Australian Stainless #59

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WINTER 2017 Wynyard Walk, Sydney. Photo courtesy of Stoddart Australia.

This Edition Proudly Sponsored by Stoddart Australia.

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COVER STORY

Wynyard Walk: Where Beauty Meets Function

New Infrastructure in the heart of Sydney is set to transform busy transport hub and provide a stylish new gateway to the Barangaroo Development.

A growing population in Australia’s most populous city calls for innovative design, so when the NSW State Government commissioned construction of the Wynyard Walk ASSDA Sponsor and Accredited Fabricator Stoddart stepped up to the challenge.

The Wynyard Walk forms one of several solutions to break congestion in the Sydney CBD, allowing pedestrians to move from the Wynyard transport hub to the new development at Barangaroo waterfront in six minutes, avoiding steep hills, busy intersections and inclement weather events.

With an estimated 75,000 commuters using the busy hub every day, traffic flow is expected to increase to 110,000 over the next seven years in what is traditionally Sydney’s thirdbusiest station.

The tunnel will become the main arterial connection between Barangaroo and the city’s transport network and provides vital infrastructure into the future.

The Project Alongside CPB Contractors, Stoddart incorporated over 1,600m2 of perforated and solid stainless steel sheeting fabricated into ceiling and fascia panelling installed in the Clarence Street entrance facade and the tunnel lining. The new Clarence Street entry point is a multilevel portal descending to Wynyard Station via escalators and elevators.

ASSDA Sponsor Austral Wright supplied the project with over 50 tonnes of 445M2 grade stainless steel sheet.

A major consideration for the design team was to ensure asthetic value for commuters and visitors alike.

The Design Inspired by nature and Sydney region geology, the design concept for Wynyard Station focuses on flow, with all materials selected to create a sense of motion as part of a unified architectural expression.

The intricate patterns were all designed and executed within Stoddart’s factory in Karawatha, Brisbane. The design work was completed wholly on CAD and Solidworks to ensure each panel fitted exactly into the pattern and alongside adjacent panels. The Brisbane facility completed all aspects of the manufacture.

The external facade from Clarence Street to Wynyard Station was completed using perforated metal panels on the new access area via escalators and elevators down to the station several levels below.

The internal fitout, including the ceilings, walls and bulkheads, were all constructed from perforated stainless steel as well as solid stainless steel panels.

The complicated ceiling pattern proved challenging but not insurmountable, resulting in a beautiful floating effect beckoning commuters along.

This project signalled the completion of Stage One of a $160 million upgrade to Wynyard Station.

The Outcome The Kent Street level incorporates an extraordinary twenty-metre digital media screen which showcases flowing images of time, travel and places from all over Sydney throughout history, providing commuters with a far more entertaining commute than traditional toiletblock-tiled underground tunnels.

ASSDA MEMBER CONTACTS: FABRICATOR: Stoddart Matthew Roe, Marketing Executive P: +61 7 3440 7600 E: info@stoddart.com.au W: www.stoddart.com.au SUPPLIER: Austral Wright Metals Natasha Araullo, Sales Manager NSW P: +61 2 9827 0790 E: awm@australwright.com.au W: www.australwright.com.au

For tens of thousands of commuters who daily traverse the tunnel, Wynyard Walk is a time and energy saving alternative to the street level traffic roulette they once faced.

The added bonus is the stunning, aesthetically pleasing surrounds, the shiny panels and beautiful architecture, all of which was made possible by the use of stainless steel.

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Wynyard Walk, Sydney. Photo courtesy of Stoddart Australia.

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Aesthetic value for commuters and visitors was a key consideration for the design team.

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Photo courtesy of Stoddart Australia.

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Wave Disc, photo courtesy of Pinches Group.

Disc Dryers Get a Makeover

Wave Disc Revolutionises Traditional Drying Process

In the search to find a more efficient way of manufacturing industrial Disc Dryers for the meat-rendering industry, Melbourne-based engineering company Pinches Group has developed a new technology called Wave Disc.

The Challenge Traditional rotary disc dryers comprise of a series of stainless steel discs, welded back-to-back and attached to a centre pipe. Together, the pipe and discs make up the shaft, which operates under steam pressure and rotates within a stainless steel shell.

Employed throughout the world in a wide range of industries, disc dryers are commonly used to dry materials such as coal, sand, sludge, paper pulp and animal waste.

There are significant inefficiencies in the manufacturing of disc dryers: •

Discs are cut from industry standard rectangular plate, with the centres and corners of the donor material often wasted;

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Flat discs rely on pressure-welded pins for structural support.

A typical two-metre diameter disc requires ninety-six support pins pressure welded with full penetration on both sides of the disc. Pressure welds are not only labour intensive, but due to the proximity of discs within the drum they’re difficult to repair once the dryer is in operation.

ASSDA Member Pinches Group began investigating designs that could overcome the need for support pins and reduce raw material waste.

Rather than cutting the discs, Pinches discovered that using specific rectangular sections of material discs could be formed through a

series of folds along one edge of the plate. This enabled all supplied materials to be used in the formulation of the disc.

Benefits Because folds occur consistently and consecutively around the disc, the folds reinforce the structure of the discs and eliminate the need for added support.

Removing the pins not only improves manufacturing time, it eliminates the chance of weld failure around the support pins, which can cause equipment faults in traditional disc dryers.

Additionally, the natural waves of the discs provide increased agitation to drying material, which can improve evaporation rates.

One design flaw with flat discs is a tendency for product to stick and build up between discs. With Wave Disc, the waves in the disc massage the product and keep it moving within the drum, preventing build up and ensuring that all raw materials are exposed to heat.

Wave Disc also provides greater surface area. Any indirect drying processes (where the heat source doesn’t make direct contact with the product) is reliant on the surface area to transfer heat.

With the addition of the folds, Wave Disc provides a surface area at least thirteen per cent larger than conventional discs within the same footprint. This means that existing disc dryers can replace their current shaft with a Wave Disc shaft and increase the capacity of the dryer.

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Award Winning Design In 2012, the Wave Disc concept received top level funding from the Australian Federal Government’s Commercialisation Australia program.

In 2014, the first Wave Disc unit was installed at animal by-product processor, Australian Tallow in Brooklyn, Victoria. Since then, further units have been exported to by-product processors in New Zealand.

As Australia’s leading supplier of processing equipment to the animal rendering industry, Pinches Group developed Wave Disc to overcome specific inefficiencies within the meat processing industry.

Now that this innovative new technology has been tested and proven in the rendering industry Pinches has plans to expand their focus to heating and cooling processing technologies in the food and agricultural sector.

Pinches Group own and operate a testing facility in Melbourne which incorporates an operational Wave Disc pilot unit used by prospective clients and educational institutions for running trials on a range of raw materials.

Wave Disc, photo courtesy of Pinches Group.

ASSDA MEMBER CONTACTS: Pinches Group David Pinches, Managing Director P: + 61 3 9460 2466 E: pci@pinches.com.au W: www.pinches.com.au

Among other metrics, the pilot units can provide clients with evaporation rates and in-and-out moisture levels for specific products.

Midway Metals

Patent

P: +61 7 3382 9500

The Wave Disc design is protected by Provisional Patent Number 593495.

E: gregh@midwaymetals.com.au

Greg Hinder, Manager

W: midwaymetals.com.au Vulcan Steel Stephen Orridge, Director P: +61 3 9238 7100 E: stephen.orridge@vulcansteel.com.au W: www.vulcansteel.com.au

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Significant inefficiencies in current manufacturing called for a creative solution.

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FEATURE

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K-TIG: A Quantum Leap for Welding

FEATURE

Innovative Design Set to Transform the Industry

For the past six decades the welding process has only been tweaked and modified but one Adelaide company has developed a new process set to save millions of dollars and change the way welds are performed.

Development In 2000, Dr Laurie Jarvis and his associates at CSIRO Adelaide studied the effect of surface tension within an active weld. It was noted that under certain conditions, namely narrow gaps and increased process conditions, that far greater speeds could be obtained when welding clean materials.

The team developed a brand new process involving a high speed, single pass, full penetration welding technology that significantly reduces the need for wire or edge bevelling and is not required where autogenous welds are acceptable.

The result is a flawless finish at a speed up to 100 times faster than TIG welding in materials up to 16mm in thickness.

By definition, clean materials include stainless steels, nickel alloys, titanium and zirconium. Other materials with higher impurities (such as alloy steels) cause the weld arc to become unstable and the process becomes unmanageable.

Next Step

The K-TIG process involves a specially controlled high current arc which opens a full penetration keyhole in the joint between the two welding surfaces.

Featuring extremely high stability and operating over a wide range of welding currents, K-TIG looks set to become the next big thing in fabrication.

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A flawless finish, high stability, reduced energy consumption.

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With Dr Jarvis as technical leader, a group of experienced materials experts formed K-TIG. Today K-TIG has progressed into many world markets with the system, winning a number of awards along the way.

Since its inception, K-TIG has achieved enormous growth in the market, with the technology being exported to eighteen countries and customers using stainless steels are typically saving 90% on production costs.

The Process The process ideally suits non-corrosive and exotic materials with a thickness range of 3mm to 16mm for single pass welding, however thicker metals can be welded by multiple passes.

K-TIG easily handles the traditionally difficult material, Super Duplex.

As for energy consumption, K-TIG consumes as little as 5% of the energy and gas consumed by TIG/GTAW for the same weld, dramatically reducing its carbon footprint.

A typical K-TIG weld is performed in a fraction of the time of a conventional weld, in a single full-penetration pass using just one welding gas.

The resulting weld is without multiple fusion lines, dramatically reducing the potential for inclusions, porosity and other defects typical of many welding processes.

The K-TIG system can monitor and control the addition of wire to a weld if that is desirable.

ASSDA MEMBER/ACCREDITED FABRICATOR CONTACTS: K-TIG C: Neil Le Quesne, CEO & Executive Director P: +61 8 7324 6800 E: sales-enquiry@k-tig.com W: www.k-tig.com Photo courtesy of K-TIG. 6 AUSTRALIAN STAINLESS 59 www.assda.asn.au AS59 Working Copy.indd 6

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INDUSTRY UPDATE

Accreditation: Raising the Bar Why an Industry Standard is Vital to Our Future

Self-regulation is a dangerous game in any industry but for fabricators of stainless steel products it can be particularly difficult.

What does ASSDA Accreditation do?

What does this mean for you?

ASSDA has developed an Accreditation scheme which sets an industry standard and benefits both accredited fabricators and end users in the following ways:

In 2017, ASSDA will be expanding the Accreditation program.

Government organisations and larger scale businesses will be encouraged to consider adopting ASSDA Accreditation standards for projects, both large and small.

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Accreditation Raises the Bar: In an industry where there are a range of often conflicting ideals, ASSDA provides a vital service in setting standards with a Code of Ethics and Code of Practice that adheres to stringent standards of competence, training, education and conduct;

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Accreditation Protects the End User: Clients can be assured that their product has been manufactured to the highest standard, minimising corrosion and other common faults;

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Accreditation Elevates Your Business: An ASSDA Accredited business leads its peers by building a reputation for excellence and purity of product while being recognised by various regulatory bodies.

For businesses who choose ASSDA Accreditation, new opportunities will flow; job tenders, projects and a level of excellence that brings respect across the industry.

For Accredited businesses, this will mean: •

New opportunities to quote for projects and jobs that might otherwise be out of reach;

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The distinction of becoming a Best Practice business in an industry where it can sometimes be difficult to distinguish one fabricator from another.

ASSDA Accreditation is separate from ASSDA membership. The program requires businesses to renew their accreditation annually with site inspections and questionnaires part of the initial process.

If you would like to join the growing number of ASSDA-Accredited Fabricators contact Trent Mackenzie (General Manager) for more information.

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ABOUT ASSDA The Australian Stainless Steel Development Association (ASSDA) is a peak industry body dedicated to the promotion of stainless steel, building businesses and training and support for its Members and Associates.

Among our vibrant community of businesses are distributors and suppliers, fabricators, engineering consultants, council and government bodies, overseas mills, end-users and service providers.

• We offer a variety of services, including: • Accreditation Program (Fabricators); • Technical Helpline;

ASSDA Inaugural Awards One of the highlights of ASSDA’s 2017 PacRim Conference will undoubtedly be the inaugural annual Supplier and Fabricator Awards. This year three categories will be recognised: 1.

ASSDA Flat Products Supplier of the Year;

2.

ASSDA Long Products Supplier of the Year;

3.

ASSDA Fabricator Project of the Year.

• Online Training (Webinars, Stainless Steel Specialist Course); • Industry Reference Manual; • Quarterly Import Statistics (Sponsor Members).

Contact the office for all enquiries about membership or any of our programmes. a: 16/324 Queen St, Brisbane Q 4000

Nominees will be announced on 15 August 2017, with the awards presented at the PacRim Gala Dinner.

We are expecting that all nominees for these prestigous awards will attend the PacRim Conference on 11 and 12 October 2017 at QT on the Gold Coast.

p: +61 7 3063 0462 e: assda@assda.asn.au w: www.assda.asn.au

From the General Manager ASSDA General Manager Trent Mackenzie is looking forward to growing the Association under the direction of the Board.

‘For me, it’s all about the members,’ said Mr Mackenzie. ‘I am looking forward to bringing value to our members.’

On 1 June 2017 the Board assumed responsibility for running the Association. A new office has been established in the heart of Brisbane.

Along with traditional offerings to members, such as Australian Stainless Magazine, Accreditation, Industry Updates, conferences and training, ASSDA will be expanding its reach to include advocacy, policy and standards development.

ASSDA members have had their projects published in worldwide forums, from ISSF to World Stainless, and that will continue to grow as the Association expands its reach in an ever-changing industry.

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I’m looking forward to bringing value to our members.

ASSDA SPONSORS 1

ASSDA SPONSORS 2 Midway Metals, Stoddart Manufacturing, Viraj Profiles Ltd., YC Inox Co., Ltd.

ASSDA SPONSORS 3 Austral Wright Metals, Australian Stainless Distributors Pty. Ltd., Chinh-Hann Industries Co., Ltd., Dalsteel Metals Pty. Ltd., Daming International Import & Export Co. Ltd., Froch Enterprise Co. Ltd., Global Stainless Steel Inc., Metal Centre Australia, Prochem Pipeline Products Pty. Ltd., SANWA Pty. Ltd., Yue-Seng Industrial Co., Ltd..

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

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