company’s Callide Power Station.

Jon Alsop is the Group Manager for Engineering Services at Origin Energy and also Chair of the Process Safety Working Group. He outlined three fundamental questions for consideration: • Do we understand what could go wrong? (Assessment) • Do we know what our systems are to prevent this from happening? (Systems) • Do we have information to assure us that these systems are working effectively? (Assurance) Alsop stressed the importance of ongoing business reviews and the role of governance and culture to achieve successful process safety outcomes at all levels of an organisation. “Process safety is owned by everybody in the business,” he said.

Rawlings said an “explosive or flammable substance”, which had the potential for a fire or explosion was noticed by operators who authorised the building to shut down. “It could have resulted in a potential major accident,” Rawlings said. Wade Underhill also presented with Rawlings, where he shared his experiences at CS Energy as a member of the Specialist Mechanical Engineering Services team. CS Energy is a Weld Australia member who proactively manage the plant hazards that can cause harm to employees, the plant and environment. Their process involves: 1. Understanding the hazards 2. Knowing the controls 3. Monitoring the controls 4. Reporting any concerns.

Another method of analysing process safety is through real-time data management and analysis of any potential hazards.

Process safety and emergency preparedness are critical to the welding sector, which is already supported by welding codes of practice.

Presenters discussed the Swiss cheese model of a process safety system. Under this model, if several slices of cheese are stacked together, the holes would not align. These protective safeguards prevent a hazard from passing through the

The webinar was the first in a series, which will include some of Australia’s leading companies, personnel and support industries. Future case studies and speakers will be drawn from the power industry and process safety management area.

Process safety requires a cultural shift in mindset. It’s very much about developing forward thinking plans based on risk and vulnerabilities.”

Australian Welding: September 2020

DJM Fabrications Poised for Expansion When established in 1994, DJM Fabrications’ core business was the design and manufacture of Operator Protective Structures for machinery used in the forestry industry. Over the years, the company has expanded its footprint to include specialised timber processing equipment and rolling stock. With their recent certification to AS/NZS ISO 3834.2 Quality requirements for fusion welding of metallic materials, and investment in a welding robot, DJM Fabrications is poised for expansion.

DJM Fabrications was established by Dennis Marshall in 1994. According to Mathew Billman (Welding Coordinator, DJM Fabrications), “Initially, our core business was focused on the design and manufacture of Operator Protective Structures for machinery used in the forestry industry. This is basically earthmoving equipment used in the forestry industry for clearing or harvesting timber.” Over the next 20 years or so, DJM developed a large range of specialised timber processing equipment, including the Hercules 3.9HD. The Hercules 3.9 is a high capacity, bucket style single front arm attachment, which offers versatility in felling, delimbing, and track building. In 2009, Chris Marshall (no relation to Dennis) partnered with Dennis. Dennis subsquently retired and Chris is now the sole owner and Managing Director of DJM.

“

The quality of the work produced by DJM was already strong, but there is always room for improvement. With the certification in place, for every project, there is more confidence in our systems and, therefore, quality.”

DJM’s heavy manufacturing experience, along with Managing Director Chris Marshall’s history in the rail sector, has enabled DJM Fabrications to secure longterm contracts in the rolling stock industry. “We currently have a long-term contract with Bombardier. The past decade of successful supply has seen DJM become a key producer of critical underframe components for the local rail industry. Similarly, in the forestry industry, Hitachi is one of our largest and longest standing clients,” said Billman. Having secured successful longterm contracts with the likes of Bombardier and Hitachi, Marshall initiated the construction of a purpose-built facility in Warragul, regional Victoria. “We currently have two separate workshops, side-by-side on the same block. One workshop is specifically for forestry equipment,

and the other for rail equipment,” said Billman. “Our state-of-the-art workshops enable us to complete all manufacturing processes in-house, rather than relying on external contractors. From automated laser cutting and CNC milling through to sandblasting and painting, we have the capabilities to complete all manufacturing processes in-house. This gives us much greater control over scheduling, as well as the quality of finished products.” Advanced Technology With a team of over 35 people, a growing client base and a renewed focus on product research, development and innovation, DJM Fabrications is currently in the process of installing a welding robot. DJM Fabrications received a $100,000 grant from the Federal Government’s Manufacturing Modernisation Fund in May 2020

DJM Fabrications Poised for Expansion

to help subsidise the installation of their welding robot. This investment will extend DJM’s advanced manufacturing capabilities, increase the company’s welding capacity and satisfy increasing customer supply demands. It will enable DJM to pursue additional rail projects and enter the defence supply chain, which will in turn extend DJM’s advanced manufacturing capabilities and create higher value jobs. “Chris Marshall is not afraid to dabble in advanced technology and manufacturing processes. A lot of manufacturing companies rely on outdated equipment and are afraid to embrace new technology. Chris is not afraid to spend money on the business. He is keen to optimise the performance of the company and make it more profitable, including through advanced equipment,” said Billman. Achieving Certification to AS/NZS ISO 3834.2 DJM Fabrications was recently awarded certification according to AS/NZS ISO 3834 Part 2. This certification demonstrates their comprehensive controls over welding activities and validates their commitment to welding quality. When DJM embarked on certification, the motivating objective was to win more work with specific clients. “Initially, our intentions were client driven—Bombardier and several other rail manufacturers wanted their suppliers to have AS/ NZS ISO 3834 certification. As there weren’t a great deal of companies in Australia certified at the time, we felt that the certification would help us win contracts with new clients,” said Billman. “Once we commenced the certification process and understood the methodology, our focus changed—the process quickly became more focused on the quality benefit. Our objective switched from winning more clients to improving the quality of our work.” “The quality of the work produced by DJM was already strong, but there is

The Hercules 3.9HD Felling and Timber Handling Attachment A high capacity, bucket style single front arm, the Hercules 3.9HD offers versatility in felling, delimbing, and track building. Its IQAN control system increases fuel efficiency and the system is programmed to demand the minimum required hydraulic flow from the base for individual head functions thus providing both fuel efficient and smooth machine operation. The cutting unit includes a powerful 56cc hydraulic saw motor with up to a 55” saw bar. The saw has a 210° rotation and return cut capability, and features a ‘quick to cut’ characteristic via rapid initial positioning. The return cut allows an operator to scarf then back-cut from the one side when tipping trees back from a boundary or filter strip area. The hydraulic system offers unique independent saw bar operation, as well as fine control of chain lubrication. Ergonomic control handles are fitted along with a cabin mounted user display interface. This allows fast and simple adjustment of head functions combined with excellent diagnostics for service. Dynamic display features such as forced chain lube operation; saw home and hydraulic filter status and head function pressures. Offering the smoothest rotator function in the industry, the high torque on board rotation system allows clean hydraulic installation with no external hoses. ‘Face to Pin’ hook up is the closest in this head class making the Hercules 3.9 HD balanced and operator friendly. Smooth proportional operation combined with the float system offers fuel efficiency, extended life and enhanced operator feel.

always room for improvement. With the certification in place, for every project, there is more confidence in our systems and, therefore, quality,” said Billman. With AS/NZS ISO 3834 certification in place, DJM has appointed a welding coordination team, which includes qualified Welding Supervisors and Inspectors who control and monitor the company’s welding activities.

For other companies considering certification, Billman encourages them to take the leap. “I would fully recommend certification to any company—not necessarily to draw in more work or new clientele, but to improve the systems you have in place and the overall quality of your product. For DJM’s owner Chris, certification gives him greater confidence in the quality of our products, and therefore the company,” said Billman.

Australian Welding: September 2020

An Update from Weld Australia’s Hotline Weld Australia offers a ‘Hotline’ service to all Corporate Members. The purpose of the Hotline is not to provide a solution, but to advise on practical next steps. If you have a Hotline query, complete our online contact form and we will respond as soon as possible: www.weldaustralia.com.au/hotline.

The Weld Australia Hotline recently received a query from a member requesting guidance on the informative section in AS/NZS 1554.1 Structural steel welding - Welding of steel structures (Appendix H) with respect to through thickness tested materials and production of welded beams according to AS/NZS 3679.2 Structural Steel - Welded Sections. Table H2 in AS/NZS 1554.1 is used to calculate ZEd values. The Weld Australia member required clarification around the Zb component of the formula. According to Table H2: 8mm Fillet weld

Za= 3

Thickest Flange = 40mm

Zc= 8

Low restraint

Zd= 0

No Preheat

Ze= 0

However, Table 3-5 in the report Commentary and Worked Examples to EN 1993-1-10 ‘Material toughness

and through thickness properties’ and other toughness oriented rules in EN 1993, seems to indicate otherwise. In Table 3-5, Zb is set as 0. In comparison, in Table H, Zb would be set at either 3 or 5. Even with Zb = 0, for 40mm plate ZEd would be 3 + 0 + 8 + 0 = 11. If Zb is 3/5, then ZEd is 14 or 16. According to Table H, with EN 10164 Steel products with improved deformation properties perpendicular to the surface of the product - Technical delivery conditions in mind, this would require the use of a Z15 grade steel for these thicknesses. Obviously, the need to specify a higher grade of steel could increase the cost of materials for a project. However, with no prior issues of lamellar tearing experienced, the Weld Australia member was unsure whether the specification of a higher grade of steel was necessary.

Weld Australia’s Response In regard to clarification on the Zb (which signifies shape and position of welds in T, cruciform and corner connections), macro tests have revealed a full penetration weld when using Submerged Arc Welding on 40mm from both sides. When welding 40mm plate (using Submerged Arc Welding), the Zb could be set at a value of 5, assuming: 8mm Fillet weld

Za = 3

Shape and position of welds in T

Zb = 5

Thickest Flange = 40mm

Zc = 8

Low restraint

Zd = 0

No Preheat

Ze = 0

For 40 mm plate ZEd would be 3 + 5 + 0 + 8 + 0 = 16. Therefore, this would require the use of a Z15 grade steel for these thicknesses.

43 43

An Update from Weld Australia’s Hotline

What is Lamellar Tearing? Lamellar tearing is a cracking phenomenon that almost always occurs during fabrication, often at an advanced stage, either directly under the weld being made or under an adjacent weld as in a cruciform joint. It is principally found in rolled steel plate fabrications. Lamellar tearing is typified by the following three distinct appearances. Surface Appearance: when a lamellar tear reaches a surface or is sectioned, it appears generally as a straight line parallel to the direction of rolling of the plate or section, almost entirely in the parent metal, usually near or in the outer limits of the visible heat-affected zone. Usually the crack has a number of small steps or changes of direction, and there is little or no surface distortion. Fracture Surface Appearance: is ‘woody’ or ‘step-like’. It has flat fibrous terraces which lie parallel to the plate surface, with “steps” or shear walls between these terraces, approximately normal to the plate surface. Some areas of brittle fracture may be present. There is usually little or no discolouration unless the fracture has corroded or been subject to high temperatures, as in removing specimens, or due to post-weld heat treatment. Cross-Sectional Appearance: shows flat fractures parallel to the direction of rolling, each linking together inclusions in the one line, and with steps between the flat fractures. Occurrence of Lamellar Tearing Lamellar tearing in steel has been

encountered almost since welding was first employed, but is rare and not a major problem in over 99% of weldments. With the advent of fully kilned continuously cast steels in the 1980s, the incidence of lamellar tearing has considerably diminished, particularly when coupled with low sulphur steels and an understanding by joint designers of the importance of limiting through-thickness stresses in welded steel structures. How to Control Lamellar Tearing Lamellar tearing can be avoided by using the following techniques: • If possible, design joints to avoid welds which cause shrinkage strains across material thickness. • Use material of the least thickness practicable. • Design connections to be as simple as possible and to minimise the accumulation and concentration of welding strains. • Use double fillet welds in preference to full penetration butt welds where permitted. • Design welds to have the minimum size necessary to transfer the loads across the thickness of the material. Oversize welds should be avoided.

• •

•

• •

•

Design welds so that the fusion face is at a maximum angle to the plate rolling direction. Design connections to minimise restraint on welds by avoiding where possible doubling plates, stiffeners, diaphragms or very thick sections, particularly in lengths less than 1 metre. Select special steels with improved resistance to lamellar tearing only where joint designs cannot be modified to reduce high restraints and fabrication techniques have proven unsuccessful for similar joints. Use weld metal with lowest acceptable yield and tensile strength. Use a welding sequence which gives the lowest restraint for the largest weld in the joint or minimises the building in of restraint, such as welding from centre to free ends. Adopt an in-situ buttering sequence of depositing weld runs to diffuse welding contraction loads and ensure the run with the maximum restraint is made on the ‘end grain’. Adopt buttering or 100°C preheat when other fabrication techniques are doubtful.

Further Information For further information about lamellar testing, including how to control the phenomenon through joint design, material selection and by fabrication, please refer to Weld Australia’s Technical Note 6: Control of Lamellar Tearing. All Technical Notes are available via Weld Australia’s website: https://shop.weldaustralia.com.au/

Australian Welding: September 2020

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

Defence Industry Group Members of the Defence Industry Group expressed concern at the lack of indigenous Australians in the defence workforce. To help overcome this challenge, Weld Australia is partnering with the Indigenous Defence and Infrastructure Consortium (iDiC), BAE Systems and Indigenous Professional Services (iPS) to develop an Indigenous Welding School. A feasibility study was recently completed, and government funding is pending. The Need for an Indigenous Welding School There is a significant need for skilled, qualified welders in Australia, driven by the defence, infrastructure and resource sectors, including the: • Hunter Class Frigates (SEA5000) • Attack Class Submarines (SEA1000). • LAND 400 Phase 2 (and potentially Phase 3) According to Geoff Crittenden (CEO, Weld Australia), “Over 1,200 qualified welders will be needed to meet the demands of defence and infrastructure projects over the next decade. Across all these projects, Australian industry capability development must be a key focus to meet demand. Growing Australia’s workforce of internationally certified welders is a critical piece of this capability puzzle.”

Michael McLeod (Chairman, iDiC) emphasised that an Indigenous Welding School will provide a culturally-safe model with the right support, and a structured pathway to employment opportunities via industry collaboration. “The importance of creating employment and economic opportunities for indigenous and other underrepresented groups cannot be understated,” said McLeod. The Training Remit The School will train indigenous and disadvantaged students and qualify them to AS/NZS ISO 9606-1 Qualification testing of welders — Fusion welding, which is the minimum standard required for employment as welders in defence and infrastructure projects. It is envisaged that graduates of the School will be ideally qualified for apprentice training to Certificate III and have the potential to follow an advanced trade or technical engineering pathway. Key to the success of the partnership is the engagement of the Indigenous community through iDiC and the recruitment and pastoral services to be supplied by iPS. According to Adam Goodes (CEO, iDiC), “We want to see hundreds of indigenous welders play a key role in building Australia’s future. From our shipyards and oil

The Benefits of Weld Australia Industry Group Membership • • • • • • • • • • •

A confidential forum for discussing issues with peers A unified body that can advocate for change among industry clients Advantageous access to technical advice and engineering support The opportunity to benchmark against industry best practice A conduit between industry and research organisations Beneficial nationally and internationally accredited training Cost effective certification products and services Collaborative sharing of resources and services for repair options in accordance with Australian and international standards Opportunities to influence Australian Standards, contract terms and specifications Opportunity to participate in industry research and development projects Technology transfer and networking via industry specific forums

Inside Weld Australia: An Update from Weld Australia’s Industry Groups

and gas infrastructure, to our high-rise buildings and highways.” It is proposed that the school is established at the Tonsley Innovation Hub, where the facilities and expertise of TAFE SA, Hunter Research and Technology and Flinders University can be leveraged to deliver training and develop micro-credentials for an ongoing pathway. Power Generation Industry Group The Power Generation Industry Group recently facilitated a free online webinar on the topic Process Safety: The Start of the Journey. The objective of process safety is to manage the integrity of operating systems by applying safer design principles, engineering and disciplined operating practices. Process safety principles help prevent incidents that have the potential for a loss of control of a hazardous material or energy. In turn, this prevents severe consequences like fire, explosion and toxic effects, which may ultimately result in loss of life, extensive property damage and environmental impact. Several industry experts spoke during the webinar, including Lara Kayess (Manager, Asset Management, Aurecon), Ralph Villarosa (Engineering Leader, Energy Australia), Ian Rawlings (Chief Mechanical Engineer, CS Energy), Ryan James (Senior Manager, Process Safety, AGL Energy) and Jon Alsop (Group Manager Engineering Services, Origin Energy). With over 65 attendees, the webinar generated a range of interesting discussions. Weld Australia to Launch Rail Industry Group Welding is a core capability critical in the delivery of rail projects, as well as the maintenance, repair and refurbishment of existing assets. As such, Weld Australia’s Rail Industry Group will help improve welding capability, facilities and supply chains throughout the rail industry. Weld Australia has a wide portfolio of accomplished work in the rail industry on infrastructure, as well as multiple fleets of trams, metropolitan trains, regional trains, and freight transport. We believe now is the right time to launch a Rail Industry Group.

The purpose of the Rail Industry Group will be to: 1. Bring the welding capability of the rail industry and its supply chain to international best practice 2. Advocate for a national railcar and wagon fabrication facility and supply chain Australia’s rail manufacturing sector is undergoing a significant transition. It is slowly evolving from a more traditional manufacturing model of end-to-end rolling stock production, to a more advanced manufacturing model, and low-volume, high-value production. The rapid advances in technology and the changing face of manufacturing generally, mean that businesses within Australia’s rail manufacturing sector are facing the immediate challenge of incorporating new technologies and processes into their operations. A world-class rail welding industry in Australia will facilitate a shift in manufacturing focus, capitalise on international opportunities, and develop the rail supply chain capabilities. Industry Group Meetings Due to the outbreak of COVID-19, some of the scheduled Industry Group meetings were postponed. These meetings will be rescheduled shortly via teleconferencing facilities, with members notified as soon as possible.

Become an Industry Group Member

Industry Group meetings are held two to three times a year in one of the state capitals. Fees are: • Existing Weld Australia Premium Corporate Members: $7,500 • Non-Members: $12,665 (includes Weld Australia Premium Corporate membership) Contact Alistair Forbes (National Manager Corporate Businesses, Weld Australia) on a.forbes@weldaustralia.com.au to become an Industry Group member today.

Australian Welding: September 2020

The Benefits of Online Training Courses In the wake of the COVID-19 pandemic, Weld Australia accelerated the development and launch of two new online training courses: those associated with the International Welding Specialist (IWS) and International Welding Inspector – Basic (IWI-B) qualifications. This new online format offers students a raft of benefits, from increased flexibility through to more efficient learning. Increased Flexibility The flexible nature of online learning also allows students to access course information with greater ease. Students are able to study in their own home and access the course material whenever is most convenient for them; before a morning run, after work, or when their children are asleep. Each person has their own unique way of learning. Online training caters more easily to these different learning styles, allowing students to leave their desk for a break when required. The comfort of a remote learning environment also reduces distractions commonly found in a busy face-to-face environment like a classroom or training centre, helping students stay focused during classes.

Self-Paced Learning Unlike face-to-face learning, students can pause or replay a recording to understand a concept in full before moving on. This helps to break down any dense or complex course material. This self-paced learning technique means students can take their time to focus on any specific knowledge gaps and retain the knowledge at their own pace. For instance, Weld Australia’s online learning platform, Moodle, stores all recordings and other content for students to access around-the-clock. This gives students the opportunity to learn at their own pace and revise the pre-recorded material several times before an examination or hurdle task. The interactive nature of Moodle assures students of what work has been completed, and any upcoming requirements.

Greater Accessibility An online format makes training more accessible, particularly for people in remote and regional areas, who are unable to attend faceto-face courses. Remote learning also saves time and travel costs for students and their respective companies. This is particularly important for welders in rural and regional areas, who may have to commute to capital cities to undertake training. In addition, Weld Australia’s new online courses are run over a longer period of time, with only two lectures per week. This gives the students the opportunity to attend the course without having to take weeks’ worth of leave to attend each module. Live Lectures for Interactivity Weld Australia’s online training also includes live lectures, which have a mandatory 90% attendance rate requirement. This combination of pre-recorded, self-paced learning and mandatory live lectures ensures that students still have the opportunity to interact with their peers and teacher in real-time. The live lectures provide the perfect opportunity for students to clarify any course materials or problems and ask questions. Further Information For further information about Weld Australia’s training courses or to enrol, visit https://portal. weldaustralia.com.au/coursetimetable or email: training@weldaustralia.com.au

Inside Weld Australia: Advanced Welder Training Centres

NSW Set to Pilot School Outreach Program Weld Australia is committed to ensuring that Australia develops and maintains a world-class, modern welding workforce. To facilitate this, greater engagement in STEM skills to attract and retain younger talent is essential. The newly launched New South Wales Advanced Manufacturing School Outreach Program is designed to help excite and inform the next generation of Australian welders.

The welding industry is facing a severe shortage of skilled, qualified welders. According to a recent employment outlook survey, skilled trades workers such as welders are scarce. This skills shortage is compounded by a rapidly ageing welding workforce, with approximately 30% of Australia’s existing welding workforce aged over 45 years. Attracting and retaining younger talent through exciting and informative STEM training is a major way to combat this looming severe skills shortage. According to Michael Pitt (National Manager Education and Training, Weld Australia), “Weld Australia is committed to ensuring that Australia develops and maintains a worldclass, modern welding workforce. To facilitate this, greater engagement in STEM skills and emerging technologies by our high school students is essential.” “As such, Weld Australia proposed the establishment of an Advanced Manufacturing School Outreach Program to the New South Wales State Government,” said Pitt. The Program received support from the New South Wales Government, with funding provided through the Department of Education’s Vocational Education and Training Program for Secondary Students. Phase one of the Program has funded 16 schools across the state, from the Wagga Wagga, Lake Illawarra and Dapto high schools in southern New South Wales, through to the Gorokan and Kurri Kurri High Schools in the Lower Hunter region.

About the Program “Based around core advanced welding technology, the Program is designed to excite and inform high school students about the wide range of opportunities available in industry,” said Pitt. “The Program is designed to not only showcase welding, but to demonstrate the possibilities made available by modern, advanced software and systems. It has a complete STEM application, and demonstrates how advanced technology fits into modern manufacturing,” said Pitt. Students who participate in the Program will have access to augmented reality welding simulators for the first time, allowing them to fast track and maintain their welding skills in a completely safe environment.

The training delivered with the augmented reality welding simulators is student-focused, allowing individuals to progress at their own pace. Welding apprentices learn and understand procedures and techniques through a more interactive training method, gaining hands-on experience in a controlled, safe environment. With zero risks involved, students can respond to realistic scenarios without pressure or fear of injury. The new augmented reality training welding systems will support the introduction of the new NESA Stage Six Manufacturing and Engineering course to deliver the MEM10119 Certificate I in Engineering and a Statement of Attainment towards MEM20413 Certificate II in Engineering Pathways.

“

Weld Australia is committed to ensuring that Australia develops and maintains a world-class, modern welding workforce. To facilitate this, greater engagement in emerging technical and learning technologies is essential.”

Australian Welding: September 2020

Member Directory Weld Australia is dedicated to providing members with a competitive advantage through access to industry, research, education, government, and the wider welding community. When you join Weld Australia, you become part of a network of engaged companies and individuals, with which you can share technology transfer, best practices, and professional opportunities. For further information, please contact membership@weldaustralia.com.au or +61 2 8748 0100.

Weld Australia Industry Group Members Weld Australia hosts and administers several Industry Groups, providing a forum for technology transfer and R&D, linking members with industry and research organisations. The Weld Australia Industry Groups: represent a source of vital technical welding information; optimise welding practices through standard development and tools; and assist members to prepare specifications. AGL Energy www.agl.com.au 131 245 customer.solutions@agl.com.au

Transport and Main Roads (Queensland) www.tmr.qld.gov.au +61 7 3066 6358 TMRStructuralMaterials@tmr.qld.gov.au

ANSTO www.ansto.gov.au +61 2 9717 3111 enquiries@ansto.gov.au

Navantia Australia www.navantia.com.au +61 2 6269 5900 navantia.australia@navantia.es

ASC www.asc.com.au +61 8 8348 7000 David.Price@asc.com.au

NRG Gladstone Operating Service www.nrggos.com.au +61 7 4976 5211 cmcguinn@nrggos.com.au

Ausgrid www.ausgrid.com.au +61 2 4951 9555 cchiodi@ausgrid.com.au

Stanwell Corporation www.stanwell.com 1800 300 351 www.stanwell.com/contact-us

Austal www.austal.com +61 8 9410 1111 info@austal.com

Synergy www.synergy.net.au +61 8 9781 6720 Doug.Harman@synergy.net.au

CB&I www.cbi.com +61 8 9324 5555 www.cbi.com/contact

Thales Australia www.thalesgroup.com +61 2 8037 6000 MaritimeBusinessSupport@thalesgroup.com.au

CS Energy www.csenergy.com.au +61 7 3854 7777 energyinfo@csenergy.com.au

Transport for NSW www.transport.nsw.gov.au +61 2 8202 2200 stakeholder.relations@transport.nsw.gov.au

Energy Australia www.energyaustralia.com.au 133 466 Wayne.Hill@energyaustraliansw.com.au

Vales Point Power Station (Delta) www.de.com.au +61 2 4352 6111 info@de.com.au

LYB Operation & Maintenance Loy Yang B Power Station www.loyyangb.com.au +61 3 77 2000 contactus@loyyangb.com

VicRoads www.vicroads.vic.gov.au +61 3 8391 3216 vicroadstechnicalservices@roads.vic.gov.au

Inside Weld Australia: Member Directory

Premium Corporate Members ALS Industrial www.alsglobal.com/au +61 2 4922 2400 powerservices@alsglobal.com

Coregas http://coregas.com.au +61 2 9794 2222 info@coregas.com

QENOS www.qenos.com +61 3 9258 7333 enquiry@qenos.com

Applied Ultrasonics Australia www.appliedultrasonics.com.au +61 2 9986 2133 info@appliedultrasonics.com.au

Hardchrome Engineering www.hardchrome.com.au +61 3 9561 9555 office@hardchrome.com.au

Quest Integrity Group www.questintegrity.com +61 7 5507 7900 Info-APAC@questintegrity.com

Baker & Provan www.bakerprovan.com.au +61 2 8801 9000 info@bakerprovan.com.au

HRL Technology Group www.hrlt.com.au 1800 475 832 info@hrl.com.au

Tronox Management www.tronox.com +61 8 9411 1444 info@tronox.com

BOC www.boc-limited.com.au +61 2 8874 4400 contact@boc.com

Lincoln Electric www.lincolnelectric.com +61 2 9772 7222 sales@lincolnelectric.com.au

UGL Pty Limited www.ugllimited.com +61 2 8925 8925 uglinfo@ugllimited.com

Callidus Welding Solutions http://callidusgroup.com.au +61 8 6241 0799 info@callidusgroup.com.au

LMATS http://lmats.com.au +61 8 9200 2231 admin@lmats.com.au

Welding Industries of Australia (WIA) www.welding.com.au 1300 300 884 info@welding.com.au

CIGWELD www.cigweld.com.au 1300 654 674 enquiries@cigweld.com.au

Main Roads Western Australia www.mainroads.wa.gov.au 138 138 enquiries@mainroads.wa.gov.au

Wilmar Sugar www.wilmarsugarmills.com.au +61 7 4722 1972 info@wilmar.com.au

Join Weld Australia Today. Help Secure the Future of

Australian Welding +61 2 8748 0100

membership@weldaustralia.com.au

www.weldaustralia.com.au

Corporate Members 3M Australia: 3m.com.au A & B Welding: abwelding.com.au A&G Engineering: agengineering.com.au Abrasion Resistant Materials: arm.com.au Able Industries Engineering: ableind.com.au Adept Inspections & Training: adeptengineering.com.au Aerison: aerison.com AF Gason: gason.com.au Aitken Welding: aitkenwelding.com Ancon Building Products: ancon.com.au Antec Group: antec.com.au ARL Laboratory Services: arllabservices.com.au ATTAR: attar.com.au Austal: austal.com Austedan Fabrications: austedan.com.au Austin Engineering: austineng.com Austral: australtechnologies.com.au Australian Rail Track Corporation: artc.com.au Australian Welding Supplies: awsi.com.au AWS Centre of Excellence: australianweldingsolutions.com.au BAE Systems: baesystems.com Barker Hume Homes: N/A Baxter Institute: baxter.vic.edu.au Ben Baden Services: craneconnection.com.au Berg Engineering: bergengineering.com.au Bisalloy Steels: bisalloy.com.au BlueScope Steel: bluescopesteel.com.au BMC Welding: bmcgroup.com.au Bombardier Transportation: bombardier.com/en/transportation.html Bossong Engineering: bossong.com.au Bradken: bradken.com Brezac Constructions: brezac.com.au Broadspectrum: broadspectrum.com Brosco Enterprises: brosco.com.au Browns Precision Welding: brownswelding.com.au Brunton Engineering & Construction: brunteng.com Caltex Refineries (QLD): caltex.com.au Catten Industries: catten.com.au CCR Group: ccrgroup.com.au Chess Engineering: chessindustries.com.au CPT Engineering: cptengineering.com.au CQ Field Mining Services: cqfma.com.au CQ Steel Industries: cqsteel.com.au Crisp Bros Haywards: haywards-steel.com Cruisemaster Australia: cruisemaster.com.au Cullen Steel: cullensteel.com.au D&L Engineering Services: fabinox.com.au DGH Engineering: dghengineering.com.au

Australian Australian Welding: Welding: September June 2020 2020

Diverse Welding: diversewelding.com.au DJM Fabrications: djmfab.com DT Hiload Australia: dthiload.com Edcon Steel: edconsteel.com.au Engineering Welding and Inspection Services Excel Marine: excelmarine.net.au Extrin: extrin.com.au FIELD Engineers: fieldengineers.com.au Flexco: flexco.com.au Fortress Systems: fortressresistors.com Foxheat: foxheat.com Frontline Manufacturing: frontlinemanufacturing.com.au Furphy Engineering: furphys.com.au G & G Mining Fabrication: ggminingfab.com Global Manufacturing Group: gmqld.com.au Hamilton Maintenance Group Hanlon Industries: hanlonindustries.com.au HEQ Diesel and Gas: heq.net.au Hilton Manufacturing: hiltonmanufacturing.com.au HVAC Queensland: hvac.com.au Industrial Installation & Maintenance: iimaust.com.au Incat Tasmania: incat.com.au Ingal EPS: ingaleps.com.au IRISndt Australia: irisndt.com ISM Manufacturing: ismmanufacturing.com.au Jacmor Engineering: jacmor.com.au JB Specialised Engineering: jordbellows.com.au JRâ&#x20AC;&#x2122;s Marine Engineering: jrsgroup.com.au JVA Engineering: jvaengineering.com.au Kangaroo Training Institute: kangarootraininginstitute.com.au KAW Engineering: kawengineering.com.au Kenro Products: kenrometal.com.au Keppel Prince Engineering: keppelprince.com Keyhole TIG: www.k-tig.com Knox Engineering: knoxeng.com LA Services: la.services LaserBond: laserbond.com.au Lendlease: lendlease.com/au Loclur Engineering: loclur.com.au Lorch South Pacific: lorch.eu/en LSW Group: lswgroup.com.au Lucky Strike Welding MacFab Engineering: macfab.com.au Mainetec: mainetec.com.au MaxiTRANS: maxitrans.com MC Quality Control: mcqualitycontrol.com Mechanical Maintenance Solutions: mms.auz.net Mechanical Testing Services: N/A Melco Engineering: melcoeng.com.au Midway Metals: midwaymetals.com.au Millmerran: intergen.com Monadelphous Group: monadelphous.com.au Monash University: monash.edu Mudgee Engineering & Fabrication:

mudgeeengineering.com.au NEPEAN Engineering & Innovation: nepeanengineering.com.au Newmont Asia Pacific: newmont.com Nix Engineering Group: nixengineering.com.au Obadare: obadare.com.au Orrcon Manufacturing: orrconsteel.com.au OSD Pipelines: osdlimited.com Outsource Institute: outsourceinstitute.com.au Precision Metal Group Aust: precisionmetalgroup.com QSM Fabrication: qsmfabrication.com.au Quality Process Services: qpspl.com.au Queensland Nitrates Plant: N/A Radio Frequency Systems: rfsworld.com RJB Industries: rjb-industries.com Robert Vernon: N/A Robot Technologies-Systems Australia: robottechnologies.com.au Rockpress: rockpress.com.au RTM Engineering: rtmengineering.com.au Russell Mineral Equipment: rmeglobal.com S&L Steel: slsteel.com.au Samaras Group: samarasgroup.com Santos: santos.com Saunders International: saundersint.com Scaffstand: scaffstand.com.au SMW Group: smwgroup.com.au Smenco: smenco.com.au Snowy Hydro: snowyhydro.com.au South32 Temco: south32.net Southern Cross Industrial Supplies: scis.com.au SSS Manufacturing: sssmanufacturing.com Steel Mains: www.steelmains.com Structural Integrity Engineering: siepl.com.au SVSR: svsr.com.au SWA Water Australia: swawater.com.au Synergy Aluminum Towers: synergyaccessandscaffolding.com.au Taurus Mining Solutions: taurusminingsolutions.com The Bloomfield Group: bloomcoll.com.au The Shotton Group: shottongroup.com.au TEi Services: tei.com.au TICS: ticsndt.com Topline Steel Fabrications: N/A Trade and Investment NSW: industry.nsw.gov.au Uneek Bending: uneek.com.au United Pacific Engineering: unitedpacificeng.com Victorian Testing & Inspection Services: victesting.com.au Veolia: www.veolia.com/anz Walz Construction: walzgroup.biz Welding Equipment Sales and Service (WESS): wess.com.au Welding Guns of Australia: unimig.com.au WGASA: wga.com.au

Inside Weld Australia: Hotline Update

Enrol Now: Advanced Welder Training Courses Fusion Welding Courses There are two ISO 9606 Qualification test of welders — Fusion welding —Part 1: Steels courses listed on Training.gov.au, the National Register of Vocational Education and Training (VET) in Australia. This is the authoritative source of Nationally Recognised Training and Registered Training Organisations (RTOs). These courses were developed in Victoria in 2018. One is intended for inexperienced welders, the other for experienced welders. Both use augmented reality welding simulators as a key component of the training. Transition Workers To complete 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: • Simulate fusion welding processes using augmented reality equipment • Identify welding processes, safe welding practices and use of hand and power tools • Interpret and apply AS/NZS ISO 9606 for fusion welding processes • Perform fusion welding procedures to meet the procedures of ISO 9606-1 (Steels – carbon steels) Experienced Welders To complete 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. Elective Units Other elective units available include: • Perform fusion welding procedures to meet AS/NZS ISO 9606-1 (Steels – stainless steel) • Perform fusion welding procedures to meet AS/NZS ISO 9606-2 (Aluminium and aluminium alloys) • Perform fusion welding procedures to meet the requirements of AS/NZS ISO 9606-3, 4 or 5 (Exotic metals) • Perform routine manual metal arc welding • Perform routine gas metal arc welding • Perform manual heating and thermal cutting • Read and interpret technical drawings and make measurements for a welding procedure Further Information For further information, contact: +61 2 8748 0100, training@weldaustralia.com.au or weldaustralia.com.au.

Enrol in a Fusion Welding Course Today

You can enrol in a Fusion Welding course through any of the Advanced Welder Training Centres across Australia. These are all listed below. Queensland TAFE Queensland Caboolture Campus https://tafeqld.edu.au Tallon Street, Caboolture, Queensland TAFE Queensland SkillsTech https://tafeqld.edu.au 247 Bradman Street, Acacia Ridge, Queensland South Australia TAFE SA Regency Campus https://www.tafesa.edu.au 137 Days Road, Regency Park, South Australia Tasmania Tasmanian Minerals and Energy Council https://tasminerals.com.au 13 Wellington Street, Burnie, Tasmania Victoria Box Hill Institute https://www.boxhill.edu.au 465 Elgar Road, Box Hill, Melbourne, Victoria Bendigo TAFE http://www.bendigotafe.edu.au 23 Mundy Street, Bendigo, Victoria Federation University https://federation.edu.au Lydiard Street South, Ballarat, Victoria

Welding: September 2020 52 Weld Australia’sAustralian Innovative, Expert

Engineering and Advisory Services By taking advantage of Weld Australia’s engineering and advisory services, you have access to the peak industry body in Australia’s welding industry. Your commercial enterprise can access expert advice services, delivered by highly qualified welding engineers and materials specialists. Each member of the Weld Australia advisory team is an International Welding Engineer (IWE). This qualification, issued by the International Institute of Welding, is the highest postgraduate professional welding qualification available. Our consulting services can help you substantially increase the operational life of your plant and equipment, and reduce your maintenance and repair overheads. Our Areas of Expertise • • • • • • • •

Design and qualification of welded connections Review of structural and pressure vessel designs Drafting and review of design specifications Evaluation of materials and facilities Analysis and resolution of complex welding problems Design, development and project management of fabrication solutions Optimisation of maintenance for risk mitigation Comprehensive failure investigations and engineering critical assessments

Resources

• • • • • • • •

Advising of safety practices as they pertain to welding, cutting and joining Expert evidence and witnessing services Comprehensive failure investigations Inspection and testing services Welding quality management to ISO 3834 Pipeline in-service welding, repairs and hot tapping Specialised welding and associated technologies (laser, ultrasonic peening and underwater welding) R&D and application of technology

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+61 2 8748 0100 | office@weldaustralia.com.au | www.welaustralia.com.au | Building 3, Level 3, 20 Bridge Street, Pymble, NSW 2073

Australian Welding |September 2020

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