Australian Stainless #68

AUSTRALIAN STAINLESS Specialising in stainless steel and its applications

MURRAY FREDERICKS PHOTOGRAPHY

ISSUE 68 2020

FEATURE

Stainless steel makes an entrance A collaboration between ASSDA Members using ‘gold’ stainless steel has delivered the epitome of opulent luxury at The Star Sydney.

The Star Sydney’s multi-million-dollar transformation has seen its Pyrmont Street entrance revolutionise the guest arrival experience, with a porte-cochère facing the glittering Darling Harbour and a refurbished Grand Foyer combining innovative architecture, contemporary art and technology.

Over 4000m2 of grade 316 stainless steel with a gold finish is featured throughout the Grand Foyer and portecochère, enriching the luxurious look and feel of the integrated resort. ASSDA Member Steel Color Australia supplied 1mm and 1.2mm thick stainless steel sheet in various lengths from 2400mm to 3500mm and widths of 1219mm

to 1500mm as the sole distributor in Australia and New Zealand for embossed, coloured, mirror finished and textured stainless steel manufactured by Steel Color S.p.a in Italy.

The stainless steel’s gold colour was achieved with a titanium film using a Physical Vapour Deposition (PVD) coating process. The environmentally-friendly method vapourises titanium in a vacuum chamber to form an extremely thin layer that bonds to the steel’s surface. The process also improves the performance of the steel, increasing durability and resistance to heat, light, abrasion, scratches and corrosion.

In addition, the steel’s surface features an anti-fingerprint (AFP) coating preventing oil and finger marks, contributing to a sleek aesthetic finish with minimal maintenance. The AFP coating provides the titanium coating with a firmer colour finish, strengthening colour stability and extending the service life of the application.

Suitable for internal and external applications, coloured stainless steel can be used in many design forms and was specified for the bespoke luxurious features in The Star Sydney’s Grand Foyer and porte-cochère.

MURRAY FREDERICKS PHOTOGRAPHY

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The Steel Color Australia supplied stainless steel sheeting was installed in the Grand Foyer and internal porte-cochère by ASSDA Member Karisma Joinery, across the door portals, elevator door jambs and ceiling panels, columns and wall panels. A V-Groove machine was used to form precise, sharp angles and folds, creating architectural profiles to achieve a seamless upmarket finish and meet the high-end specification.

The stainless steel clad elements for the external porte-cochère, including luxury retailer finishes for Gucci, was fabricated and installed by ASSDA Member Fabmetal Specialists. All

profiles and clad elements were fabricated at their workshop in Melbourne, using an in-house V-Groove machine to achieve a crisp bend profile, prior to installation on-site by the Fabmetal team. A split batten system was used to clad the stainless steel elements across the retail façade fixtures, window mullions, headers and kickers. The Fabmetal team were also tasked to clad the revolving doors and overcame challenges with complex curved works, laminating gold stainless steel on to curved fabricated T-sections in powder-coated aluminium to create a striking two-tone effect.

In a nod to architectural innovation, The Star Sydney will continue to welcome and awe its guests with its everlasting stainless steel gleam and elegance.

ASSDA MEMBER CONTACTS Fabmetal Specialists \ Gordon Heald, Director, gordon@fabmetal.com.au \ Clinton Truong, Project Coordinator, clinton@fabmetal.com.au 03 9720 2177 \ fabmetal.com.au Karisma Joinery \ Joseph Zarantonello \ 02 9624 7733 \ contactus@karisma.com.au \ karisma.com.au Steel Color Australia \ Vince Araullo \ 0488 249 999 \ vince@steelcolor.com.au \ steelcolor.com.au

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MURRAY FREDERICKS PHOTOGRAPHY

ART & DESIGN

Stainless steel behind high-tech visual art Australian designed and manufactured stainless steel wedge wire grating has been instrumental in delivering ‘Aquatique’, the first sculptural water installation of its design in the Southern Hemisphere.

The Star Sydney’s Grand Foyer has been transformed as part of an $850 million redevelopment for the integrated resort. A unique immersive visual experience is now welcoming guests in a masterfully choreographed interplay of light, water, digital art and live performance.

The key elements of the installation include an 8K resolution, 25m wide crescent-shaped digital screen, laser light shows and ‘Aquatique’, a cascading sculptural water feature spanning 8m with a 2m diameter centre stage.

Central to the design and function of the sculptural water feature is the use of Australian designed and manufactured stainless steel wedge wire by ASSDA Member and Accredited Fabricator, Paige Stainless.

PAIGE STAINLESS HEELGUARD® is at the cutting edge of water drainage technology, offering continuous drainage through its 5mm aperture and high-water volume intake and removal efficiency. The water feature was designed with a throughput capacity of 30,000L, with water being pumped up to 15m vertically to the water feature jets, recirculated through the PAIGE STAINLESS HEELGUARD® and reused whilst the water feature is in operation. The key was to minimise water splash during the process with PAIGE STAINLESS HEELGUARD® delivering the brief through its unique wedge design. In addition, stainless steel is an excellent material choice for water drainage technology, offering durability, aesthetics and ease-of-cleaning during maintenance inspections.

Paige Stainless’ project scope also included the design, fabrication and installation of the water collection tank, substructure for the grating PAIGE STAINLESS HEELGUARD® and centre stage area within the water feature. Over 3.5 tonnes of grade 316 stainless steel was supplied for the project by ASSDA Members Austral Wright Metals and Midway Metals, including 4mm thick plate and rectangular hollow sections.

The water feature body was manufactured at Paige Stainless’ manufacturing facility in Caboolture, Queensland, and fabricated in 14 components for ease of interstate transportation logistics, efficient installation and maintenance.

Delivery and installation logistics were a focal point of the design as The Star Sydney was fully operational and open to the public during installation. Provisions were made for specific delivery times and material management to make for a successful, non-disruptive transition from truck to site. Careful planning and design resulted in minimal on-site welding and passivation treatment using citric acid by the Paige Stainless installation team.

The water feature uses 100% recycled water. Its sculptural display is complemented by a theatrical light show and digital art canvas inspired by Australian artists, cinematographers and animators.

As the world’s largest permanent multi-sensory art experience, the Grand Foyer at The Star Sydney is a visual feast entertaining an average 30,000 guests per day.

ASSDA MEMBER CONTACTS Austral Wright Metals \ Natasha Araullo, Sydney Service Centre Manager \ 02 9827 0790 \ natasha.araullo@australwright.com.au \ australwright.com.au Midway Metals \ Craig Wallace, Brisbane Branch Manager \ 07 3382 9500 \ craigw@midwaymetals.com.au \ midwaymetals.com.au Paige Stainless \ Kevin Finn, Director \ 07 5499 1511 \ kevin@paigestainless.com.au \ paigestainless.com.au 4 – Australian Stainless Issue 68

SCIENCE

SABRE Veto Vessel A scientific quest to search for dark matter has led to the opportunity for ASSDA Member and Accredited Fabricator Tasweld Engineering to fabricate a specialised stainless steel tank, known as SABRE (Sodium Iodide with Active Background Rejection) Veto Vessel to help facilitate Australian research into answering one of the universe’s unsolved mysteries.

The University of Melbourne received $5 million in federal funding to build the Stawell Underground Physics Laboratory (SUPL) in an unused gold mine in Western Victoria. The facility will house the SABRE Veto Vessel, shielding it from astrophysical particles and enabling a range of experiments to be undertaken to determine the existence of dark matter, a form of matter that does not directly interact with light.

Dark matter is by its nature, extremely hard to detect. The SUPL location is approximately 1km underground to use the earth’s shield to screen out astrophysical particles, background noise and environmental factors that interfere with signals from dark matter.

The SABRE Veto Vessel was designed by the University of Melbourne in conjunction with FE Consulting Design Engineers and Tasweld Engineering.

To deliver the best probabilities for experimental success, grade 304 stainless steel was used for the vessel’s manufacture. In addition to the material’s durability, cleanability and corrosion resistance, stainless steel was specified most importantly for a specific property; low radioactive content.

The presence of certain radionuclides negatively affects the detection experiments, and therefore sourcing material with low radio emissivity was critical. The stainless steel plate was imported from a supplier in Germany

with experience in this application and involved stringent validation testing.

The vessel took 600 manhours and was manufactured at Tasweld Engineering’s Warrnambool workshop to AS 1210 standards with rigorous equipment and welding processes applied to prevent material contamination. All welding was carried out using a TIG process with lanthanated tungsten electrodes, and all consumables were new to avoid cross contamination. The 2.6m tall, 1800kg vessel features access ports for electrical and other connections.

Stainless steel plays vital role in Australian research

The SABRE Veto Vessel was completed in October 2019 and has been temporarily installed in a laboratory at Swinburne University of Technology’s Wantirna Campus for preliminary testing while the SUPL is being constructed. For the next stage of the project, Tasweld Engineering have been contracted to manufacture an additional flange assembly to allow the use of different attachments during various experiments.

Tasweld Engineering’s expertise and superior workmanship, and the use of stainless steel, has delivered a positive contribution to science in a quest to unlock the mystery of dark matter and to a research facility that aims to conduct better quality experiments, including the effects of radiation in cancer cells.

ASSDA MEMBER CONTACT Tasweld Engineering \ Richard Parkinson, Director \ 03 5564 6700 \ richard.parkinson@tasweld-eng.com.au \ tasweldengineering.com.au 5 – Australian Stainless Issue 68

TECHNICAL

AS 1528:2019 A NEW EDITION PITCHED AT FOOD SAFETY, CONSISTENCY, USEABILITY AND CURRENT PRACTICE

The aim of AS 1528: Stainless steel tubes and tube fittings for food processing and hygienic applications is to standardise hygienic tube and fittings for use in dairy, food and beverage manufacturing. It has been successful in maintaining the required food safety standards in Australia and New Zealand.

AS 1528 was first issued in 2001 and developed by an ASSDA group of stakeholders in the manufacture, supply, fabrication and use of stainless steel tube and associated fittings in the food manufacturing industries.

Changing industry practice, some existing errors, internal consistencies and expansion of sizes required a revision of the standard. The drafting journey to bring AS 1528 up-to-date began in 2015 and has been a challenge, but its successful outcome is significant for the industry and a testament to everyone involved.

The new edition of AS 1528 was published in four parts by Standards Australia in October 2019: Part 1

Tubes

Part 2

Screwed tube couplings

Part 3

Butt weld tube fittings

Part 4

Clamp tube fittings

The revision of the AS 1528 suite of standards from the 2001 edition has brought the documents’ technical coverage up to current practice and recognised the target industries in which hygienic tube is used. The suite is easier to understand and use, and facilitates verification of product compliance so that it achieves the required hygienic conditions.

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What the revision achieved The 2019 edition achieved all of the original aims, except one (see below). The suite of four standards now presents as a consistent coverage of all the tube and fittings regularly supplied in Australia.

1. Addition of a consistent set of pressure ratings across all parts of AS 1528. Useful for designers.

2. The wall thickness tolerance for tube has been changed.

Previously it was +nil/-0.10mm for all sizes of tube.

Widening it out to ±10% brings it into line with most other tube specifications and makes it more economical to manufacture without compromising product quality.

It also then matches the tolerances of the fittings in other parts.

3. The title now includes ‘hygienic applications’ in addition to food processing. This recognises the wider range of applications in which these products are already used.

4. The reference to duplex stainless steels has been removed. In practice all tube and fittings referenced by these standards are austenitic.

5. All tube and fittings can be produced without grit polishing the internal surface. Internal surface finish is specified by measurable roughness for hygiene and cleanability.

6. Inner tube surface roughness has been set as 0.8µm Ra maximum; this is consistent across all four parts of the standard and is also consistent with US and European specifications. From a cleanability perspective this is adequate. In addition there is now a specified maximum roughness for the inner weld bead, specified as ‘Rt’. This is an unusual specification but it does address directly the requirement for cleanability of the remnant weld line.

7. For the first time there is a stated limit for inner weld surface heat tint (no more than Level 3 in AWS D18.1M, commonly referred to as ‘pale straw’). Again this aligns with US and European standards and much research work promoted by ASSDA and others.

8. Consistent working pressures and temperature ranges have been given for all tube and fittings, with the exception of clamp fittings above 152.4mm.

9. The range of sizes has been expanded generally up to 304.8mm or 12” diameter, but lesser maximum sizes for certain fittings, depending on market availability. Smaller diameter tubes have also been included as these have some niche applications. Additional wall thicknesses have been added. It is not anticipated that there will be a sudden move away from the usual 1.60mm WT and the common OD range, but there were some industry requests for the expanded size range.

10. Part 2 covering screwed couplings has been completely re-structured. The two fundamental types – RJT and IDF / Trapezoidal – are clearly separated, with all dimensional specifications included in Sections 2 and 3. Section 1 deals with the requirements common to both types.

11. Fittings not previously recognised have now been included. This includes both an RJT blank hexagonal nut and an IDF blank cap in screwed couplings (AS 1528 Part 2). Butt weld fittings (Part 3) has addition of crosses, equal radius tees and 45 degree tees. In clamp fittings (Part 4) an end cap has now been included.

12. The branch lengths of reducing tees and crosses (Part 3) have been clarified. The previous edition gave a specification for this dimension that was in some cases contradictory and in all cases confusing. The new requirement is that the branch length, measured as the extension beyond the run surface, is the same as the branch OD. 13. Reducers, both concentric and eccentric (Part 3), now include the option of a short extension to enable orbital welding.

14. Reducers are now standardised as ‘short reducers’, with the ‘full flow’ reducers still specified but in the absence of request the standard type is short.

15. New appendices in Part 4 cover a very useful description of clamp conditions for correct installation (App C), specification of grooves for expanded-type clamp liners (App D) and the method for expanding (App E).

16. Correction of a long list of typos and inconsistencies in dimensions.

What was not achieved The New Zealand market is already using AS 1528 and keen to have it branded as their own, but early discussions between the committee, Standards Australia and Standards New Zealand revealed that the cost imposed by Standards Australia to make the project a joint cross-Tasman effort was prohibitive. As a result, the project became simply Australian, but the committee was able to co-opt a New Zealand member, and a tube manufacturer active in both Australia and New Zealand was also included as a Drafting Leader. The project therefore included New Zealand input, even though the document is branded Australian. The committee was mindful that there is substantial cross-Tasman movement of tube and fittings, of manufactured processing equipment, of engineering expertise and of food product, so joint output was essential to maximise all-round benefits.

Why this revision was important The AS 1528 suite is the only fully integrated set of standards to Australian industry’s traditional dimensions for stainless steel tube and tube fittings for hygienic applications.

The Australian food manufacturing industry is critical both because of our high standards for domestic consumption and also as a very significant export earner. Australia has a clean and green reputation that only thrives if we can guarantee freedom from contamination.

All the commonly used and some niche tube and fitting products are now covered and all are consistent.

Food manufacturing plant is getting bigger, so this edition includes provision for larger size tube and fittings. The applications are also increasingly diverse, so an expanded range of products is appropriate.

This revision presents manufacturers of tube and fittings with a clear, consistent and measurable standard for these critical products. The standard offers a pathway to economical outcomes for tube and fitting manufacturers, designers, installers and asset owners.

This article was written by Technical Consultant and AS 1528 Committee Chairman, Peter Moore.

Australian Stainless Reference Manual 2020 EDITION 8 OUT NOW!

Exceptional corrosion resistance, durability, sleek good looks and complete recyclability: These features combined have made stainless steel a popular material for industrial and domestic applications worldwide.

As the use of stainless steel in existing applications grow, so too does the range of new applications where stainless steel is proving to be the material of choice in even the most demanding environments.

So, why stainless?

ASSDA’s Australian Stainless Reference Manual is an industry guide and comprehensive resource providing both basic and advanced information on stainless steel.

The 232-page Manual opens with a useful introduction to the material, contains a COSTS

wealth of technical information, guidance on relevant national and international standards, an extensive glossary of stainless steel terminology and a full listing of ASSDA Members, Accredited Fabricators and their services.

Technical sections of the Manual include: • Properties and performance • Grade selection • Surface finishes • Design • Fabrication • Product specifications • Conversion tables A well-respected industry publication, the Australian Stainless Reference Manual has assisted specifiers, fabricators and end-users of stainless steel for over two decades. Currently being published a minimum of every five years, the Manual is an essential guide for anyone connected with the building, manufacturing and design industries.

Contact ASSDA to order your copy +61 7 3220 0722 assda@assda.asn.au assda.asn.au

Book or PDF: $85 ASSDA Members / $160 Non-Members Book and PDF: $100 ASSDA Members / $175 Non-Members *Postage and handling additional.

PLATINUM MEMBERS:

GOLD MEMBERS:

SILVER MEMBERS:

Stanch Stainless Steel Co., Ltd. Stoddart Viraj Profiles Ltd. YC Inox Co., Ltd.

Acerinox \ Amity Pacific \ Aqseptence Group \ Arcus Wire Group \ AusPress Systems \ Austral Wright Metals \ Australian Stainless Distributors \ Callidus Welding Solutions \ Ching-Hann Industries Co., Ltd. \ Chromeni Steels Pvt. Ltd. \ Dalsteel Metals \ Fagersta Steels \ Laxcon Steels Limited \ Metal Centre Australia \ Prochem Pipeline Products \ Sanwa \ Stainless Steel Wire & Mesh \ Yue-Seng Industrial Co., Ltd.

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

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