steel Australia (Vol 32 No. 1) Autumn 2019 by Australian Steel Institute

Global Steel Industry Rises to the Challenges of

Industry 4.0

PLUS 2018 Sorel Awards

New Museum for Western Australia Launch of CROSS-AUS Autumn 2019 Vol. 32 | No. 1 ISSN 2208-7486 (online) ISSN 1447-5359 (print)

Autumn 2019

steel Australia

Building Possibilities

At LIBERTY we believe in being empowered by possibilities. We believe in a future that serves tomorrow’s generation as much as today’s. We believe it’s not the scale of the project but the passion to bring the vision to life. We believe it’s the strength of our people and what we do, how we do it, and why we do it, from recycling to design and manufacture, fabrication, service delivery and distribution. We believe in building a future full of possibilities.

LIBERTY. Building Possibilities.

LIBERTY HRS steel now features LS AS markings. LIBERTY’s extensive range of hot rolled structural steel products now feature LS AS in place of earlier ONE AS markings. LIBERTY’S products are designed to comply with all relevant Australian Standards and carry ACRS certification: https://www.libertygfg.com/news/non-conformingbuilding-products-senate-report/

www.libertygfg.com

steel Australia

Vol 32 No 1, Autumn 2019 ASI Head Office Level 3, Building 3 Pymble Corporate Centre 20 Bridge Street Pymble NSW 2073 T: (02) 8748 0180 E: enquiries@steel.org.au W: www.steel.org.au ASI State Offices New South Wales & ACT Phil Casey on (02) 8748 0185 Victoria Ian Cairns on (03) 9694 4499 Western Australia James England on (08) 9355 1544

08 Contents 04

Message from the Chief Executive

Industry Insights

On the Beam

Gow Gates Update

AustralianSuper Update

Launch of CROSS-AUS

ShedSafe Launches Site Check

The Value of Using Steel

Queensland & Northern Territory John Gardner on (07) 3853 5320

Feature: Industry 4.0 and Steel

South Australia Secretariat on (02) 8748 0180

Global Steel Industry Rises to the Challenges of Industry 4.0 Industry 4.0 and BIM: Reshaping the Construction Industry

ASI Steel Shed Group Office Neil Creek on (07) 3853 5204

steel Australia Contacts Editor Sally Wood on 0434 442 687 or sally@wordly.com.au

Message from the Chairman

2019: The Year of Data

18 20

Robotics and Automation in Australia’s Fabrication Industry

Project Case Studies

New Museum for Western Australia

Advertising and Distribution Julie Fidler on (02) 8748 0104

Feature: 2018 Sorel Awards Disclaimer While every effort has been made and all reasonable care taken to ensure the accuracy of the material contained herein, the Publisher does not assume any responsibility or liability for any loss or damage which may result from any inaccuracy or omission in this publication, or from the use of the information contained herein and the Publisher makes no warranties, express or implied, with respect to any of the material contained herein.

Potts Hill Pressure Tunnel Bridge

Boral CBD Concrete Manufacturing Plant

Barramundi Discovery Centre

ASI Insights

ASI’s Digital Transformation Project eLibrary and Bookshop New Members

Upcoming Events

Copyright Reproduction of the material is permitted only with the express permission of the Publisher and due acknowledgment of steel Australia.

About the Australian Steel Institute steel Australia is published by the Australian Steel Institute (ASI)—the peak national body of the steel industry. The ASI works to increase the awareness of the benefits of steel and promote Australian made steel as the material of choice. Increasing the competitiveness of the Australian steel industry and its member companies is central to that vision. The organisation conducts engineering seminars and disseminates relevant, timely and detailed information. Expert technical advice, a library and a resource centre are available to all members, along with a range of other member benefits.

Galvanizing Delivers Durability, Sustainability and Cost Savings

31 Cover image: Global Steel Industry Rises to the Challenges of Industry 4.0. Full story on page 16.

Autumn 2019

steel Australia

Chairman’s Report

Message from the Chairman Despite the constant media attention on issues that allude to economic risk—from international trade tensions and an uncertain energy market, to the upcoming Federal election and a downturn in the residential construction industry—there is reason for optimism in Australia’s steel construction industry. There is solid demand coming from both commercial and non-residential construction, and booming demand from major infrastructure projects. Perhaps most encouraging, this demand is not constrained to the short term. Much needed infrastructure development is already in full swing, with many years of continued demand ahead. In fact, it is estimated that Australian governments will spend upwards of $70 billion on infrastructure over the next decade. Just some of the projects announced by the Federal Government over the last few years include: the $16 billion WestConnex project in Sydney; the $12 billion Sydney Metro project; the $11 billion Melbourne Metro Tunnel; the $9.3 billion Inland Rail project from Melbourne to Brisbane; the $8.5 billion Bruce Highway Upgrade program; the $5.4 billion Cross River Rail project in Queensland; the $5.3 billion Western Sydney Airport; the $5 billion Melbourne Airport Rail Link; and the $1.8 billion METRONET in Perth. This robust forecast for infrastructure project spending in Australia is essential given our rapid population growth. Australia’s population recently hit 25 million and is growing rapidly at a rate of 1.6% per annum—well ahead of growth rates currently prevalent in most of the world’s other developed economies. And, with both state and federal governments increasingly reliant on population growth to support the economy, underpin their budgets, and no deceleration in population growth expected any time soon, infrastructure investment should remain at around current levels for years to come. With a buoyant market ahead of us, the Australian Steel Institute (ASI) is of the view that it is an opportune time for our members, particularly those operating within the fabrication sector, to invest in their own capabilities and workforce. Such investment will strengthen not only these individual businesses, but Australian industry as a whole.

“There is solid demand coming from commercial and non-residential construction, and booming demand from major infrastructure projects. Perhaps most encouraging, this demand is not constrained to the short term. Much needed infrastructure development is already in full swing, with many years of continued demand ahead.”

steel Australia

Autumn 2019

ASI Member Initiatives The first quarter of 2019 has been busy for the entire ASI team, with several important events and initiatives underway. We have already facilitated the national roll-out of two very successful series of seminars. Presented by Dr Tim Wilkinson (Associate Professor in Civil Engineering at the University of Sydney), the AS 4100 Steel Structures Design seminars had over 180 attendees. Similarly, the seminars focused on AS/NZS1252 High Strength Bolts Design and Installation were an outstanding success, with over 400 people in attendance. The ASI also facilitated a Steel Education Workshop in February with representatives from Australian universities, constructors and engineers all in attendance. The feedback to date has been very positive. Finally, planning is already well underway for the 2019 Australian Steel Convention, which will be held in Sydney from 15 to 17 September. As always, the Convention will bring together an impressive array of business leaders and experts in their field, and encourage industry collaboration and knowledge sharing. I urge all ASI members to save the date; the 2019 Australian Steel Convention is not to be missed. Bernie Landy Chair Australian Steel Institute

MATERIAL HANDLING SOLUTIONS FOR YOUR INDUSTRY

SAFER PRODUCT HANDLING IMPROVED STORAGE CAPACITY INCREASED PRODUCTIVITY

SAFETY | STORAGE | EFFICIENCY 1300 552 422

combilift.com

Chief Executive’s Report

Message from the Chief Executive Australian Steel Industry: Forging Ahead The ASI welcomed the findings of the two year national Senate Economics References Committee Inquiry into the Future of Australia’s Steel Industry, which was released in late 2017. Inquiry submissions from a wide range of stakeholder groups across the public and private sectors confirmed broad recognition of the issues hindering the Australian steel sector, including inconsistent application of Australian Standards, unfair and dishonest dumping practices, and short-sighted public procurement decisions. The Federal Government issued its response to the Senate Economics References Committee in February 2019. Disappointingly, the Government has rejected most, if not all of the 28 recommendations that arose from the Inquiry. If Australian steel is allowed to go the same way as motor vehicle production, the consequences will be felt throughout Australia’s manufacturing and industrial sectors. Australian governments must revise the relevant policies, legislation and guidelines to ensure that: industry participation and collaboration is increased; Australian Standards are applied effectively and consistently; unfair and dishonest dumping practices are eradicated; and public procurement decisions consider whole-of-life economic value. The ASI is ready to work with the state and federal governments, company owners, workers and unions to ensure the sustainability of the Australian steel industry. Growing Steel Intensity During the first quarter of 2019, the ASI has continued its work promoting the use of steel and growing steel intensity throughout Australia. With the launch of the Steel Innovation Portal late last year, the ASI is already facilitating important connections between industry and Australian research institutions. As the collection point for a significant body of world-class steelrelated research, the Portal will help promote innovation, collaboration and communication. We already have more than 20 universities registered on the Portal, with the process of loading projects and researcher details well underway. Following on from the launch of the ASI’s new website late

“Australian governments must revise the relevant policies, legislation and guidelines to ensure that: industry participation and collaboration is increased; Australian Standards are applied effectively and consistently; unfair and dishonest dumping practices are eradicated; and public procurement decisions consider whole-oflife economic value.”

steel Australia

Autumn 2019

last year, the development of our new eLearning Platform is progressing, with the content for all training modules being finalised. All these digital tools have been designed to help the Australian steel industry navigate a changing landscape, and win more business. For further details, see page 32. Quality and Compliance I am pleased to report that the ASI’s National Structural Steelwork Compliance Scheme (NSSCS) is going from strength to strength. We have just obtained approval to proceed with JAS-ANZ (Joint Accreditation System of Australia and New Zealand) accreditation. Steelwork Compliance Australia will now commence work on the accreditation process. Equally as pleasing is the recent launch of Site Check by ShedSafe (an initiative of the ASI). Site Check is a webbased site classification tool specifically designed for the steel shed industry. The purpose of the tool is to provide re-sellers and consumers with accurate shed site-specific wind speed classifications. For further details, see page 13. Two important Australian Standards are currently under revision and will be released for public comment within the next few months: AS 4100 Steel Structures and AS/NZS 5131 Structural steelwork – Fabrication and erection. Given their importance to the Australian steel industry, I encourage all members to provide feedback. The Institution of Structural Engineers has launched CROSS-AUS (Confidential Reporting on Structural Safety – Australasia). This is a unique safety reporting scheme that allows construction professionals to make confidential reports about structural failures and safety concerns. I urge all ASI members to submit structural safety incidents via the CROSSAUS website: www.cross-aus.org.au. For further details, see page 12. Tony Dixon Chief Executive Australian Steel Institute

Industry Insights

On the Beam $3 Million Upgrade for Whyalla Steel Mill A $3 million upgrade to Liberty Primary Steel’s Whyalla Structural Mill and finishing ends will deliver enhanced accuracy and reduced tolerances to hot rolled steel (HRS) sections and rails. The installation of two laser measuring systems will deliver significant enhancements to accuracy and tighter tolerances that will exceed the requirements of Australian Standards at Liberty Primary Steel’s Whyalla Structural Mill. In accordance with Liberty’s rigorous maintenance and upgrade program that requires planned shutdowns to undertake major works, the $3 million upgrade began in early 2019. Liberty Primary Steel’s Peter Rostig explains that the laserbased system will deliver a significant enhancement to the measuring process of HRS and Rail sections.“The laserbased Inline Measurement Device will give a real-time 3D measurement of the product as it rolls through the Finishing Stand of the Mill,” Peter said. “These measurements are critical to ensuring the mill’s output is within customer specification. With the implementation of the new laser-based system, measurement accuracy will be further improved with measurements taken and results reported in real time, opening up the future potential of dynamically adjustable mills.”

e t a m i Ult

Coopers Malting Facility Named Equal Best In World Ahrens’ work on Coopers’ $65 million-dollar malting facility in South Australia has been named equal best maltster in the world. An international judging panel at the World Barley, Malt and Beer Conference held in Poland, awarded the title of Maltster of the Year 2019. The prestigious event attracts attendees from around the globe every two years to recognise innovation and technology in the brewing world. Identified as leading the way in innovation and technology, the Coopers malting facility was one of Ahrens’ most complex projects to date. The extensive project saw the design and construct of the entire malting facility, featuring 25 silos of varying sizes, conveyor bridge, conveyor gantry, processing buildings, germinating vessels and kiln. The project utilised 1,100 tonnes of structural steel manufactured by Ahrens’ steel division. Particular care and attention was paid to the aesthetics of the building in fitting with Coopers design brief. The facility has been admired for its distinguished finished compared to more agricultural-looking malting facilities around the world. Ahrens completed majority of the project works at a value of $40 million with the remainder of the $65 million facility, consisting of specialised equipment imported from overseas partner, Buhler.

VALIANT

Automatic CNC drilling & thermal coping line with “FRC” flexible robot

ABC123

Valiant line is equipped with an advanced piece pincher clamping system and a new hold down system with two independent cylinders that allows the best processing of the beam head and end. Another advantage is the enhanced auxiliary axis with 300 mm stroke for each operating head, which permits to achieve numerous operations as special milling and “rat holes” without moving the beam. Valiant can be configured with an automatic tool-changer with up to 14 positions per head: a significant increase of the tools availability that allows completing all the necessary operations on the beam (drilling, milling, scribing, etc.)

21045 Gazzada Schianno Varese - Italy - Via Matteotti, 21 Tel. +39 0332 876111 - Fax +39 0332 462459 E-mail: ficep@ficep.it • www.ficepgroup.com

Industry Insights

AustralianSuper Welcomes WestConnex Sydney AustralianSuper members recently became part owners of the WestConnex motorway project, a major piece of New South Wales infrastructure. The Fund is part of the Australian-controlled consortium, Sydney Transport Partners, which recently won the bid for 51% ownership of WestConnex. WestConnex is the largest road infrastructure project underway in Australia, and is one of the single largest investments the Fund has made on behalf of members. AustralianSuper Chief Investment Officer, Mark Delaney, said the deal will boost economic growth and employ thousands of workers, while providing returns that will contribute to the long term retirement savings of members. “This is a great result for AustralianSuper’s more than two million members, of which over 600,000 are New South Wales based. It also represents a major investment in critical infrastructure, to the long-term benefit of the broader New South Wales community,” Delaney said. WestConnex will fund a range of improvements to Sydney’s road transport network, including road widening, extending the M4 motorway and connecting the M4 and M5 to provide a western bypass of the Sydney CBD. A large part of the network will be in underground motorway tunnels, and the project will also deliver more than 18 hectares of new recreational green space for local communities. AustralianSuper is a significant global investor, managing more than $140 billion on behalf of members. The Fund has been investing in infrastructure assets for more than 20 years, with a current portfolio valued in excess of $16 billion. Preceding the WestConnex investment, AustralianSuper members became part-owners of core infrastructure assets like Ausgrid (an electricity distribution and transmission business based in New South Wales), and NSW Ports and

Queensland Motorways (now Transurban Queensland). A big advantage of AustralianSuper’s size is that it can partner with major investors to acquire large, high quality assets on behalf of members, many of them directly. In fact, since 2012, AustralianSuper has been expanding its in-house capability and investing more directly, rather than through a fund manager. It is a style of investment that has a number of benefits, including the ability to buy and sell assets at times that suit AustralianSuper. An added bonus is a cost saving of approximately 1% of returns because the Fund does not have to pay someone else to manage the asset. Our Approach to Investing in Infrastructure The role of infrastructure, across AustralianSuper’s broader portfolio, is to provide steady investment returns through most economic cycles, delivering growth and income when other asset classes aren’t performing well, and providing steady investment returns across economic cycles. Investments in this area are managed by a strong crossfunctional team, which consists of people dedicated to infrastructure origination, and a team of internal legal and tax experts who assist in the due diligence of potential opportunities. Nik Kemp, Head of Infrastructure at AustralianSuper explains: “Generally, we look at core infrastructure assets, which have lower volatility and lower risk.” Core infrastructure assets are those that keep the country running, such as airports, ports and regulated utilities. AustralianSuper’s infrastructure team assesses hundreds of opportunities each year, and of these, pursues a select few of the most attractive ones. “We do look around the world in core geographies – North America, Australia and northern and western Europe”, Kemp said. “We then take into consideration the competitive dynamics, why the asset is being sold and the quality of the investment.” Like most asset classes, infrastructure returns can fluctuate depending on the phase of the economic cycle. During a growth phase, listed shares tend to do better; when the economy is taking a downward turn, fixed interest often outperforms. AustralianSuper members that have exposure to infrastructure assets, including the WestConnex motorway project, are those in the Balanced, High Growth, Conservative Balanced, Capital Stable and Socially Aware PreMixed options. Content Sponsored by AustralianSuper

WestConnex Sydney, the largest road infrastructure project currently underway in Australia.

steel Australia

Autumn 2019

This information may be general financial advice which doesn’t take into account your personal objectives, situation or needs. Before making a decision about AustralianSuper, you should think about your financial requirements and refer to the relevant Product Disclosure Statement, available at australiansuper.com/pds or by calling 1300 300 273. You should consider your debt levels before adding to your super. AustralianSuper Pty Ltd ABN 94 006 457 987, AFSL 233788, Trustee of AustralianSuper ABN 65 714 394 898.

It’s Australian. It’s super. And it’s yours.

As Australia’s biggest super fund, 2.2 million Australians trust us with their hard-earned money. And they do their bit too by taking small simple actions, so together we can make a big difference to their future.

This is general information only and doesn’t take into account you personal objectives, situation or needs. Before making a decision about AustralianSuper, consider the PDS at australiansuper.com. AustralianSuper Pty Ltd ABN 94 006 457 987, AFSL 233788, Trustee of AustralianSuper ABN 65 714 394 898.

A035 08/18

We could make a big difference to yours too. Let’s get started at australiansuper.com

Industry Insights

How to Lower Your Workers’ Compensation Insurance Premium Workers’ compensation is typically the largest insurance cost for a business. Unlike other types of business insurance, if workers’ compensation insurance is not actively managed, your premium can increase materially and quickly. In fact, unless there are controls in place, the cost of workers’ compensation has the potential to cripple companies, both large and small. The way in which insurance companies calculate workers’ compensation premiums varies from state-to-state. However, the typical factors that influence the cost of workers’ compensation premiums include wages, the costs associated with previous claims lodged, the type of business insured, and the risk profile associated with the business. Tips to Keep Your Insurance Premium Low There are a few tactics and programs that business owners and managers can implement to help keep insurance premiums as low as possible. Establish an effective safety program. With the cost of premiums based on the cost of previously lodged claims, reducing the frequency of injury in the workplace is essential. The most effective way to do this is to implement an effective safety program. This program should include factors such as the appointment of a dedicated Workplace Health and Safety Officer, hazard prevention and control, and education and training for all employees. Respond to on-the-job injuries immediately. It is important to develop and implement processes that ensure employees injured while on-the-job receive immediate, appropriate care. Employees should also know that they need to immediately notify their supervisor or employer if an injury occurs, and to document the incident so that it can be avoided in the future. Implement a strong, comprehensive ‘Return to Work’ program. A strong ‘Return to Work’ program ensures that injured employees return to work as quickly as possible, thereby minimising (or in some instances, eliminating) lost-time claims. A strong ‘Return to Work’ program also demonstrates to employees that they are a valued member of the team who can contribute to the business in ways other than just that outlined in their Position Description. This, in turn, has been shown to speed up recovery rates. How Gow-Gates Can Help Gow-Gates has provided clients with national workers’ compensation services since 1963. Their dedicated Workplace Solutions Team specialises in delivering cost-effective insurance solutions to businesses of all sizes. Gow-Gates holistic and innovative approach focuses not just on reducing workers’ compensation premiums, but also on mitigating workplace risk and minimising the administrative

steel Australia

Autumn 2019

burden and indirect costs of workers compensation to your business. Gow-Gates National Workers Compensation Services include: • Design and implementation of the optimal policy structure for your business, delivering immediate and sustainable premium savings • Strategic claims and injury management • Early intervention solutions • Premium forecasting and management strategies • Formulation and negotiation of premium appeal submissions • Marketing and placement of policies • Performance reporting and analysis • Insurer and service provider management • Advice on alternative premium models and schemes (Loss Prevention and Recovery, Authorised Provider, self-insurance and Comcare) • Education and training • Key market and legislative updates • Ad hoc professional advice and recommendations Complimentary ‘Health Check’ for ASI Members As a partner of the Australian Steel Institute, Gow-Gates Insurance Brokers are offering members a complimentary ‘health check’ of your Workers Compensation program, together with an executive report. To learn more and arrange a complimentary ‘health check’ for your business today, please contact Chad Hewitt (Manager, Workplace Solutions) for further information on: (02) 8267 9913 or chewitt@gowgates.com.au. For further information, please visit: www.gowgates.com.au

Gow-Gates Insurance Brokers Proud partner of the Australian Steel Institute. Our specialist team understands the unique requirements of your industry and can tailor a comprehensive and competitive insurance programme to support you and your business. Contact us today to discuss your insurance needs and how you can take advantage of our risk management services. P: (02) 8267 9999 E: asi@gowgates.com.au W: gowgates.com.au Gow-Gates Insurance Brokers Pty Ltd ABN 12 000 837 785 | AFSL 245432

Industry Insights

Confidential Structural Safety Reporting Scheme Launched The Institution of Structural Engineers has launched CROSS-AUS (Confidential Reporting on Structural Safety – Australasia). This is a unique safety reporting scheme that allows construction professionals to make confidential reports about structural failures and safety concerns. CROSS-AUS is designed to share structural safety issues and help prevent future failures. The CROSS model uses the same confidential reporting techniques developed in the United States aviation sector to ensure that all identifiable details are kept completely confidential, while providing valuable insight into how safety issues occur. Reports can be made via the CROSS-AUS website: www.cross-aus.org.au. All reports will be published on the CROSS-AUS website (after all identifiable details are removed), helping to facilitate knowledge sharing and spur the development of safety improvement measures. CROSS-AUS will also publish quarterly newsletters on its website with the latest reports and comments from the Expert Panel.

2005 it has been instrumental in influencing improvements in safety. With growing interest from organisations in several countries, parallel schemes are developing internationally. Each has its own identity, but reports and publications are held in a common database for engineers everywhere to use. For details and examples, visit: www.structural-safety.org.

According to the President of The Institution of Structural Engineers, Faith Wainwright, “As professional engineers, we have a profound duty to ensure the safety of all those who use the structures we design and build. Sharing feedback on near misses or concerns is not always easy and CROSS is a successful community platform to allow professionals to do this simply, without attributing blame.”

What You Should Report to CROSS-AUS There are various concerns that should be reported to CROSSAUS, including structural failures and collapses, as well as safety concerns about the design, construction or use of structures. Near misses, or observations relating to failures or collapses which have not been uncovered through formal investigation are also welcomed. Small scale events are equally as important—they can be a precursor to major failures. No concern is too small to be reported and conversely nothing is too large. Your report might relate to a specific experience or it could be based on a series of experiences indicating a trend, which may require industry or regulatory action.

“Newsletters provide expert insights for all, and the more reports we gather the better we can understand the extent and occurrence of safety issues. I would therefore encourage all those involved in construction activity to submit reports to CROSS-AUS. Learning across national boundaries is vital, as frequently the experiences in one country are directly relevant to another. The CROSS model has operated successfully in the UK for many years, and we are working to expand as an international safety reporting scheme wherever we can.” Why You Should Report to CROSS-AUS Analysis of the reported safety issues can provide insight into how the concerns or events occurred, and spur the development of measures to improve public safety. Since CROSS was first established in the United Kingdom in

The Benefits Offered By CROSS-AUS • Share lessons learned to prevent future failures • Spur development of safety improvements • Unique source of information • Improved quality of design and construction • Possible reduction in injuries and fatalities • Lower costs to the industry

steel Australia

Autumn 2019

Given the strong link between non-compliance and structural safety, the ASI believes it would also be appropriate to report instances of non-compliance that have the potential to affect structural safety. We do not necessarily need to wait until a failure occurs to highlight structural safety related issues. Why CROSS-AUS is Confidential The confidential reporting techniques employed by CROSS were first developed by NASA for the aviation industry in the United States. A confidential system allows safety issues to be reported without creating concerns in areas like coworker relations, client loyalty, or insurance. It promotes a no-blame culture. The reporter’s personal information and any identifiable details, such as a project, product, individual or organisation, are completely confidential to CROSS-AUS, with only the Designated Persons having access to personal information. Information on the Designated Persons can be found on the CROSS-AUS website. Further Information For further information, visit www.cross-aus.org.au, or contact administrator@cross-aus.org.au.

ShedSafe® Launches Site Check ShedSafe® is pleased to announce the launch of Site Check—a web-based site classification tool specifically designed for the Australian steel shed industry. Utilising ShedSafe®’s proprietary Site Check software, engineers are able to review both the location and design of a proposed shed, and certify that the structure is compliant to Australian Standards for wind, snow and earthquake loadings for the specific location. As such, consumers have peace of mind that the correct specifications are adhered to for their specific shed and site. According to Neil Creek (National Manager, ASI ShedSafe®), “The Site Check program applies the wind loading factors outlined in AS1170.2 Structural Design Actions - Wind Actions, and determines site specific wind speed for a specific location.” “Utilising Google earth to pinpoint the site location, Site Check can establish Building Importance Level, snow load and earthquake loadings. The software also offers durability to up to 1km around the site and is able to prompt a response for bodies of water.” “Site Check can be used by shed re-sellers to provide site specific quotations. Once a re-seller completes a job, it is automatically referred to an engineer to evaluate and provide site specific certification,” said Creek. Site Check Benefits The benefits offered by Site Check include: • All quotations for the same site will utilise the same engineering design criteria, so that consumers can compare ‘apples with apples’ • Ability to pin the site for accurate site assessment for any location in Australia • Re-sellers can email the Site Check link to consumers to pin their site • Consumers can be encouraged to look for wind speed site ratings on all quotes, thereby exposing any issues of non-compliance • All ShedSafe® accredited manufacturers will be using the Site Check program

About ShedSafe® Founded in 2010, ShedSafe® is the national industry benchmark for Australian manufactured steel sheds. It is a third party accreditation program intended to ensure buyers have confidence in the engineering, steel products and site specification of the steel shed they are purchasing. ShedSafe® is managed by the Australian Steel Institute. The ASI ShedSafe® program requires members to have their engineering designs routinely audited by an independent panel of consulting engineers to ensure designs are compliant with current Australian Standards. As such, ShedSafe® accreditation offers assurance that your shed is compliant with the Building Code of Australia. Comprehensive Testing & Trials Prior to its launch, the Site Check Software underwent in-depth testing and trials. Several of ShedSafe®’s manufacturing members provided valuable feedback, enabling ShedSafe® to make some important user enhancements to the Site Check software program. “The feedback provided by ShedSafe® members led to several improvements within the Site Check software. For instance, Site Check now allows for the automation of terrain category, shielding and topography. This greatly streamlined the classification selection process,” said Creek. “In fact, in Site Check trials run to date, some manufacturers have experienced improvements in up to of 50% of their designs, allowing for more accurate and more economical classification.” Further Information For further information, visit http://shedsafe.com.au, or contact shedsafe@steel.org.au.

Autumn 2019

steel Australia

Industry Insights

The Value of Using Steel Steel provides a particularly high quality, safe, and costeffective solution for building structures, delivering value both during the initial construction, and over the full lifecycle of an operating structure. Choosing steel as the key construction material from the outset of a building structure project can provide myriad benefits, from savings in the construction schedule, through to on-site labour and logistics cost-efficiencies. The use of steel can also minimise impacts on the design of other major elements within a project, such as cladding and service installations. The choice of material for both framework and form generally occurs early in the design process, and is often based on early design principles, limited information and budget costings. While it is possible to change framework material at a later stage—which happens regularly when a steel option is presented—choosing a steel solution from the outset can have several positive outcomes. According to Peter Key (National Technical Development Manager, Australian Steel Institute), “Cost is obviously a key consideration in the decision-making process, but it should not the only one. It is vital to support informed decision-making with realistic cost information at the conceptual design phase, before it is then refining during the detailed design phases.” “This may be a challenging task given that the cost of structural steel can fluctuate throughout the economic cycle and steel frame costs are also heavily affected by projectspecific key-cost drivers, such as program, access, spans, and building form,” said Key. “In addition, the initial construction cost of a structure is usually only one small component of its long-term lifecycle cost. In fact, it is estimated that the initial construction price of a building accounts for only approximately 2% of the lifecycle cost over a 30 year period. Therefore, value engineering

steel Australia

Autumn 2019

should realistically take account of the life-cycle cost of a structure, not just its initial construction cost.” Value Engineering “The most effective approach to reducing steelwork construction costs is through pragmatic value engineering. Steelwork responds exceedingly well to considered approaches to rationalisation, with the potential to reduce costs in all phases of the building supply process,” said Key. “Ideally, value engineering should commence at project inception when the capacity to influence design outcomes and the benefit to the final design are the greatest. Specific value engineering workshops early in the project planning and conceptual design process can help maximise value for money. The definition of what is good value on any particular project will change from client-to-client and project-to-project.” Structural Frame Cost Components To rationally cost a constructed steelwork project at each stage of the design development process, it is therefore necessary to have an appreciation for the approximate relative cost components of a completed steelwork structure. The raw material cost accounts for approximately 30% to 40% of the finished structure cost, with fabrication accounting for another 30% to 40%. Therefore, while a minimum structure weight is an admirable objective, if achieving this objective comes at the expense of overly complicated fabrication or connections, any cost saving in weight are likely to be overridden by an increased fabrication cost. “The art and science to a cost-effective overall structure lies in the right balance between steel tonnage and fabrication complexity. Value engineering aims to find that right balance,” said Key. The construction cost accounts for 10% to 15% of the finished

Stage 1: Building Type-Based Costing Initial cost estimates before any substantive design is undertaken may be based on the costings of similar, already complete projects. Standard industry publications providing regularly updated cost indices for various types of construction may also be utilised, although care should be taken to understand the scope and limitations of these figures.

Image courtesy of worldsteel and Shawn Koh.

structure cost. Factors that mitigate the erection cost should be examined carefully. Prefabrication of assemblies, the extent of repetition, the piece count and the ease of assembly of connections can all significantly impact on the construction cost of the framing Fire protection is another 10% to 15% of the finished structure cost. According to Key, “A fire-engineered solution can significantly reduce the cost of fire protection, including negating the requirement for any fire protection in some cases. An initial investment in fire engineering will, for all but the simplest of structures, have a very positive return on investment.” Engineering is a small percentage of the finished structure cost. A contractual arrangement that incentivises value engineering can lead to a significant multiplier effect in relation to savings in overall project cost. The supplied cost (raw material + fabrication) of the fabricated steelwork represents a very significant 60% to 80% of the finished structure cost. It is therefore very important that the correct representative cost figures are used, often quoted as $/tonne. Costing Structural Steelwork The approach to costing structural steelwork necessarily varies depending on the stage of the project design development. The accuracy of any costing exercise depends on the level of design information on which it is based. At very early stages of project evaluation, a quantity surveyor may utilise simple area-based ($/m2) rates for different types of structural steelwork based buildings. As the design progresses, and information becomes available on the type of steelwork and member sizing, the $/m2 rates can be refined with input from fabricators, culminating finally in a ‘hardnumber’ quotation from selected fabricators during tendering. “An important part of obtaining a value-for-money solution is taking the opportunity to value-engineer the design during the design development. Early engagement with fabricators and steel detailers can help inform the selection of the member and connection details to achieve the right balance of structural weight versus simplicity of fabrication and erection,” said Key. Design Cost Planning The type and accuracy of cost data depends on the level of design information on which it is based and is therefore related to the design development stages, summarised below.

Stage 2: Structural System-Based Costing Once some early-stage design development has been undertaken, the structural engineer should be able to provide indicative area-based tonnage rates (kg/m2) for the different structural systems present in the building (such as suspended floors, columns, secondary infill steelwork, and so on). A more refined estimate of the erected structure cost can be developed once several factors are understood, including: the area or linear meterage of the respective structural systems, a realistic rate for supplied and fabricated steelwork ($/tonne) for each of the structural systems, and the corresponding erection rate. “At this stage, it is important to have a realistic, representative cost per tonne for the particular structural system type. The fabricated cost per tonne for steelwork can vary significantly depending on the complexity of fabrication and the type of raw material. However, the type of fabricated steelwork utilised for standard multi-level building construction is usually at the lower end of the cost per tonne range,” said Key. Stage 3: Elemental Costing As the design progresses, information on member sizing and connection detail should be made available by the project’s structural engineers. At this stage, the structural system can be broken down into four prototypical components: • Main members: carry the primary loads through to the foundations, and include beams, columns and trusses. • Secondary members: carry specific loads or trimming openings and the like. These members are usually smaller than the main members, but may involve similar levels of fabrication. • Fittings and connections: including bracing, stiffeners and the connections that transfer load between structural members. • Miscellaneous items: such as temporary steelwork, steel decking for composite floors and stair units. Building Information Modelling and Costing “Building Information Modelling (BIM) is becoming increasingly prevalent, particularly as it provides an opportunity for achieving higher-quality and more accurate costing at earlier stages of a project’s lifecycle,” said Key. So-called 5D modelling (3D + project schedule + project costing) makes use of the element-based 3D modelling in BIM to overlay cost data, including down to the element level. If current accurate cost data is utilised in the model, the overall project cost may be continuously and virtually automatically updated as design development within the BIM model evolves. This article was first published in The Building Economist published by Australian Institute of Quantity Surveyors. References • https://www.steel.org.au/focus-areas/steel-in-buildings/ • https://www.steel.org.au/focus-areas/steel-in-buildings/steel-costing--multi-level-construction/ • https://www.steel.org.au/focus-areas/value-engineering/

Autumn 2019

steel Australia

Feature: Industry 4.0 and Steel

Global Steel Industry Rises to the Challenges of Industry 4.0 The advent of more and more sophisticated artificial intelligence systems is allowing the steel industry to augment and improve its production processes. The steel industry is leading the way in ‘smart production’, and seizing the opportunities presented by the fourth industrial revolution. From the steel industry’s perspective, Industry 4.0 means almost-autonomous steelworks. People, products and production facilities are fully connected through the Internet of Things (IoT). Sensors collect vast amounts of data, and that information is then interpreted by artificial intelligence (AI). This optimises the production line and creates synergies across the facility. Welcome to the smart factory. The Brains of the Operation South Korean firm, POSCO, operates two of the largest steelworks in the world – in Gwangyang and Pohang – and produced 41.6 million tonnes of steel in 2016. Its POSFrame software platform amasses big data gathered by a huge cluster of sensors, and then sends it out to inform AI processes. “Whereas before we had silos of data everywhere, now we put it all in [the POSFrame software platform],” said JinSoo Park, project leader for POSCO’s Smart Factory. As the brains of the operation, POSFrame has had a lot to learn, and POSCO has been asking its most experienced staff to help educate its AI. “Much of the great know-how we have is hidden inside our operators or engineers. We’re trying to get that knowledge out of their heads and codify it into something that we can then call ‘intelligence’,” said Park. A quote from famed management consultant and author, Peter Drucker, is a guiding maxim for POSCO and other steel producers: “If you can’t measure it, you can’t manage it. If you can’t manage it, you can’t improve it.” Safety, Efficiency and Productivity Dr Franz Androsch, Head of R&D and Innovation at Austrian steelmaker, voestalpine, stresses that this potential for the complete documentation of all production steps is what defines Industry 4.0 as a concept. “A wide array of electronic measurement and monitoring systems automatically record, network, and use numerous machine and product parameters to control the machine and ensure quality. This makes it easier to plan downtimes, increase productivity, and ensure top quality.” Knowhow from the floor is at the heart of any smart steelworks, and at the heart of any steelworks is the blast furnace.

steel Australia

Autumn 2019

Continuous casting machine. Image courtesy of worldsteel and Robert Kolykhalov.

voestalpine has already seen impressive results at its integrated facility in Linz. Blast furnaces need to be continually charged with alternating layers of coke and sinter; these layers ensure a uniformly efficient gas flow. Until recently, topography and temperature irregularities were difficult to identify. Now, using 3D-radar technology, voestalpine has been able to develop a comprehensive model of the charging process that includes real-time measurement of blast furnace conditions, which has led to higher yields and reduced emissions. The convergence of experience from the factory floor and new technologies is also making for a safer place to work. Nippon Steel and Sumitomo Metal Corporation (NSSMC) is trying to predict hazardous situations before they occur, in order to become a zero accident-workplace. Engineers wear smart hardhats equipped with cameras, hazardous gas sensors and accelerometers. Geo-fencing technology provides an indoor positioning system within the plant. If a worker arrives in an area known to be dangerous, the hardhat can alert them. Likewise, if they fall or end up in an abnormal position, it alerts the system. A Data Revolution Data sets on the steelmaking process were available before, but the technologies of the fourth industrial revolution are unlocking new possibilities that allow steel producers to collect more data in different ways from of a myriad of smart sensors and smart systems that communicate over a local network. For example, when a slab makes its way to the reheating furnace, laser sensors check the air intake. The results are fed back to the AI to get the right temperature on the plate. The heat on the top and bottom of the slab are then measured to gauge if there is a difference.

“It is so important to control that differential. Otherwise the slab will have to go through another rolling process,” said Park. “The data allows us to trace back to exactly which operation and at which position a defect in a product occurs. On which shift and on which day, and under what conditions. A slab can also get twisted in there, and that can wreak havoc on the production process and cause accidents.” POSCO has been using time-based maintenance to keep its equipment in good working order, and smart factories open up greater possibilities for improving this. “We’re trying to inject some kind of intelligence into our processes so we can do more predictive maintenance,” Park said. “That means we’re not only lowering the cost, but also reducing the unplanned downtime.” Steel plants are 24/7 operations that have to be online. Just as you cannot replace an aeroplane’s engine while it is in the air, it is very difficult to replace individual units one at a time in a plant. For Androsch, “Digitalisation also changes how we interact with suppliers and customers, for example using new online platforms, apps, and other systems that offer order tracking and other services.” As such, it is opening up possibilities for entirely new business models. Dr Martin Pei, Executive Vice President and Chief Technology Officer at Swedish steel producer SSAB, foresees the development of an entire digital ‘manufacturing ecosystem’ in which the data accumulated by both downstream and upstream industries is incorporated through the whole value chain. “Ecosystem participants get to provide new services and enter new business positions,” he said. Conserving Energy In addition to using data to make gains in productivity, steel producers are installing smart meters and other sensors to cut their CO2 emissions and reduce wasted energy. Many plants generate a lot of their own electricity using the gas from their furnaces and rolling processes. However, many also use large amounts of power from the grid, which they are always looking to reduce. Different steel grades need different amounts of energy, and sensors are now able to measure exactly which grades of steel are the most energy intensive. Steel producers can then analyse energy pricing to position certain grades in the production line so that they are manufactured when power is cheapest.

Digitalisation changes how we interact with suppliers and customers, for example using new online platforms, apps, and other systems that offer order tracking and other services. As such, it is opening up possibilities for entirely new business models. Putting the Right Team Together Assembling the right team of people is also very tough. A data scientist can come to work at POSCO, but they might not have the specific domain expertise required. To ensure successful team operations, the company has been running a ‘Smart’ program to instill its engineers with its ‘Smart culture’ in order to trigger a group-level mind-set change. Customers and suppliers also have access to the program, as do young jobseekers. “Korea’s unemployment is serious at the moment, so we’re also opening up the big data and AI course to them,” Park said. Despite fears of robots taking jobs from people, the Smart Factory is not leading to a reduction in the operational workforce at POSCO. Instead, an employee is less likely to find themselves on the factory floor and more likely to be analysing data or working in R&D on the next innovation. According to Androsch, these kinds of changes are not surprising. “Automated processes and plants require employees, who understand how robots function, their requirements, and how they need to be managed. That is a lot of work for humans. There are training facilities for employees implemented at the relevant production plants.” Faced with increasing competition – not just from other steel companies, but a wide range of manufacturers of other materials – steel producers are embracing the opportunities that industry 4.0 presents to increase efficiencies and enhance their sustainability credentials. This article was originally published by the World Steel Association (worldsteel).

Modern control centre in a blast furnace ironmaking plant. Image courtesy of worldsteel and Gregor Schläger.

Autumn 2019

steel Australia

Feature: Industry 4.0 and Steel

Industry 4.0 and BIM: Reshaping the Construction Industry According to some commentators, the construction industry is on the cusp of a new industrial age. The fourth industrial revolution (or Industry 4.0) will see construction practices and players alike adopting more advanced technology, bringing the industry in line with some of the more digitally developed industries. This will revolutionise not only how physical structures are designed and built, but how they are maintained across their entire lifecycle. One of the vital components of Industry 4.0 is digital data. With improved access to accurate, live data during all stages of an asset’s lifecycle – from design and construction right through to ongoing maintenance – both cost and time efficiencies can be pinpointed, thereby reducing errors. The benefits that are possible through the use of digital data are already evident in the construction industry’s initial adoption of Building Information Modelling (BIM). According to Vinod Muthanna (CEO, DBM Vircon—owner of PDC, Candraft and BDS VirCon), “In the past, BIM has typically been used in relation to the construction of projects. The steel industry is a little ahead of the curve in terms of its utilisation of BIM. For years now, milimetre perfect models have been supplied to fabricators, who feed these into their CNC machines and welding robots—everything is already highly digitised.” “However, in recent times, the application of models has expanded. We are taking the multitude of models used during construction, to create one consolidated model that can be used for long-term facility management.” “Construction is a relatively short process of just one or two years. But the building itself has a lifecycle that can go on for over a century. Models can be used over that lifecycle to effectively manage the facility, particularly if the building is a plant, such as a power station.”

Smart Facilities Management Imagine being able to visually manage a crisis in an asset intensive process plant through a graphical interface with live streams of data and visuals; whilst accessing data from the plant’s Enterprise Resource Planning (ERP) system, all through your tablet, while you are located miles away. “Smart connected facilities with a graphical interface to mobile devices offer exponential opportunities in functionality, as well as vast benefits in safety and productivity,” said Muthanna. “Utilising BIM as the visual front-end to the facility’s ERP system creates a cutting edge platform for facilities management.” Why Demand is Gaining Rapid Momentum The demand for such cloud based, mobile augmented reality platforms is gaining rapid momentum with: • The wide spread adoption of ‘Industrial Internet’ and ‘Internet of Things’ based strategies driving demand for smart, connected facilities • Growing demand for remote facilities management driven by safety and productivity considerations • Advances in BIM software interoperability, increased integration with ERP systems and the development of visual integrators by firms such as SAP and IBM • Advancements in cloud computing, coupled with increased penetration and capabilities of mobile devices Integrating BIM and ERP Systems “Integrating the BIM into an ERP system, and then to sites sensors, cameras and other monitoring devices, is key to unlocking value and providing a connected, augmented reality interface to the typical menu driven ERP system. This will enable operators to select items from the model to get live feeds from on-site sensors and cameras,” said Muthanna.

“There are a lot of moving parts in a power station that require constant maintenance—having a live model that reflects the real-world circumstances on the ground really helps simplify and streamline ongoing management and maintenance processes.”

“Work order history and maintenance data can be dynamically retrieved by clicking on the graphical object on the model. Conversely, the ERP system can be queried to ‘show all items that are due for preventive maintenance in the next week’. The system will then visually highlight all the objects in the model, enabling tasks such as routing, sequencing and spatial analytics to increase safety and ‘wrench time’.”

“For example, PDC (a DBM Vircon firm) is currently working on a project in which we are consolidating over 250 construction models into one. The aim is that, at the end of construction, we will be in a position to hand over a fully complete federated model to the building owner who will then use it to manage the facility. The model can be integrated into whatever asset management platform the building owner wishes to use – typically IBM’s Maximo, or SAP. We expect our model to be the visual centrepiece for this particular facility within the chosen asset management program,” said Muthanna.

The Key Attributes of a BIM To achieve this, a smart connected facility’s BIM must have three key attributes: 1. An accurate, data-rich, model that is navigable and accessible—a lightweight easy to use model 2. A model that is fully integrated with the facility through smart technology, so that site sensors and cameras can be accessed and monitored through the model 3. A model that is integrated to the facility’s ERP system so that data (manuals, maintenance schedules, parts

steel Australia

Autumn 2019

inventory, assembly videos, engineering drawings, and so on) can be readily assessed by just clicking on the relevant object on the screen Benefits of Linking Smart Facilities with BIM “The BIM makes it easy to visualise tasks, when compared with viewing printed or on-screen lists of equipment numbers,” said Muthanna. “It unlocks immense benefits for the operation and maintenance of facilities such as, improved site safety, by planning and coordinating field tasks remotely.” “Virtual walk-through of plants for training purposes and quick, safe problem resolution. It also offers enhanced knowledge capture through the graphical interface and visuals, as well as improved safety, productivity, responsiveness and decision making through one touch graphical access to asset information, engineering and facility data. Shutdowns are safer due to pre-planning, animating and rehearsing remotely, and even using virtual reality.”

The Future According to Muthanna, “The whole facilities management space is still in its infancy – it hasn’t really powered up yet. Once building owners and facility managers realise the benefits of using these models, it will force change on the entire construction industry.” “At the moment, players within the construction industry sometimes use BIM, and sometimes they do not. However, if facilities managers begin to demand models as part of the construction output, construction project requirements for contractors and constructors will change dramatically.” “With some state governments—including the Victorian and Queensland State Governments—demanding models for newly constructed buildings, it is looking more and more likely that these models will become commonplace,” said Muthanna.

Perth Children’s Hospital.

Perth Children’s Hospital The $1.3 Billion Perth Children’s hospital is the first LOD 500 BIM project delivered for the Western Australian State Government and John Holland. PDC (a DBM Vircon company) was engaged by John Holland throughout all phases of the project, from concept design all the way through to completion and will stay with the project throughout the initial phases of operations. PDC was responsible for the entirety of the BIM strategy, implementation and management of the project, stationing BIM Managers directly within the client’s project offices. Acting as an extension of the contractor team, PDC implemented BIM solutions ranging from initial model setup and coordination strategies, through to 4D simulations, 5D cost extraction and work packaging, and ultimately the transition of the fully as-built model to the customer’s facility management solution. These integrations within the project team enables PDC to maximise the utilisation and benefit of the project BIM environment, which included over 250 individual models updated and coordinated on a weekly basis. At the height of the project, PDC allocated three full time BIM managers to the site to manage the interface with designers, contractors, sub-contractors and end users, ensuring the requirements of all parties were adequately represented and BIM could be leveraged to build efficiency into all work streams. PDC also implemented numerous automated processes into the project, through the use of its in-house software development team, effectively reducing repeat effort for BIM workflows by as much as 90%.

Autumn 2019

steel Australia

Feature: Industry 4.0 and Steel

2019: The Year of Data

By David Dawson (General Manager, PDC Group)

Over the past 30 years, there has been an extraordinary transformation in steel design processes. Drawing boards, 2D CAD and 3D models have now progressed to intelligent, data rich environments, linking all facets of design, fabrication, construction, commissioning and asset operation. Whilst earlier stages of innovation and adoption of technology were easier to pinpoint, the gradual uptake of utilising the data embedded and appended to 3D models, has often happened in the background—many of the providers of information may not have even been aware of how the data was being used. To some, this year will be like any other. Engineers will produce design drawings, shop detailers will provide fabrication drawings, fabricators will fabricate, and with each step closer to a finished project, the information that each party has worked hard to perfect will be gradually lost, until it is no longer reliable or useful. For others, 2019 is the year of data. It is a year in which tools and technology have become increasingly user friendly and cost effective, presenting enormous opportunities to extract further value from the data within the design process—all of which reduce delivery costs, improve schedules, and assist in effective planning that reduces risk and safety concerns. So far in this article, I have avoided using the term BIM (Building Information Modelling) because—quite frankly— many people are scared by it. Many have had a bad experience where they have been engaged on a project without any clear understanding of what ‘BIM’ really means, what they are required to do, or why anyone wants them to conform to a BIM standard in the first place. Furthermore, even when able to comply with a standard, many people have not had the opportunity to understand how BIM may benefit their own businesses. BIM is often equated to one of the latest buzz words—a bit like the ‘superfoods’ spirulina or quinoa. All these products advertise great benefits, but, after purchase, consumers cannot help but question whether it is really as good as ‘the experts’ claim.

4D Construction Sequence - Primary Crusher Structure.

Instead, I will discuss Digital Engineering; the broader, less over-hyped cousin of BIM. Digital Engineering encompasses BIM and delves into other means and methods of combining, controlling and using design, fabrication, construction and operational data and documentation. Digital Engineering does this in order to improve the efficiency and performance of each step of a project’s development and delivery. Digital Engineering and Steel: 1990 to 2018 In Australia, early examples of the steel industry transitioning towards 3D models started to emerge in the early 90s. The technology was new, but immediate benefits were realised as a result of the ability to visualise a project in 3D before fabrication. Throughout the 1990s, the ability to identify and virtually resolve constructability and erectibility issues improved scheduling and reduced site based rectification. By the time we entered the 2010s, 3D modelling software had advanced far from its simple roots. Today, the software enables teams to work across multiple locations in the same models, interface and clash check against other disciplines, ‘clone’ repetitious portions of the model, and create, append, store and extract vast amounts of useful metadata. Engineering and shop detailing companies have sought more efficient workflows through earlier commencement of detailed modelling activities, in collaborative and integrated environments, providing earlier and more constructible deliverables to fabrication. Beyond the realms of engineering and shop detailing, fabricators use the electronic data, created by the 3D modelling process, to automate significant amounts of the fabrication process. In addition to reducing the fabrication schedule, fabrication is safer and competitive against similar quality offshore fabrication. The Australian steel industry has embraced technology, but, going forward, there is still much more that can be achieved.

Feed Bin - Iron Ore Handling Plant.

steel Australia

Autumn 2019

2019 Schedule control is critical to all commercial, industrial and infrastructure projects. On large scale projects, digital engineering processes are now being used to extract incomplete design information contained within detailed

3D models, combine with non-3D model data to provide early material information to allow for earlier planning and ordering of materials. The ability to access and utilise this information, across an entire project, weeks, or even months prior to finalised design information, allows project teams to commence procurement earlier. This ensures that long lead items are ordered and available. With continued advancement of software, it is now quick and cost effective to use 4D schedule sequenced animations to support construction planning. Accurately scaled cranes and equipment are combined with detailed design models and then animated with schedule information. Another example of the uptake in Digital Engineering processes is the back modelling of existing facilities to enable digital engineering processes to be utilised. There are numerous industrial facilities across our country that have been designed and constructed prior to 3D modelling technology, or before there was identified value in retaining and updating the models. With more cost effective and accurate laser scanning solutions becoming available, more and more industrial companies are considering how to best manage and maintain their facilities. Through millimetre accurate laser scans, it is possible to combine any existing facility models and back-model, using existing drawings and laser scan information, to provide an up to date model of the facility. Once a digital asset has been created, there is an extremely powerful model that not only provides a fabrication-ready model for any structural remediation work, but also provides a visual platform to support efficiently capturing new data and information. Predictive maintenance programs are being widely considered across the industrial sector, and open new opportunities for owners, contractors, and fabricators to work collaboratively to improve maintenance activity. The Downside of Reliance on Technology One of the most notable changes, currently occurring across Australia in the steel industry, is a loss of skill and experience as companies become reliant on technology. 30 years ago, a shop detailing draftsperson was highly skilled at understanding how something was put together. The ability to visualise the process in their minds, and convert this information to 2D drawings for others to then carry out this work, is a skill developed over many years of experience. New technology no longer requires a 3D construction modeller to develop this skill, and there is now a strong reliance on technology to undertake this process. This is not to say that the modern

“As all parts of the design and construction industry become more reliant on technology, it is becoming increasingly important for all parts of the supply chain to utilise and embrace technology.” “With 2019 continuing to unfold, it is exciting to see the steel industry continuing to evolve through capitalising on new and improved ways of utilising Digital Engineering. The question will be whether companies will embrace Digital Engineering because their clients require them to, or whether they will use it to their own competitive advantage.”

workforce is not highly skilled and capable—rather, their skills and capabilities are different. Their value is tied to their capability in the use of the technology, rather than their experience and knowledge of the respective field. There is a similar impact across all aspects of the delivery cycle, where companies are reliant on technology, rather than experience. Many companies are beginning to understand the potential impact of losing this knowledge and experience, and are taking measures to retain and develop these skills. Beyond 2019 As all parts of the design and construction industry become more reliant on technology, it is becoming increasingly important for all parts of the supply chain to utilise and embrace technology. Many government and private company projects are now mandating processes that are reliant on accurate 3D models and data. Ultimately, these processes are only as useful as the information and data is reliable. Whilst for many design consultants and digital engineering service providers, these processes and requirements are second nature, for other companies, there is a requirement to upskill or develop close collaborative relationships with third parties to support their requirements. Additionally, many of the complex BIM processes that have relied on experts to create and manage are becoming increasingly user friendly. Activities that have previously required weeks of set up and ongoing effort to extract information are being built into software and applications. This allow less experienced operators to achieve value from digital engineering solutions. The role of a ‘BIM Manager’ is transforming from a functional management role to an educator, policy maker and innovator. With 2019 unfolding, it is exciting to see the steel industry continuing to evolve through capitalising on new and improved ways of utilising Digital Engineering. The question will be whether companies will embrace Digital Engineering because their clients require them to, or whether they will use it to their own competitive advantage.

Wilshire Grand, Los Angeles.

This article was supplied by David Dawson (General Manager, PDC Group). For further information about PDC Group, please visit: http://pdcgroup.com

Autumn 2019

steel Australia

Feature: Industry 4.0 and Steel

Robotics and Automation in Australia’s Fabrication Industry Industry 4.0—the emergence of automation and data exchange in manufacturing technologies—can help fabrication operations of all sizes meet expectations from even the most demanding of customers. In the increasingly interconnected world around us, a small fabrication workshop has the potential to be as reliable and as responsive as even the largest welding competitors. While the adoption of Industry 4.0 concepts is a relatively new trend—it has really only gained momentum since 2015— technology such as robotics and automation are already changing the nature of the Australian fabrication industry. According to Dr Paul Shelley (Global VP Innovation, MolyCop), “One might define the change as a fundamental movement in work content and associated skill requirements. Industry 4.0 is significantly less labour intensive in the doing of work than our recent past practices. There are less people exerting physical effort. Work content has moved toward a technology skill set.” “This appears the case in all aspects of the job. Consider, for example, how we clock on with a handprint, how we are paid by electronic deposit, how we virtually train on new capital equipment, and so on. A business without a digital strategy or a developing digital portfolio is very difficult to find.” “Consider the case of a small Queensland fabrication business we are collaborating with (automation and digital has facilitated genuine collaborations like never before).

steel Australia

Autumn 2019

Struggling for growth, the owner purchased latest technology, automated machining centres from offshore. Securing that cost and quality benefit, the business pursued 3D scanning as a revenue stream. The concept is a success. As we speak, the business has experienced reasonable growth, has a better cost position and has funds for further growth,” said Shelley. Similarly, Jack Bain (Project Manager, Robot TechnologiesSystems Australia (RTA))—one of Australia’s largest robotics and automation companies) has seen fabricators enjoy a myriad of benefits as a result of introducing Industry 4.0 concepts. “The key benefits fabricators experience are more efficient and higher output and improved quality assurance of their products. Product consistency is also improved, both in terms of structural and cosmetic properties of components. There is usually a reduction in workplace occupational health and safety incidents, particularly cuts, burns and abrasions, and inhalation of hazardous fumes. Fabricators are better able to keep up with their competition through technological advances,” said Bain. The Challenges of Commoditisation and Differentiation However, Shelley emphasises that not everyone is seeing the benefit of Industry 4.0 concepts, automation and robotics. “We need to take a step back, and think about the Australian fabrication industry. There are the massive steel making monoliths like BlueScope and Liberty. Then, we have the first tier fabrication business such as Fremantle Steel,

Civmec, Thornton Engineering and Ahrens. After this, the industry becomes quite fragmented. The second and third tier fabricators are often small, regional, family-owned businesses.” “In this context, automation really does commoditise the offer. This makes it difficult to differentiate yourself, unless you have a really special offering. Increasingly, technology demands standardisation and process stability. Differentiation is more difficult. I think that will bring about a consolidation of the Australian fabrication industry.” Bain too, is well-aware that many fabricators face a raft of challenges, particularly when it comes to implementing robotics and automation. “One of the largest challenges fabricators encounter is adapting their existing product, process or workflow to suit automation. Oftentimes, fabricators are unwilling to deviate from the way in which they have built something for the last 20 years. This simply does not work when it comes to automation. You need to be flexible in terms of the way in which products are manufactured if you want to successfully implement automation.”

Artificially Intelligent Automation Delivers Fabrication Benchmark IR4—a global benchmark in artificially intelligent automation solutions—has recently delivered a world first demonstration for Rheinmetall. According to Chris Brugeaud (Chief Executive Officer, IR4 and SSS Manufacturing), “IR4’s track record is clearly on display at SSS Manufacturing’s facility, which operates the IR4 technology in the fabricated structural steel market. Utilising the IR4 automation technology, SSS Manufacturing has been able to establish itself as a global benchmark. Following a site tour, Rheinmetall identified that IR4 had the potential to deliver automation solutions that it is yet to achieve globally. As such, Rheinmetall sought for IR4 to deliver what would be a world first capability demonstration.” The Rheinmetall Combat Reconnaissance Vehicle (CRV) has hundreds of cylindrical bosses welded to the hull of the vehicle. Globally, Rheinmetall places and welds these bosses to the CRV manually, due to the variability in the hull shape at the point in the process where the bosses are attached.

“It can also be difficult to identify which part of an existing fabrication process would most benefit from automation. Automation may not be applicable to a fabricator’s entire workflow—automating smaller components within the workflow can improve the overall efficiency of production.”

This variability would typically create significant issues for an automation solution that needs to seamlessly integrate: 3D scanning of the hull profile; picking and placing the parts; welding the parts; and 3D scanning and measurement of the fabricated hull.

“Supporting the implementation of automation and robotics technology internally within a company is also essential. If a company is going to gear up—especially if the company has no existing automation—they must invest in the right skill sets internally to support the machinery,” said Bain.

“Not only did IR4 deliver a fully integrated demonstration with all these capabilities, it did it with an artificially intelligent solution where the only required input was the 3D model of the hull. This was achieved using IR4’s task-based approach to automation,” said Brugeaud.

Offline Programming and Advanced Laser Seam Tracking According to Peter Kuebler (Key Customer Technical Solutions Engineer, BOC), “Welding automation had previously been considered impossible due to extensive programming time, the size and geometry of the equipment, and the damage, distortion and uneven wear of components.”

“The system interrogates the 3D model to establish the tasks that need to be completed for fabrication. It then uses Artificial Intelligence to determine the fastest and most efficient way to complete those tasks, managing the full production environment and all processes, not just the welding paths. Product variants of the CRV would simply need the 3D model uploaded, and the system would automatically complete all of the integrated processing requirements. Impressively, the system could be just as easily used to undertake the same tasks on the LYNX vehicles, by simply uploading the model for that vehicle.”

“Advanced laser seam tracking, adaptive welding software, a new generation welding system and a modular robot configuration were used to develop a unique robot welding system for adaptive maintenance welding of heavy mining buckets and dump truck bodies,” said Kuebler. Laser imaging for welding and other processes has evolved into intelligent laser vision and sensing systems. Using a line configuration, the camera now only requires three measurements to recalculate the welding trajectory in 3D or 6D, allowing seam-finding to take only a matter of seconds.

“Not content to leave it here, as part of the demonstration IR4 delivered additional capability, including automated transition to weave welds for opening root gaps; and dimensional deviation heat map reports for management of the supply chain and through life support. And there is still significant further capability that currently remains untapped,” said Brugeaud.

“Today’s advanced, real-time laser tracking enables highspeed adaptation to dimensional variations, requiring minimal programming and tooling. Tracking ensures precise weld wire positioning in the joint, which enhances weld quality and appearance,” said Kuebler. The laser camera that was used includes adaptive welding software, which is essential for multi-pass welding. Travel speed and weave amplitude are modified to suit variations of root gaps and joint cross-sectional areas. If a gap exceeds a given dimension, the algorithm will stop the robot and move to the next tack or joint.

IR4 delivers a world first demonstration for Rheinmetall.

Autumn 2019

steel Australia

Feature: Industry 4.0 and Steel Robotics and Automation in Australia’s Fabrication Industry (continued) “The software enables real-time adjustment of weld placement and parameters for each pass using a fill control algorithm, which allows the controller to calculate the location of subsequent passes. This dramatically reduces programming time and maximises productivity. The laser camera is also used to ‘visually’ inspect the completed weld. The 2D images can be recorded, providing a permanent record of the weld profile and an integrated video camera enables remote monitoring of the weld,” said Kuebler.

understanding of how to implement a successful program.”

Shelley is enthusiastic about the impact that offline programming and laser tracking are having on robotics. “The development of sensors and sensor systems that integrate machine centres is impressive. Process control, condition monitoring, Reliability-Centered Maintenance (RCM) and lean manufacturing are moving forward very quickly with the help of automation and robotics. The use of laser technology is quite extensive now in safety, production, design, development, drone applications, and so on.”

For Shelley, fabricators must look at their overarching digital strategy. “Perhaps one might say robotics and automation is not the strategy, rather it is part of the broader digital strategy. I feel compelled to advise that any business must have a digital strategy and must understand what Industry 4.0 is, for them. A robot is not just a better way to cut plate, it is an integrated, self-learning, self-monitoring production centre that is able to communicate with your customer, if you wish,” said Shelley.

“I was recently part of a team to investigate rapid prototyping, including 3D printing, for our forging business. Team members were from Australia, Chile and the US. It seems very real that developing and commercialising products using offline processes (rather than disrupting existing production) will significantly reduce the total time to market for metal products,” said Shelley. Implementation of Industry 4.0 Concepts For fabricators looking to incorporate Industry 4.0 concepts within their business, expert advice, detailed planning and an overarching digital strategy are essential. Bain has some sage advice for fabricators, “If you have had little to no experience with automation and robotics, start at the lower end—on a simpler scale—so that you can gain a better

“If you have had little to no experience with automation and robotics, start at the lower end—on a simpler scale—so that you can gain a better understanding of how to implement a successful program.” “Your first step should be to quantify where automation is most needed within your business, and where it will be most beneficial. Then, calculate your expected return on investment, as well as the other costs that are likely to be incurred, such as technical support and consumables. Above all, do your research.”

steel Australia

Autumn 2019

“Your first step should be to quantify where automation is most needed within your business, and where it will be most beneficial. Then, calculate your expected return on investment, as well as the other costs that are likely to be incurred, such as technical support and consumables. Above all, do your research. Or, engage a consultant if you’re unsure where to start,” said Bain.

Multi-Process Welding Robot Cuts Weld Time By Up To 90 Percent Servicing, Maintenance and Welding (SMW) Group provides field servicing, maintenance and emergency repair and rebuild services to customers in Central Queensland. The team also provides complete plant and equipment management, supported by a range of mine site compliance activities. In response to SMW’s desire to make its large welding workshop more efficient, BOC and its integrator partner Robot Technologies-Systems Australia Pty Ltd (RTA) supplied and installed a unique robot welding system for adaptive maintenance welding of heavy mining buckets and dump truck bodies. Jack Trenaman, SMW Group Managing Director, said: “Our welding robot has dramatically increased our production capabilities, improved safety and quality, and reduced costs. BOC and RTA have helped set us apart from our competitors – no one else is doing this type of work with robots in Australia.” The Challenge A downturn in profitability across the mining sector caused by decreasing iron ore and coal prices has placed increasing pressure on suppliers like SMW Group to reduce costs for mining and haulage equipment maintenance, repair and remanufacturing. This was a challenge for SMW, as the maintenance and repair of buckets and truck trays required significant welding hours due to large quantities of weld metal and pre-heat temperatures of over 200°C. Safety measures to prevent operator injury, fatigue and heat stress also contributed substantial time and cost. With all this, it was not uncommon

for a single dragline bucket repair to take upwards of 2,000 man hours of welding.

solution and integrated software enable live monitoring and real-time analysis of welding procedures and data storage.

Automation of repair welding had not been considered a feasible solution due to the size and geometry of the equipment, as well as the damage, distortion and uneven wear of components.

To minimise programming time, RTA developed world-leading technology to convert encoded data from a DXF file into data that allows the robot to scan and weld any type of weld geometry. The SMW operator only needs to ‘teach’ the robot where the piece was located in space; the robot then uses the laser camera to scan the part and build weld paths based on data in the DXF file.

“It wasn’t until we met with BOC and RTA that we were able to find a solution that could meet the demanding welding procedures required for this type of work,” said Trenaman. The Solution To kick off one of the most complex automation projects they had worked on to date, RTA and BOC conducted indepth feasibility trials followed by an extensive research and development process – crucial to the ability to deliver a unique customised robotic system that suited SMW’s welding procedures. Utilising advanced laser seam tracking, adaptive welding software, a new generation welding system and a modular robot configuration, BOC and RTA built and installed the robot welding package and provided training for all SMW operators. The portable robot cell is the most versatile multiprocess welding robot in the world – comprised of a Kawasaki RA 15X robot equipped with a Servo Robot PowerCam laser camera and an EWM Phoenix 552 welding package, supplied exclusively by BOC. SMW’s robot is supplied Argoshield from a BOC CRYOSPEED Mix Onsite system. Built on a modular base, the robot can be positioned on, beside or beneath the component being welded, and utilises real-time laser seam tracking to enable multi-pass welding and to cope with complex weld joint geometry. The welding

The Benefits Since installing the welding robot, SMW has reduced its welding time by 70 to 90 percent. It has also reduced overall production costs, improved safety, quality and reporting, and broadened its range of work scope capabilities. “We noticed the benefits straight away – our team can now complete a specific welding task in just 30 hours, made up of 20 hours of robot welding and 10 hours of man labour. That same task previously took 120 hours of man-only weld time. “The real standout for our customers has been the consistently top quality of the weld – and greater quality assurance documentation. We can now access live detailed reports on temperature, gas flow, voltage and amps at any point in the welding process – all by logging in from a mobile device.” The robot has also eliminated the risks of fatigue, heat stress and working height restrictions, minimising risk of human injury and the need for ergonomic access planning. Commercially, it has boosted overall productivity, while reducing labour and associated personal protective equipment (PPE) costs. “Everyone at SMW has witnessed the robot’s potential and we’re fully invested in setting it up for continuous success.”

RTA’s robot system for adaptive maintenance welding at SMW Group.

Autumn 2019

steel Australia

Project Case Studies

New Museum for Western Australia The New Museum for Western Australia will integrate a new state-of-the-art building with the Museum’s existing heritage buildings to create contemporary and innovative visitor experiences. It will be almost four times larger than the old museum and feature nearly 6,500 square metres of galleries, including a single 1,000 square metre space to stage temporary exhibitions. There will also be education studios, and retail, food and beverage outlets. The $395.9 million project includes: • The design and construction of a new building that integrates with the existing heritage buildings • Heritage restoration works to the Old Gaol, Jubilee, Beaufort and Hackett buildings • A public art project at the New Museum Perth site • The design, production and installation of Museum content including collections, exhibitions, multimedia and artworks for gallery and activated circulation spaces • The Harry Butler Research Centre at the Museum’s Collections and Research Centre, Welshpool • A Central Energy Plant servicing the Perth Cultural Centre, which will reduce energy use and CO2 emissions in the Perth Cultural Centre The New Museum is being developed on the site of the existing Western Australian Museum in Perth. The heritagelisted buildings are being retained as part of the New Museum project, and the new building will integrate with these buildings to create a world-class museum. Design Excellence Multiplex—and its design team comprising HASSELL + OMA—was appointed as the Managing Contractor to design and construct the New Museum for Western Australia. The dramatic new design links contemporary architecture with the historic and heritage-listed buildings, creating a visual landmark for the state. The HASSELL + OMA design, to be

steel Australia

Autumn 2019

located in the heart of Perth’s cultural precinct, has been conceived as a collection of physical and virtual ‘stories’, providing a multidimensional framework for visitors to engage with the Western Australian people and places. HASSELL Principal and Board Director Mark Loughnan, and OMA Managing Partner and Architect David Gianotten said, “Our vision for the design is to create spaces that promote engagement and collaboration, responding to the needs of the Western Australia Museum and the community.” “We want it to create a civic place for everyone, an interesting mix of heritage and contemporary architecture that helps revitalise the Perth Cultural Centre while celebrating the culture of Western Australia on the world stage.” “Perth and Western Australia have a dramatic natural landscape, unique history and diverse population. We have tried to capture all these elements and celebrate them within the design concept,” said Loughnan and Gianotten. The scale of the natural landscape is reflected in the large public space at the heart of the design; the city’s history is celebrated by the integration of the existing heritage-listed buildings, and its stories which have driven every aspect of the Museum design. The design is based on the intersection of a horizontal and vertical loop creating large possibilities for curatorial strategies, for both temporary and fixed exhibitions. “At the heart of the design is a public space that is the central point of the new museum, in terms of both location and programming. It is a spectacular outdoor room framed by refurbished heritage buildings and intersected by new buildings and virtual platforms, enabling the diverse stories of Western Australia to be told,” said Loughnan and Gianotten. Conservation work to the facades of the Old Gaol, Hackett Hall, Jubilee and Beaufort Street buildings is now complete

BlueScope’s High Strength, Long Span Solution

According to Ian Thow (Specifications Manager – Western Australia, BlueScope), “Our involvement in the New Museum Project started a few years ago when the architect and engineer were investigating a number of solutions, including concrete and high strength steel for the long spanning structure.” “The construction site is right in the centre of the city. So, the structure needed to be as lightweight as possible. This way, the size of the crane and the number of lifts the crane needed to complete could be reduced as much as possible. We approached the engineers about using high strength XLERPLATE® steel manufactured by BlueScope, undertook a costings comparison, and pre-designed the structure using BlueScope’s materials.”

Artists’ impression of the completed New Museum in Perth.

and the interiors of these buildings will be revitalised as part of the main works. A large new temporary gallery space will complement the extensive permanent collection of the museum that includes renowned collections including the much-loved Blue Whale skeleton. The Museum will host a diverse range of cultural, retail and dining experiences, increasing visitor numbers especially after hours. Based in Forrestfield, Liberty is one of the local companies working on the New Museum. They are delivering and installing the reinforced steel bar that will strengthen and support the structure of the new building. By the time the New Museum is complete in 2020, over 1,500 tonnes of steel will have been laid within 12,100 cubic metres of concrete.

ASI members tour the New Museum construction site in early 2019.

“As a result, BlueScope’s high strength XLERPLATE® steel in G400 and G450 were specified for the New Museum project. In total, BlueScope has supplied over 1,000 tonnes of steel for the project, ranging from the high strength XLERPLATE® steel, through to COLORBOND® steel for the roofing and DECKFORM® steel for the structural steel decking.” “The top floor of the New Museum features a large span roof that cantilevers over a heritage building. The trusses in the top floor are up to 85m in length. The only way to achieve this was to design the trusses in segments, and install them up in the air. With BlueScope’s high strength XLERPLATE® steel, the engineers were able to reduce the number of segments for the large span trusses and reduced additional lifts for the crane.” Collaboration for Local Benefit

“With local content requirements clearly outlined by the Western Australia State Government and included within the New Museum project’s contract, the use of Australian steel on the project was an important component in fulfilling these obligations.” “The contractor, Multiplex, was particularly keen to ensure the use of local content, local fabricators and locally sourced materials. Multiplex worked closely with BlueScope to incorporate an Australian solution into the project. In terms of cost, BlueScope was very competitive, and was able to help the architect and designer achieve the span and the open plan they wanted,” said Thow. Project Team • • • • • • • • • •

Client: Government of Western Australia Architect: Hassell and OMA Heritage Architect: Element Main Contractor: Multiplex Structural Engineer: BG&E Services Engineer: Wood and Grieve Engineers Facade Engineer: Hera Engineering Steel Fabricator: Pacific Industrial Company Steel Manufacturer: BlueScope and Liberty Steel Distributor: Southern Steel (WA)

Autumn 2019

steel Australia

Feature: 2018 Sorel Award Winners

Galvanizing Delivers Durability, Sustainability and Cost Savings Held annually by the Galvanizers Association of Australia (GAA), the Sorel Award highlights the high standards of design, fabrication, construction and corrosion protection achieved when hot dip galvanizing features as a key component of a project. In 2018, there were three entries into the Sorel Awards, all of which were evaluated by the expert judges: Arun Syam, from Liberty, and Peter Dove, from GHD. According to Syam and Dove, “All three projects exhibited strong sustainability credentials and, combined with the durability aspects, provided excellent market development potential. They are all worthy Sorel entrants.” The winner of the 2018 Sorel Award was the Boral CBD Concrete Manufacturing Plant in Melbourne. This project is a stand out example of why hot dip galvanizing is the surface coating of choice, particularly compared to the traditional option of ‘paint over steel’. Boral’s previous CBD concrete manufacturing facility was compulsorily acquired for the Melbourne Metro Tunnel Project. As such, Boral chose to build a new high capacity plant in West Melbourne. The brand new, three acre site has the greatest capacity of any Boral concrete plant in Australia, and is expected to produce 120,000m³ of concrete in the first year of operation, with an overall capacity of up to 350,000m³ per annum. Originally specified as a ‘paint over steel’ project, Boral switched to hot dip galvanizing due to its superior performance in an aggressive environment. Steel structures in concrete manufacturing facilities are exposed to water, aggregate, cementitious binders and additives. Over 380 tonnes of steel was used on this three acre site, with approximately 85% of the steel galvanized. Hot dip galvanizing offers Boral an extended time to first maintenance, and its performance delivers total life cycle cost benefits to the facility.

Boral Concrete Manufacturing Plant.

steel Australia

Autumn 2019

“Boral was quite visionary for using hot dip galvanizing. The project’s environmental commitment and community engagement in inner city Melbourne demonstrated its responsibility to the community at large,” said Syam and Dove. The $9.8 million Les Wilson Barramundi Discovery Centre received a High Commendation. The project involved the redevelopment and expansion of a visitor centre on a barramundi farm and hatchery in Karumba, a remote town near the Gulf of Carpentaria in Far North Queensland. Hot dip galvanizing was used in the 87 tonnes of structural steel members (including tubular sections) used on the project, which are visible to the visitors to the Centre. According to the judges, “Architectural merit and sustainability combine in a remote location. Galvanizing, combined with the architect’s vision, provides a durable iconic land mark for the community and tourists alike.” The Potts Hill Pressure Tunnel Bridge also received a High Commendation. Metal structures at the Potts Hill Pressure Tunnel intake tower had deteriorated. As such, Sydney Water deemed it necessary to replace the truss bridge that provides access to their operational assets. This project involved the design, fabrication and installation of a truss a replacement truss bridge that not only looked similar to the existing heritage-listed Potts Hill bridge, but was compliant with today’s design codes and standards. The new bridge consists of two 12.3m long, 1.5m wide fully welded truss frames that were each galvanized in a single dip. “There were some inherent complexities for the hot dip galvanizing process. The Potts Hill Pressure Tunnel Bridge provides an innovative example of a heritage replica, which incorporated elements of the original structure, while meeting modern design requirements,” said Syam and Dove.

Les Wilson Barramundi Discovery Centre.

Potts Hill Pressure Tunnel Bridge.

Boral Concrete Manufacturing Plant Boral’s existing CBD concrete manufacturing facility in Melbourne was compulsorily acquired for the Melbourne Metro Tunnel Project. As such, Boral chose to build a new high capacity plant in West Melbourne. The location provides excellent site accessibility to road infrastructure and expands Boral’s supply radius to 20km. The new three acre site has the greatest capacity of any Boral concrete plant in Australia and is expected to produce 120,000m³ of concrete in the first year of operation, with an overall capacity of up to 350,000m³ per annum. The Use of Hot Dip Galvanizing Over 380 tonnes of steel was used in the construction of the manufacturing plant, approximately 85% of which was hot dip galvanized for a range of applications. Boral’s plant was purpose built with an expected life span of 30 years. The selection of hot dip galvanizing delivered a protective coating manufactured to last for the life of the plant. In comparison, ‘paint over steel’ offered a shorter life span, which would have contributed to additional costs in scheduled maintenance to retain corrosion protection. Galvanizing was used in: • The building framework and substructure, as the site sits 1.5m to 2m above the ground with a storm water capture system established under the plant floor. • Silos and hoppers, as well as conveyor systems, cable trays, truck cleaning bays and access systems. • The slump stand; this is where mixer trucks measure the concrete consistency, then add water or additives to achieve the optimal consistency. • The 4.5 tonne grates in the vehicle bays; these grates hold quarry trucks weighing up to 45 tonnes as they release the raw materials (such as rock and sand) into the holding bins beneath the grates. The concrete manufacturing process requires quarry trucks to dump rocks and sand through galvanized grates into catchment bins. The rocks are separated, transported by conveyor, and stored by size (ranging from 20mm to 14mm, sand and dust) in silos. Boral’s plant also consists of large

Originally specified as a ‘paint over steel’ project, Boral switched to hot dip galvanizing due to its superior performance in aggressive environments. Steel structures in concrete manufacturing facilities are exposed to water, aggregate, cementitious binders and additives. Hot dip galvanizing offered Boral an extended time to first maintenance and its performance delivers total life cycle cost benefits.

galvanized storage silos that hold various bulk ingredients like cement, aggregate and water, mechanisms for the addition of various additives and amendments, machinery to accurately weigh, move, and mix some or all of those ingredients, and facilities to dispense the mixed concrete, often to a concrete mixer truck (concrete agitator truck). It is an aggressive environment that requires high performance structures in order to support the high-capacity demands of a plant with a time sensitive product. In an environment that involves large rocks moving through the production process, along with chemicals, additives and water, hot dip galvanizing delivers long term performance. Galvanizing not only prevents corrosion in water prone areas of the plant, it also offers a low maintenance alternative to paint in less corrosive zones of the plant and has greater resilience to chemical residues used during the manufacturing process. Technical and Engineering Innovation The West Melbourne site is designed for efficiency. It has the largest capacity of any concrete manufacturing plant in Australia, with 24-hour production capabilities and 16 storage silos. The site features process flows that maximise production volume, product storage and vehicle filling, for high efficiency output. The site architecture flows light vehicles anti-clockwise and heavy vehicles, clockwise for more efficient traffic flows across the site. This system combined with a three lane structure for truck loading and the site structure enables mixer trucks to be loaded in three minute intervals. Project Team • • • • • • •

Client: Boral Architect: P&P Products Main Contractor: P&P Products Hot Dip Galvanizer: Kingfield Galvanizing Steel Fabricator: P&P Products Steel Manufacturer: Liberty Steel Distributor: BlueScope

Autumn 2019

steel Australia

Feature: 2018 Sorel Award Winners

Potts Hill Pressure Tunnel Bridge Sydney Water’s Potts Hill Reservoir and Water Pressure Tunnel have serviced Sydney since the mid 1920s. The Potts Hill Water Supply Reservoirs were an integral part of the Upper Nepean Water Supply Scheme, which was crucial to the development and growth of Sydney, from the late nineteenth century. The construction of the Reservoirs was a major achievement in hydraulic technology and associated construction methods at the time. The complex also includes the inlet for an early twentiethcentury high pressure tunnel and bridge. When it was built, the tunnel was an outstanding engineering feat and the third largest water supply tunnel in the world. Today, the lower reservoir is not used for bulk water storage, the connecting infrastructure is still an operational network asset. Due to the deterioration of metal structures at the tunnel intake tower, it was deemed necessary to replace the tower’s metal roof and truss bridge that provides access to Sydney Water’s operational assets. The truss bridge—like several bridges around the reservoir—is of historical significance and is, therefore, heritage listed. This necessitated an extensive approval process for the design and aesthetics of any components requiring replacement. Process Engineering Technologies (PET) was engaged to design, fabricate and install a replacement truss bridge that not only looked similar to the existing Potts Hill bridge, but was compliant with today’s design codes and standards. To help retain the bridge’s original, heritage-listed appearance, the original painted bridge gate and intruder bars were salvaged and blasted, and corroded sections were repaired, prior to hot dipped galvanizing. The Use of Hot Dip Galvanizing The new bridge consists of two 12.3m long, 1.5m wide fully welded truss frames that were each galvanized in a single dip. Galvanized grating and handrails were also used across the access walkway. Galvanizing of the bridge was considered a superior solution, particularly compared to traditional painted coatings that had been used previously, which required a significant amount of ongoing maintenance and inspection. This was an important consideration for Sydney Water given the reservoir assets are of heritage significance and the other (nonoperational) bridges around the reservoir site remain painted. Technical and Engineering Innovation The main challenges faced by the project team were logistics and execution, particularly how the large 12.3m long truss frames would be fabricated, transported, and galvanized. Industrial Galvanizers reviewed the project constraints during the initial concept of the project to ensure that the truss frames could be galvanized using a single dip process—this all depended on the size of the galvanizing bath at Industrial Galvanizers’ premises in Girraween, Sydney. To ensure that the 12.3m long truss frames could be galvanized using a single dip process, the stabilising members on the exterior of the truss frame (a feature designed to maintain the historical appearance of the bridge) were

steel Australia

Autumn 2019

removed during the galvanizing process. This required the installation of temporary cross bracing inside the frames during transportation and lifting. The stabilising members were then bolted onto the outside of the truss prior to installation, and the temporary cross bracing was removed. Galvanizing such a large, fully welded structure meant that consideration had to be given to preparing weld joints, corners and lapped joints. Industrial Galvanizers inspected the completed fabrications at PET’s workshop before they were transportation to their premises in Girraween. This collaborative working relationship between the fabricator and the galvanizer ensured the smooth delivery of the project not only during the galvanizing process, but throughout the transportation and installation phases. The existing bridge gates and security spikes (another historical feature of the bridge’s appearance) were also salvaged, grit blasted and the damaged elements were repaired. It was discovered that one security spike was missing. As such, PET fabricated a replica to complete the installation. The original spikes were not welded but were a brazed fabrication. Unsure of how the low temperature of brazing would perform during the galvanizing process, a test piece was successfully galvanized prior to undertaking the remaining repairs. Project Team • • • •

Client: Sydney Water and Ventia Services Design, Fabrication and Installation: Process Engineering Technologies Galvanizer: Valmont Coatings Steel Supplier: Horans Steel

Barramundi Discovery Centre Designed by Brisbane-based practice Bud Brannigan Architects for the Carpentaria Shire Council, the new Les Wilson Barramundi Discovery Centre project involved the redevelopment and expansion of a visitor centre on a barramundi farm and hatchery in Karumba, a remote town near the Gulf of Carpentaria in Far North Queensland. The 130m long building is suspended 1m from the ground and takes the form of a linear arc, which wraps around a 2,500m2 growing pond. The building increases in height from the southern to northern end, where a pitched-roof tower covers an external arrival and gathering verandah. The growing pond contains several thousand young barramundi from the hatchery. On the pond side of the building, a continuous verandah shaded by a perforated metal screen provides external circulation and access to internal spaces and outdoor pathways. The Centre was constructed using 87 tonnes of (mostly) hot dip galvanized structural steel, 11,000 bolts, and 50 tonnes of hardwood joists to form the floor frame. With a construction cost of $9.8 million, the project was funded by the Queensland Government Building Our Regions Program, local council funding, and other Queensland government sources. The Use of Hot Dip Galvanizing Hot dip galvanizing was used predominantly in the structural steel members (including tubular sections), which are visible to the visitors to the Centre. The Centre is located on the banks of the Norman River, approximately 4km inland from the Gulf of Carpentaria. While it is described by the council as a highly corrosive environment, the site is also remote, being about 2,200km equidistant from both Darwin and Brisbane, or approximately 24 hours driving. The use of low maintenance materials was critical for the council and the designers. Obviously, the remoteness of the site demanded the use of materials that

could travel long distances by road with only minor damage – a factor critical to the use of hot dip galvanizing with its hard, abrasion resistant zinc-iron alloy layers. Also important was the compatibility of the preferred building materials, with the architect’s preference to use hardwood joists for longevity in the elevated underfloor areas, which are susceptible to collection of airborne salts. Finally, the location experiences cyclonic activity. Although these have been somewhat rare (six in the last 130 years), the area is classed by AS 1170.2 as Region C (Cyclonic), with ultimate design wind speeds of 248km per hour, and rainfall averaging over 800mm per year. This meant the structure had to have a robust design, for which hot dip galvanized structural steel was a perfect fit. Technical and Engineering Innovation The technical and engineering innovation for this project rests in the design of the structure. Lead architect Bud Brannigan stated that the design for the Centre’s simple plan and structure derived from a consideration of the barramundi itself, as well as an appreciation for the harsh local conditions. “Karumba is remote, a corrosive environment, and often subject to extreme weather events, requiring a robust materials and assembly strategy for the building,” Brannigan wrote in his design statement. “The structure comprises a series of prefabricated skeletal steel portals set out on a regular radial grid, connected on-site, onto which standard framing and metal external cladding is applied, simplifying construction.” Project Team • • • • •

Client: Carpentaria Shire Council Fabricator: Wrens Construction Architect: Bud Brannigan Architects Galvanizer: Valmont Coatings (Townsville) Steel Supplier: Tonkin Steel

Autumn 2019

steel Australia

ASI Insights

ASI’s Digital Transformation Project The ASI is dedicated to equipping the Australian steel industry with the tools needed to navigate a changing landscape, and compete and win business. We want all our members to be prepared to maximise the opportunities presented by the dynamic—and at times volatile—global industry in which they operate.

The powerful in-built search engine enables detailed searching of the website, putting ASI’s multitude of resources at your finger-tips in no time. Another advantage of the new search engine is that it offers handy filter options for the Industry Directory and the eLibrary. This has already led to a considerable increase in the use of ASI Library materials.

As such, the ASI is currently undertaking a comprehensive Digital Transformation Project. This Project includes the design, development and launch of a cutting-edge digital platform, featuring a new website and innovative e-learning capabilities. Most aspects of the Project have already been rolled out, with more due for completion in the coming months.

The look and feel of the website is vastly upgraded, modern and uncluttered. The homepage offers clear access to key areas, as well as the option to select your areas of interests so that communications can be adjusted to suit.

One of the main objectives of the Project is to personalise the experience that ASI members (and registered guests) have when interacting with the ASI. With our new digital platforms, members will have access to their own personal user area, complete with records of all their transactions with ASI, whether these are purchases, events attended, or electronic publications access. The ASI intends for its digital platforms to become a central place in which the ASI community can come together to be informed, educated and record their journey with steel. ASI Website If you have not yet visited the new ASI website, we suggest you do so. It can be found at https://www.steel.org.au The new website will facilitate the way in which members interact with the ASI. Offering improved functionality and streamlined usability for members, the website will enable us to better tailor our services to member needs. There is a wealth of up-to-date information on structural steel, particularly in the new ‘Focus Areas’ section of the site. These ‘Focus Areas’ include a variety of new and updated material on topics such as Innovation, Quality and Compliance, Steel and Fire, and Steel and Design. There is also a new section dedicated to ‘Advocacy’ that sets out the ASI’s eight key advocacy platforms: The Economy; Infrastructure; Local Content Procurement; Quality, Productivity and Safety; Anti-Dumping; Skills and Vocational Training; Energy; and Sustainability and the Environment.

The homepage of the new ASI website.

steel Australia

Autumn 2019

Once logged in to the members’ only area, the user dashboard provides a raft of additional features. There is a transaction and event attendance history, which allows you to download copies of your invoices and event attendance certificates, at your own convenience. There are also useful features for ASI member companies, such as the ability to update your Industry Directory records or manage your company contacts, edit existing details or invite new colleagues to gain member access. eLearning Platform The development of the ASI’s new eLearning Platform is well underway, with the content for all training modules being finalised. The eLearning Platform will revolutionise the way in which the ASI is able to deliver training to members and the wider steel industry. It will make our training programs and courses accessible to a much wider audience. Steel Innovation Portal The ASI Steel Innovation Portal was launched late last year. If you have not yet visited the site, we suggest you do so. It can be found at https://innovate.steel.org.au The ASI Steel Innovation Portal is a central web-based repository designed to house innovative steel-related research and developments, which will be accessible to the entire community. The Portal is designed to positively connect industry with Australian research institutions. There are currently more than 20 Australian universities registered on the Portal, with the process of loading projects and researcher details well underway.

A project listing on the ASI Steel Innovation Portal.

eLibrary & Bookshop: Fast, Flexible Dissemination of Information The New Look ASI eLibrary As part of the ASI’s Digital Transformation Project, the eLibrary has been updated and improved. It can be found at https://www.steel.org.au/resources/elibrary Steel Resources at Your Finger Tips The eLibrary contains over 20,000 items. Its powerful in-built Google-like search engine enables detailed searching, putting ASI’s multitude of steel resources at your finger-tips in no time. All these resources can be requested online, and many items are also freely downloadable. Downloadable Resources Just some of the resources available to download include: • PDFs and images free to access in the eLibrary Steel Resources • ASI Technical Notes, which are practical reference tools for Australian steel design professionals • Back issues of the ASI’s technical journal Steel Construction (ASI members only), which are a great source of steel design information for the Australian context Hard Copy Resources Some of the resources on-hand include: • Full set of books published by ASI • Local and international codes and Standards • Various conference proceedings • A range of industry journals and magazines. Current subscriptions include everything from Architectural Review and Building Economist, right through to the International Journal of Steel Structures and more Ask Us If you have a technical enquiry, simply complete the form in the Members Area of the website (https://www.steel.org. au/member-area/technical-enquiries). Alternatively, you can contact the librarian who is on-hand from Tuesday to Thursday to help you with your requests. The librarian can be reached via library@steel.org.au or 02 8748 0190.

New Additions to the eLibrary We have added 50 new technical papers to the eLibrary since February. These technical papers can be accessed via: https://www.steel.org.au/resources/elibrary/what-s-new-in-themember-library. Simply access the website and then click on the required paper to request any in which you are interested. Just some of the newly added technical papers include: • Behaviour of end-plate connections in 3D frames under fire conditions: experimental study, 2018, Khonsari, Grayli, P.V., et al. In: International Journal of Steel Structures, vol. 18, no. 3, pp. 734-749. • Buckling-restrained brace with high structural performance, 2018, Iwata, M., Midorikawa, M. and Koyano, K.. In: Steel Construction Design and Research, vol. 11, no. 1, pp. 3-9. • Clearance for welded joints, 2019, Dowswell, B.F., In: Engineering Journal, vol. 56, no. 1, pp. 7-26. • Provision of appropriate levels of information to steelwork contractors/fabricators, 2018, Byatt, M. In: The Structural Engineer, vol. 96, no. 8, pp. 18-21. • Study of the ultimate load capacity of K-type tube-gusset plate connections, 2018, Ju, Y-Z., Li, J-Y. et al. In: International Journal of Steel Structures, vol. 18, no. 2, pp. 596-608. ASI Bookshop ASI offers an extensive range of technical literature on the use of steel in construction. You can browse the bookshop and purchase publications via https://www.steel.org.au/resources/ bookshop. From design capacity tables for structural steel, guidance on steel connections, portal frame design and the design of cold-formed steel structures, to fabrication methods, fire safety design, corrosion and coatings and composite design, the ASI has a well-rounded selection of publications to assist the structural steel designer. The ASI currently delivers some publications digitally. This is set to increase as part of our Digital Transformation Project. Be sure to keep an eye out for further announcements.

The Australian Steel Institute (ASI) Library is the largest of its kind in the Southern Hemisphere. It contains well over 3,000 volumes, as well as steel and structural journals dating back to 1964. Founded in 1971, the Library provides ASI members with the most comprehensive and upto-date resources on the steel industry. It also has links with libraries throughout Australia and overseas, should members require resources not already on-hand.

Autumn 2019

steel Australia

ASI Insights

New Members The ASI would like to welcome several new members who joined the Institute over the last three months. There are innumerable membership benefits when joining the ASI, from access to expert advisory services, specialist groups and leading industry publications, through to discounts on training and events. For further information, or to become an ASI member, simply visit: http://steel.org.au/membership

Associate Members Austcorp Consulting T: 1300 574 575 E: sydney@austcorpexecutive.com.au W: https://www.austcorpexecutive.com.au A: Levels 9 & 10, 16 Spring Street, Sydney, New South Wales Bay & Coast Metal Roofing T: 02 4472 7373 E: bcoast@bigpond.net.au W: https://www.baycoastroofing.com.au A: Suite 10, Connells Arcade, Batemans Bay, New South Wales Building Point T: 07 3851 8380 E: sales@buildingpoint.com.au W: https://buildingpoint.com.au A: 33 Allison Street, Bowen Hills, Queensland

Fabricator Members Brown Engineering & Construction T: 07 4614 3999 E: accounts@brownsteel.com.au W: http://www.brownsteel.com.au A: Unit 1B, 13 Carrington Road, Torrington, Queensland Rollwell Engineering T: 08 9439 5920 E: admin@rollwell.com.au W: http://www.rollwell.com.au A: 4 Rollings Crescent, Kwinana Beach, Western Australia

steel Australia | Winter 2019 A Spotlight on Offsite Manufacturing and Modular Construction To secure your advertising space, contact Julie Fidler (Commercial Manager, ASI) on (02) 8748 0104 or julief@steel.org.au

steel Australia

Autumn 2019

Calbah Industries T: 03 9792 3111 E: quotes@calbah.com W: http://www.calbah.com A: 17-29 Arkwright Drive, Dandenong South, Victoria Bhullar Engineering T: 1300 278 335 E: info@bhullargroup.com.au W: http://bhullargroup.com.au A: 5 Junction Street, Auburn, New South Wales Ferrocom T: 02 4573 8805 W: http://www.ferrocom.com.au A: 61 Argyle Street, South Windsor, New South Wales

Professional Members Property Development Systems (PDS) T: 02 8318 2988 E: info@pdsaust.com.au W: https://www.propertydevelopmentsystems.com A: Level 1, 8 Knox Lane, Double Bay, New South Wales HR Design Group T: 07 5444 5578 E: engineers@hrdesigngroup.com.au W: https://www.hrdesigngroup.com.au A: 35/13 Norval Court, Maroochydore, Queensland Stassi Consulting Engineers T: 08 8645 2244 E: support@stassieng.com.au W: http://www.stassieng.com.au A: 17B Darling Terrace, Whyalla, South Australia

Manufacturer Members Australian Pipe and Tube T: 03 8361 8366 E: sales@auspipetube.com.au W: http://auspipetube.com.au A: 2-14 Independent Way, Ravenhall, Victoria

Upcoming Events Industry Events

ASI Events

National Manufacturing Week 14 to 17 May, Melbourne, Australia https://www.nationalmanufacturingweek.com.au

Paint Coatings for Steelwork: Design, Specification and Application Perspectives 13 August, Adelaide; 14 August, Perth; 26 August, Brisbane; 27 August, Sydney; 28 August, Melbourne

Held annually, National Manufacturing Week is Australia’s largest gathering of manufacturing decision-makers. 13th International Conference on the Mechanical Behaviour of Materials (ICM-13) 11 to 14 June, Melbourne, Australia https://www.icm-13.com RMIT University is proud to host ICM-13. The theme is ‘Advanced Materials, Manufacturing, Design and Optimisation’. International Conference on Steel and Aluminium Structures 3 to 5 July, West Yorkshire, England https://www.bradford.ac.uk The conference brings international experts to discuss the design and construction of steel and aluminium structures. National Manufacturing Summit 21 to 22 August, Melbourne, Australia https://www.manufacturingsummit.com.au With an impressive line-up of speakers and panelists, the third Summit will explore the theme ‘Skills for the Future’.

NATIONAL MANUFACTURING

SUMMIT 2019

Colloquium on Stability and Ductility of Steel Structures 11 to 13 September, Prague, Czech Republic http://sdss2019.cz/ The Colloquium is focused on progress in theoretical, numerical and experimental research in steel structures. 12th Pacific Structural Steel Conference 9 to 11 November, Tokyo, Japan http://pssc2019.jp This conference promotes cooperation among structural steel associations operating throughout the Pacific.

The correct specification of paint coatings on steelwork for both corrosion protection and fire protection is critical to achieve the design life of structures. This presentation by experts from AkzoNobel, including Souma Kichenamourthy, (AkzoNobel Passive Fire Protection Specialist, South Asia), provides the necessary guidance to achieve a cost effective solution whilst achieving the required durability and protection of the steelwork. With a myriad of options available and the risk of failure due to an incorrect specification or application, increased pressure is being placed on the whole supply chain to ensure that correct solutions are being provided for projects. The presentation, which is sponsored by AkzoNobel, will include fire design and how structures requiring Passive Fire Protection (PFP) can be optimised to reduce overall cost and minimise the amount of time required to apply PFP. Standards relevant to passive fire protection and the protection of structural steel will be discussed and AkzoNobel will introduce a new product which can deliver a high quality aesthetic finish and is externally durable. Who Should Attend? The seminar will provide clarity for all parties in the steel construction supply chain. It will greatly assist: • Architects, Engineers and those who need to understand and specify the correct coatings for steelwork to ensure best practice and durability. • Coating Applicators, Fabricators and Contractors to appreciate the performance requirements, correct application procedures and coatings performance. • Procurers and all others in the supply chain needing to understand their obligations with regards to providing the correct coating products and application specifications to embrace best practice to minimise risk. For details, please contact Dr Peter Key (National Technical Development Manager, ASI) on (02) 8748 0186 or peterk@steel.org.au. Book now via the ASI website: https://www.steel.org.au/events-awards/events Australian Steel Convention 15 to 17 September, Sydney, Australia https://www.steel.org The Australian Steel Convention explores existing and emerging trends in Australian industry and economy. It is focused on equipping Australian Steel with the tools needed to navigate a changing landscape, qualify, differentiate and compete.

Autumn 2019

steel Australia

ASI Members: Are You Taking Advantage of Your Member Benefits?

Advocacy at the local, state and federal levels to advance the cause of Australian steel

Member discount on technical presentations, seminars, networking events and conventions

Regular industry news & steel Australia magazine and Steel Construction journal

For corporate members, promotion in the ASI Directory and use of the ASI logo

Member discounts on ASI bookshop publications and eLearning packages

Superior technical advisory services, delivered by experienced industry experts

Opportunities to participate in specialist committees and groups to address steel industry issues

Countless other benefits from joining and networking with a community of likeminded companies & people