Berg Engineering - Year In Review 2023

As 2023 draws to a close we explore Berg Engineering’s round-up of news stories and photo galleries that dominated the year

In 2023, Berg is celebrating 51 years in manufacturing and engineering which build the infrastructure that connects family, friends and communities. Founded in 1972 by Roger and Pam Berg, the company has grown into a global, milliondollar manufacturer.

Pictured: Derek, Nilu, Pam and Roger Berg

From its humble roots, the company has become a leader in the industry by tailoring its services to meet customer needs.

"Roger was an inventor and entrepreneur, and under his leadership, Berg revolutionised the industry. We carry his legacy of commitment to customers forward as we evolve our operations to work more efficiently and drive more value through our services."

- Derek Berg, CEO of Berg Engineering Today, Berg is a one-stop shop - with manufacturing and welding under one roof. The company employs more than 100 people with sales and manufacturing operations located globally.

2023 YEAR IN REVIEW

BERG

ManuFACTURING CAPABILITIES bergengineering.com.au

brisbane facility

machining capabilities include: Machining Centre Table 2200 x 1300 • Okuma MCM20 5 Axis, Double Column, twin pallet (1.3m X 2.2m) 69 station ATC

Milling Machines (2 off) • Comprehensive range of vertical, horizontal & universal machines Drilling • Radial drilling capacity 50mm Manual Lathes

Mazak Vertical Milling machine centre - 510c

• 1100mm Swing; 9m bed; 10 tonne capacity swing 550mm over saddle, has 3m travel

• With live 4th Axis • 1050mm travel in “X” • 510mm travel in “Y” • 600mm under milling spindle 30 pre-set tools • Calibrated measuring probe 1200kg

• 2x small lathes; swing 300mm over saddle, has 2m travel

CNC Lathes • Doosan S670L, 670mm swing, 1800mm between centres • Daewoo Puma 12C, 490mm swing, 600mm between centres • Doosan Puma 700, 870mm swing, 12 station tooling turret, 1800mm between centres Mazak Intergrex e 410H • 5 axis milling & turning machine Swing 600mm in chuck • Swing 240mm through travelling steady 3000mm travel • 1 Tonne capacity • 120 pre-tool sets • Calibrated measuring probe CNC Borers • OM-TDC-20N turning centre, 2.0m dia. table, 2.6m swing x 1.8m high, live tooling, 15000kg • Union horizontal Borer, 2750 x 2200 x 2000 high travel, CNC drilling 2000 x 1800 table, 8000kg

Mazak Quick Turn 350 ii MY • Live Tooling • Swing 400mm in chuck 1500mm travel in “X” 70mm travel in “Y” • Ferranti CMM 1100 x 1900 table

MECHANICAL FITTING capabilities include: Valve Bay - Full refurbishment Testing and Certification of PSV • Kemet 20 Lapping Machine • Kemet Optical Measuring Machine for flatness • Pressure Testing Equipment • Hydrostatic Testing from 0-15,000 kPa • Nitrogen Testing from 0-25,000 KPa • 2 carriage 10 tonne Overhead Gantry Crane • 10 tonne Overhead Gantry Crane • 150 & 200 tonne Horizontal Press • Enerpac Pullers and hydraulic cylinders up to 150 tonne capacity • 2 x SKF Induction Heaters

Borers

• Maintained & Filtered, Eco Friendly Wash Bay.

• Webster & Bennet vertical borer, 1.8m table - Digital readout

• 2 Opti-Line Laser Pulley Alignment

• TOS Horizontal borer, 1.6m x 1.1m table, 1.2m table

• Associated tooling required for valve refurbishment

• Site Truck

GLADSTONE facility

Kearns Richard SF125

machining capabilities include:

• Table size – 1200mm X 1200mm

Titan SC 40/50 4HY – CNC Vertical Turret Lathe Double Column

Richards • Table size – 1070mm X 1070mm

• 3 Tool post with live tooling and milling function • Chuck Diameter – 4000mm • Max. swing diameter – 5000mm Height – 3000mm • Maximum Workpiece weight – 50,000 kg

Tos

HNK HB 130CX – CNC Horizontal Boring and Milling Machine

Shenyang

• 4th axis rotary table – 1600mm X 1600mm • Length – 4000mm • Height – 2300mm Depth – 1300mm • W Axis – 700mm • Rotary table load – 10,000 kg • Side table load – 15,000 kg

Mazak VTC 200C – Vertical Machining Centre • 4th axis rotary chuck – 420mm diameter max • Table length – 1950mm • Height – 500mm Width – 510mm • Table load – 1000 kg

Alpha Harrison – 2 Axis CNC Lathe • Bed length – 3000mm • Max swing diameter – 550mm • Swing over saddle – 370mm

Puma – 2 Axis CNC Lathe (Turret type 10 tools) • Bed length – 1200mm • Max swing diameter – 550mm

• Table size – 1120mm X 900mm

• Bed length – 8000mm • Max swing diameter – 1200mm • Swing over saddle – 880mm

Shenyang CW6280C • Bed length – 3000mm • Max swing diameter – 820mm • Swing over saddle – 350mm

Shenyang CW61125B • Bed length – 3000mm • Max swing diameter – 500mm • Swing over saddle – 480mm

ZC530 • Bed length – 3000mm • Max swing diameter – 560mm • Swing over saddle – 330mm

John Lang and Sons

Alpha Harrison – 2 Axis CNC Lathe

• Bed length – 7000mm • Max swing diameter – 2500mm • Swing over saddle – 1800mm

• Bed length – 2000mm • Max swing diameter – 550mm • Swing over saddle – 370mm

MISCELLANEous:

Webster And Bennett - Medium Vertical • Borer Chuck Diameter – 1500mm • Max. swing diameter – 2000mm Height – 750mm • Maximum Workpiece weight – 25000 kg

Webster And Bennett - Large Vertical Borer • Chuck Diameter – 2750mm • Maximum swing diameter – 3100mm • Height – 1980mm • Maximum Workpiece weight – 25,000 kg

Shibaura TB14 - Medium Vertical Borer • Chuck Diameter – 1200mm • Max. swing diameter – 1400mm • Height – 1100mm

Webster And Bennett - Small Vertical Borer • Chuck Diameter – 900mm • Max. swing diameter – 1100mm • Height – 900mm

2023 YEAR IN REVIEW

Surface Grinder 150 Tonne Horizontal Press 60 Tonne Vertical Press NATA accredited Dye Penetrant NATA accredited Magnetic Particle NATA accredited Ultra Sonic thickness NATA accredited Hydrostatic testing Eddy Current 10, 16 & 50 Tonne Overhead Crane

BERG

SHARED RESOURCES: Assembly & Testing Equipment Hydrostatic Testing from 0-15,000 kPa 2 off Pump Test Benches for Vibration Analysis Pressurised Clean Room – 12.5m x 6.5m (Includes 5 tonne bridge crane overhead)

Welding & Fabrication 15x Lincoln Powerwave (5th gen) 500 amp, with water coolers 5x GTAW, 300-400 amp water-cooled 1x GTAW 400 amp hot wire (TIP TIG) 2x PTAW – Plasma welding system Overlay/ cladding and autogenious key hole joining

Manipulation 7x 5t positioners 4x 1-2t positioners 1x 20t turn table 1x 10t turn table Column and boom (2x2.5m) integratedwith positioner (1.2t), fully programable Drive rollers up to 5t Various mechanised oscillating systems

Engineering & Drafting Inhouse drafting & 3D modelling Offline CNC programming and machine simulation Engineering services

bergengineering.com.au

2023 YEAR IN REVIEW

NON DESTRUCTIVE TESTING NATA ACCREDITED

2023 HIGHLIGHTS

2023 Berg Engineering Staff Awards

Berg Engineering staff were honoured at the Annual Staff Awards.

The awards recognise and reward staff who exemplify Berg’s core values of persistence, accountability, humility, excellence and respect, and who achieve outstanding outcomes in one of the three award categories.

CEO Derek Berg congratulated all winners.

"These recipients deserve to be recognised for going above and beyond in their dedication to our company and clients, Mr Berg said."

“I’d also like to take this opportunity to thank all of the highly skilled Berg staff for the excellent work they do across our workshops.”

Derek Berg - CEO of Berg Engineering

2023 YEAR IN REVIEW

2023 HIGHLIGHTS

2023 Staff Awards “Winners of the Staff Excellence Awards for 2023 have gone above and beyond for Berg demonstrating excellence, innovation, dedication and an unwavering commitment to our values.”

Derek Berg - CEO of Berg Engineering

Brisbane Workshop Choice Award Keith Pavey

Office Choice Award Shane Anderson

MVP Zane Traves Gladstone Workshop Choice Award Jeffery Pulido MVP Amy Bramer

Office Choice Award Joshua Rose

2023 HIGHLIGHTS

BERG STAFF CELEBRATE MILESTONE On October 25, long-serving Berg Engineering staff – with 40 years of service between them – celebrated their service milestones of 10 years with a special morning tea.

The team members, from our Gladstone site, were Ruth Sutherland, Julius Salcedo, Matthew Harms and Eric Fourie.

CEO of Berg Engineering, Mr Derek Berg praised the hard work and dedication of staff members, and their essential role at Berg.

“People are and always will be our greatest asset. It’s great we can show our long serving staff how much their long service means to us,” CEO OF Berg Engineering, Derek Berg said. “Everyone wants to be acknowledged, it’s a proud moment for Berg that we have so many long-serving staff.”

Over the past two years, 24 Berg staff reached service milestones of ten years or more, with the largest milestone being an incredible 50 years!

2023 YEAR IN REVIEW

2023 HIGHLIGHTS

International WOMEN'S DAY Berg Engineering marked International Women’s Day today with a morning tea and BBQ event (March 9) across its sites.

Berg Engineering supports equality and diversity in the workplace. This includes but is not limited to our commitment to women in non-traditional trade roles within the business. Berg’s support staff (administration, technical, estimating, scheduling, and management team) is made up of 21% women.

CAN YOU TELL US ABOUT A FEMALE WHO INSPIRES YOU - IN EITHER YOUR PROFESSIONAL OR PERSONAL LIFE? The female who inspires me in my personal life is my mum, who taught me a lot of different things that I get to apply at my job daily.

Values to show love, care, and kindness to those around me such as my colleagues. But having said that, I am earning respect as a yound woman and the team treat me like their sister or daughter.

Eliza Estoya - NDT Technician

CAN YOU TELL US ABOUT A FEMALE WHO INSPIRES YOU - IN EITHER YOUR PROFESSIONAL OR PERSONAL LIFE? I would say that the women who inspire me the most is my mum. She is super smart and so dedicated and has always put her kids first and has given us such a privileged life while balancing her jobs as an AIN. She always puts others first instead of herself, so growing up watching her dedication to her career and her family has made me value marking my own path and has shaped me into who I am today. She is a massive role model for me and as cliche as it sounds, I wouldn’t be who I am today without her.

Katelyn Wilson - Customer Service & Purchasing Officer

2023 YEAR IN REVIEW

WHAT'S A PRACTICAL EXAMPLE OF SOMETHING YOU OR YOUR COLLEAGUES CAN DO TO CHALLENGE GENDER BIAS AND SUPPORT GENDER EQUALITY? One practical example of something my colleagues and I can do to challenge gender bias and support gender equality is to be mindful of the language and assumptions we use in our communications and interactions with others.

This means avoiding gender sterotypes and assumptions, using inclusive language, and actively listening to and amplifying the voices of under represented groups. We can also work to identify and address any biases we may hold and commit to ongoing education and awareness – building around gender equality.

Jeanetee Baynton - Onsite Coordiantor, WHS&E Coordinator

WHAT DO YOU THINK WILL BE THE GREATEST CHALLENGE FOR WOMNE IN OUR INDUSTRY MOVING FORWARD I think that is it still a big challenge for women to manage parenting and career advancement. Things do seem to be getting a bit easier with childcare I believe becoming more affordable however, that is still one of the biggest killes.

The hours that are required to either study or advance in your role at work can make things stressful at home.

Women that start out as an apprentice or have studied prior to having children definitely have a much less stressful transition into an industry working life I believe.

I know a lady recently who was trying to become a nurse and she couldn’t do the placement hours (night shift etc) as she has a young son, so she just had to give that dream away for the time being and find a day job. Berg is flexible with hours which is very helpful, so I am able to juggle my hours to be able to collect my daughter when required, however it still seems to be favoured to do long hours if you want to advance in industry roles (that I have had experience with) which is harder for mothers I think.

Anita Huxley - Production Support

2023 HIGHLIGHTS

Gladstone Christmas Party

2023 YEAR IN REVIEW

2023 HIGHLIGHTS

Brisbane Christmas Party

2023 YEAR IN REVIEW

2023 HIGHLIGHTS

Happy 20 years to the GEA! The team celebrated 20 years of the GEA at the 2023 Major Industry, Manufacturing, and Energy Conference Dinner.

Berg has been a member of the GEA since Day 1 and congratulates the Alliance on the work they do in linking businesses with opportunities to create sustainable growth and diversity in the Gladstone Region.

About Berg Engineering: Founded in 1972, Berg has grown from humble beginnings as a single room setup to an operation that spans multiple facilities.

Berg are still a proud family-owned Australian engineering business that has built a reputation for excellence on the back of two generations – and more than four decades – of Berg family passion.

Headquartered in Brisbane/Gladstone and with bases in the Asia Pacific we strive to provide our clients with intelligent asset lifecycle management solutions that reduce operating costs, maximize performance, and

extend asset life; all the while ensuring we meet our sustainability standards.

We achieve our best results when working in partnership with our clients to explore and fully ––understand the challenges at hand, before designing and implementing a tailored solution. Having been a local Queensland business for more than four decades, we have evolved, matured, and diversified in tandem with our clients.

Berg has amassed considerable expertise providing our clients with high-risk, critical parts. We have developed a strong reputation for maintaining and managing fleets of rotable assets such as pumps, valves, and gearboxes.

We understand that globalization, competition from emerging markets and price pressures are constantly driving asset owners and operators to achieve greater performance and reduce costs. That is where Berg steps in to optimize assets – unlocking potential and achieving exceptional cost savings while ensuring the highest safety standards.

Taralga Windfarm, New South Wales Australia

2023 HIGHLIGHTS

SUNSHINE SUGAR SITE SHUT DOWN

Scope

• Berg were engaged to perform multiple jobs while onsite at Yamba sunshine sugar mill.

• Shut down duration spanning from 27/03/2023 to 14/06/2023.

• Berg supplied 4-5 boiler makers and 3-4 fitters on site during the shutdown.

Boiler Makers

Berg were engaged to repair and replace structural sections of buildings and flooring throughout the site. Various head chutes on numerous conveyor systems repaired and bought back to a safe secure standard.

Boiler tubes blanked off and welded, guards remanufactured and installed. Many parts made as required in sunshine sugars onsite workshop.

WORK COMPLETED Damaged boiler tubes pressure vented blanked and plug welded.

Structural columns removed and repaired in damaged sections.

Chutes repaired and replaced as requested by sunshine sugar.

Flooring removed and replaced in many areas of the plant due to being unsafe for walking. In control rooms and up and down 6 conveyor systems.

Head chutes repaired and replaced.

FITTERS

Berg fitters onsite were required to strip and assess several pumps, replace bearings, replace belts. Remove and replace gland packing, maintenance on pullies and drums realign and tension belts. Replace scrappers on return belts.

2023 YEAR IN REVIEW

Damaged boiler tubes pressure vented blanked and plug welded.

Damaged boiler tubes pressure vented blanked and plug welded.

Structural columns removed and repaired in damaged sections.

Flooring removed and replaced in many areas of the plant, control rooms and down 6 conveyors.

Chutes repaired and replaced

2023 HIGHLIGHTS

BERG BOOSTS PRODUCTION CAPACITY

It’s been decades since Berg Engineering invested in the company’s first CNC machine and it opened up new possibilities for the company, today Berg continues to invest in CNC machines and is taking advantage of the benefits that CNC machining offers.

Berg is expanding its manufacturing versatility and capacity with the recent purchase of two new CNC machines: Mazak Quick Turn 350mb and SMEC SL4500AX. The machines enable growth and diversification with additional CNC turning services, and will support the growing demand for precision machining of high-performance superalloys and other specialty materials commonly used in aerospace, defence, energy, and shipbuilding applications.

2023 YEAR IN REVIEW

“The new machines expand our capacity & capability to support the growing demand and complexity of industry. It’s no secret that CNC machine tools increase productivity and repeatability for machine shops. However, by automating manual operations we are not only able to increase the complexity of items, increases in repeatable accuracy, and efficiency gains of up to 300 per cent can be achieved. All while reducing waste, rework and manufacturing costs”.

Shannon Jansen - COO of Berg Engineering

The new machines boast impressive technical specifications, automatic tool changers, automatic bar feeders, and diverse high-speed machining capabilities, including milling and turning in a single operation.

These advanced features bolster the Company’s vertical integration, providing customers with a single-source supplier for all of their high-precision and large-scale CNC machining needs.

The two new machines represent a significant step forward in the business’s five-year strategic plan and will ensure Berg Engineering is well placed to capture more international business, adding to its existing customer base in Indonesia, New Caledonia, Philippines, and Fiji.

The Made in Queensland grant has helped secure the two new machines that will position the business to capture more overseas customers and add eight new jobs over the next five years.

Since 2017, the Made in Queensland grant program has supported 105 advanced manufacturing projects, these projects are anticipated to create and support 7,445 jobs over five years and generate more than $140 million in private sector investment.

2023 HIGHLIGHTS

BERG ENGINEERING JOINS AUSTMINE Berg Engineering is pleased to announce

Our membership with Austmine broadens

its membership with Austmine, a mining

our opportunities to:

body which advocates on behalf of Australia’s

• Raise Berg’s profile within the wider mining

Mining Equipment, Technology and Services

industry

(METS) sector. The METS sector is a key

• Network with key players in the METS sector

economic driver to our nation, contributing

• Connect into strategic conversations shaping

over $110 billion in gross annual revenue to our

future trends and technologies

country’s prosperity.

• Build stronger relationships and new connections

Austmine has over 700 corporate members

• Gain new skills for organisational success

from the mining equipment, technology and

• Stay on top of opportunities, insights and

services (METS) sector Australia-wide. A not-

changing trends

for-profit industry association, it develops, promotes and supports the METS sector by providing growth opportunities to its network of members.

Derek Berg, CEO of Berg Engineering said, “We are looking forward to opening the conversation with key players in the mining industry through Austmine, to learn from our peers and continue to evolve our product and service offering to meet the mining market.

Our membership and association with Austmine will continue to maintain our strong ties to the mining industry with our innovative solutions.”

Berg joins Austmine members from across the Australian mining value chain, from greenfields exploration through to production, processing and export.

2023 YEAR IN REVIEW

2023 HIGHLIGHTS

High tea generates support for domestic violence awareness

Berg Engineering has donated towards Red Rose Foundation following their annual high tea held at The Emporium – Brisbane, March 4, 2023.

The Red Rose Foundation is a national not for profit charity who works to address the damaging impact of domestic violence across our communities.

The High Tea was hosted by Loretta Ryan, co-host of ABC Radio Brisbane’s Number One rated Breakfast radio program and attended by, Her Excellency the Honourable Dr Jeannette Young AC PSM, where the Governor presented a Certificate of Patronage and addressed guests.

Nilu Berg said “supporting a charity is something very close to my heart. I have always tried to give back as much as I can. I feel that I am blessed in my professional and personal life and honoured that I am able to give back to support the Red Rose Foundation’s fundraising event to ensure maximum funds go directly to the women and families Red Rose support.”

“We’re committed to making a positive contribution to the communities we serve. We’re proud to support a Foundation that have an important social impact.”

2023 HIGHLIGHTS

Re-Engineer of Coal Mill Spider for CS Energy Our team at Berg managed the process of the re-engineering of 2 x Coal Mill Spider's for CS Energy.

CS Energy provides power to some of our state's biggest industries and employers.

The project involved an initial process: * 3D scanning and establishing wear patterns to predict original measurements (these items had been worn after more than 30 years of service) * Developing 3D models and production drawings

Fast Forward Berg Brisbane received notification we were successful in our bid to manufacture 2x Coal Mill Spiders.

This came after months of tendering, technical clarifications, and supplier and customer meetings. Not only was our bid successful, but we had also demonstrated areas of the tender that were not achievable for short-run castings and provided options for how to handle this.

The result was:

1 2022) at the Energy Transition Day G20 Summit Indonesia held in Nusa Dua. With supply chain constraints continuing for all since Covid-19, this particular job highlights the importance of manufacturing within Australia and what we can achieve within our country alone.

2023 YEAR IN REVIEW

- We secured the manufacture of both coal mill spiders - additional scope to conduct an FEA analysis - provided recommendations on scope changes post FEA.

In the background...

While Brisbane had been successful and won the tender, and whilst this project was within +-5% of Berg’s “true north” for the nature of work (large capacity machining), it was BIG, bigger than any of our current machines had the capacity to undertake. Enter the TITAN.

The project begins!

Now we had to deliver, this involved all aspects of project management • • •

Managing sub-contractors Monthly project meetings with the customer Organising transport

As with any project, not everything goes to plan, the first casting did not contract at the rate that was expected which meant we would now be welding: • • • •

Develop weld procedure Develop a methodology to weld these items Obtain customer approval and sign-off.

Determine how we were going to support a 10-tonne item vertically at 300 degrees Celsius, utilising open flame to maintain pre-heat temperatures whilst simultaneously welding it.

Project Highlights - END TO END SOLUTIONS • • • • • • • • • • • •

- 1 Request for quotation – WON! - Win the project via competitive tender process - 2 Coal Mill Spiders weighing in at just under 10tonne each - 300℃ pre-heat to apply welded metal - Approx. 400kg of material removed through machining - Over 450 individual items of correspondence and communication (submissions, emails, phone calls, text messages, and meetings) - It involved teams across all of our business units - The project commenced in Gladstone - Tender was won and run through Brisbane - Project managed through Brisbane - Cast and manufactured through Brisbane - Welded, finished machined, & assembled in Gladstone

2023 HIGHLIGHTS

Berg expanding to the Pacific South Pacific markets are offering expansion beyond manufacturing, engineering and fabrication projects.

Pictured: Hon. Manoa. S.N. Kamikamica, Deputy Prime Minister and Minister for Trade, Co-operations with Nilu Berg

Pictured: Derek and Nilu Berg with Navinesh Kumar from Suva Port

2023 YEAR IN REVIEW