steel Australia (Vol 35 No 1) Autumn 2022

INNOVATION IN FABRICATION

PLUS

Autumn 2022 Vol. 35 | No. 1 ISSN 2208-7486 (online) ISSN 1447-5359 (print)

MOLYCOP AWARDED INDUSTRY COMMERCIALISATION GRANT PROJECT CASE STUDY: SYDNEY FOOTBALL STADIUM

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Vol. 35 No. 1 | Autumn 2022 ASI HEAD OFFICE

34 CONTENTS

Suite G1, Ground Floor 25 Ryde Road Pymble, NSW 2073 T: (02) 8748 0180 E: enquiries@steel.org.au W: https://www.steel.org.au

INDUSTRY INSIGHTS

ASI STATE OFFICES

New South Wales & ACT David Varcoe on 0419 136 720 Victoria, Tasmania & South Australia Michael Dawson on (03) 9694 4499 Western Australia James England on (08) 9355 1544

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Queensland & Northern Territory John Gardner on (07) 3853 5320 ShedSafe Neil Creek on (07) 3853 5204

STEEL AUSTRALIA CONTACTS

Editor Sally Wood on sally@wordly.com.au Advertising and Distribution Jacqueline Polson on (02) 8748 0133

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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.

COPYRIGHT

Message from the Chair

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Message from the Chief Executive

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Raising Business Potential at the ASI's 2022 Economic Briefing

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How Banjo Supports Australian Steel Manufacturers Finance Growth & Innovation

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With Cyber Crime Rates Heating Up, Are You Protected?

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Lean Initiatives Help Re-Engineer Processes

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PPSR Registration Versus Credit Insurance

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Measuring the Performance of Your Super

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The New Combi-MR4

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On the Beam

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Diab Secures More Tonnage for its Workshop with a Zeman

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Molycop Awarded Industry Commercialisation Grant

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FEATURE: INNOVATION IN FABRICATION

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NEPEAN: An Innovative Culture Breeds Success

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Project Case Study: Sydney Football Stadium

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ArmorGalv: Thermal Diffusion Galvanizing

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An Iconic Approach to Innovative Fabrication

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Strength in Ahrens' Steel

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INSIDE THE ASI

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ASI Library and Bookshop Update

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New ASI Members

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New ASI Website Launched

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Upcoming ASI Events

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CONTENTS | STEEL AUSTRALIA | AUTUMN 2022

steel Australia

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

ABOUT THE ASI

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. For further information, please visit: https://www.steel.org.au

48 Cover image: With solid investment decisions, strong inhouse capabilities and world-leading technology, Ahrens is a leader in steel fabrication. Story on page 48.

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Circular economy

Hot dip galvanizing and the circular economy. Two phrases that fit perfectly together.

Hot dip galvanized steel offers the highest level of durability and robustness – giving ‘once-only’ solutions that last the lifetime of a structure. And, If the long life of galvanized steel eventually ends, steel and zinc are recycled together – without loss of properties – to produce new galvanized steel.

Scan the QR code to read about all the sustainable aspects of hot-dip galvanizing, as well as the Galvanizers Association of Australia’s Environmental Product Declaration (EPD).

www.gaa.com.au

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

MESSAGE FROM THE ASI CHAIR THE AUSTRALIAN STEEL INSTITUTE (ASI) WOULD LIKE TO WELCOME TONY SCHREIBER (GENERAL MANAGER, ORRCON STEEL) AS THE NEW CHAIR OF OUR BOARD OF DIRECTORS. BORN AND BRED IN NEWCASTLE, TONY HAS OVER 40 YEARS' EXPERIENCE IN THE STEEL INDUSTRY. HE HAS SPENT THE LAST 25 YEARS IN GENERAL MANAGEMENT AND CHIEF EXECUTIVE ROLES AT COMPANIES SUCH AS PALMER TUBE MILLS, AUSTRALIAN TUBE MILLS, AND BLUESCOPE. TONY HAS BEEN A MEMBER OF THE ASI BOARD SINCE 2017, AND WAS APPOINTED AS THE VICE CHAIR IN 2021.

TONY HAS LED ORRCON STEEL SINCE MID-2016. AS A PIPE AND TUBE MANUFACTURER AND A STEEL DISTRIBUTOR, ORRCON'S OPERATIONS SPAN THE DEPTH AND BREADTH OF THE ECONOMY, FROM SUPPLYING INTO MAJOR CONSTRUCTION PROJECTS, RIGHT THROUGH AGRICULTURE, LIVESTOCK, HOME RENOVATIONS, STEEL FABRICATION, AND TRANSPORTATION. THIS RANGE OF EXPERIENCE ENSURES THAT TONY HAS AN IN-DEPTH UNDERSTANDING OF THE UNIQUE CHALLENGES AND OPPORTUNITIES RIGHT THROUGHOUT THE AUSTRALIAN STEEL INDUSTRY.

Being a member of the ASI Board of Directors is not something that you can plan to do. Invariably, you are invited to contribute. Given this mindset, my approach to the position of Chair is that it is not a position of stature. Instead, it is a position in which I can serve the industry.

Alongside all the other ASI Directors, as the Chair, I will work to ensure that the Australian steel industry is as relevant as possible to the contemporary needs of society. We will continue to work to strengthen the future of the industry, and to ensure that all the people and companies operating within the industry have access to exciting opportunities.

Tony Schreiber Chair, Australian Steel Institute

There has never been a more exciting time for the Australian steel industry.

Just think about the role that steel plays in the betterment of society—society couldn’t be what it is today without steel.

Steel helps us transport things. It helps educate us in university campuses and schools across the nation. It allows us to do our shopping. It houses people. It helps entertain us at sporting stadiums and concert halls.

If we look at Australia's recovery from the COVID-19 experience, there is an enormous amount of stimulus on the horizon for our economy, much of which steel will play a key role in. Construction and infrastructure activity is set for strong growth and performance over the next five to ten years.

Possibly the most exciting part for me is—if we overlay the world's ambition to reduce greenhouse gases and carbon emissions—and apply this ambition to all the intellectual challenges of how to make structures less burdensome on the environment, and how to make steel products more environmentally credentialled, you see an entire generation of innovation. There is an entire generation breaking the status quo and transforming processes, people and companies.

I'd like to close by acknowledging the legacy that Bernie Landy leaves behind

as the ASI's outgoing Chair. It doesn’t matter whether you wereTony a colleague, Schreiber a customer,Chair, a supplier, orSteel someone Australian Institute in the industry that just sought out counsel or guidance, there are so many of us in the industry that are better at what we do because of the influence of Bernie Landy.

Bernie hasn’t just left a legacy. He is personally responsible for so much of what the Australian steel industry is today. It is a great honour to succeed him in this role.

One of the things that Bernie did before retiring from the ASI Board, was to expand the breadth of experience of the Board. Bernie was passionate about the fact that the Board represent the entire Australian steel supply chain: architects, engineers, fabricators, manufacturers, distributors, processors, and educators.

Today, we have 16 Directors on the ASI Board, who represent the breadth and depth of the industry and are able to advocate for all our members.

I look forward to working with the Board, Mark Cain and his team, and the broader steel industry.

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MESSAGE FROM THE ASI CHIEF EXECUTIVE INNOVATION IN FABRICATION

Our feature in this edition of steel Australia magazine is 'Innovation in Fabrication'. In recent years, Australia’s imports of selected steel fabricated products have been historically high compared to a decade earlier.

Recognising the competitive pressures that the international procurement environment has brought to Australia’s doorstep, the industry has responded through innovation and investing in improved capability and mechanisms.

Innovation in construction of steelwork structures is endemic, driven by continual striving for cost-effective, timeefficient and risk-minimised solutions in a nationally and internationally competitive market. Every steel structure is ultimately a bespoke design, responding to external environmental influences and complex user requirements. The power of bespoke design is evident in the Sydney Football Stadium (page 36), and the work undertaken by ASI members DBM Vircon and S&L Steel to bring this steel structure to life.

Australian fabricators are also innovating in different ways, diversifying their business into new sectors. For instance, NEPEAN Engineering & Innovation has branched out into additive manufacturing of medical devices (page 34), and ArmorGalv has developed a thermal diffusion galvanizing technology (page 41). Others still‚ like Icon Metal (page 44), have invested in innovative approaches to company culture to shore up future success.

AUSTRALIAN STEEL CONVENTION

I'm pleased to announce that the Australian Steel Convention will be held from 9 to 12 October 2022 at the Four Seasons Hotel in Sydney.

The program is shaping up to be exciting. Just some of the confirmed speakers include Donna Looney (Acting Head of Division to Industry Growth, Department of Industry, Innovation and Science), Professor Veena Sahajwalla (Director of Sustainable Materials Research and Technology, University of New South Wales). We've also lined up a special

Mark Cain Chief Executive Australian Steel Institute

presentation from Future Crunch Founders, Dr Angus Hervey and Tane Hunter, as well as case studies on Lachlan's Line Bridge and Sky Walk.

Plus, we have secured the Museum of Contemporary Arts as the venue for the cocktail party on the opening night, as well as entertainment by Diesel at the Convention dinner.

If you haven't already done so, I encourage you to register for the Conference via our website: steel.org.au.

2022 STEEL EXCELLENCE AWARDS

The ASI Steel Excellence Awards will be held this year. The 2022 Awards will adopt the very successful format that was introduced in 2020. This saw statebased award presentations take place online. With a huge digital reach, finalists and winners will also be celebrated via video presentations, as well as the ASI website and social media channels.

All state-based finalists and winners will then be invited to attend the 2022 Australian Steel Excellence National Awards Gala, which will be held in Sydney later in the year.

This year’s award categories include: • Buildings (Large Projects) • Buildings (Small Projects) • Steel-Clad Structures • Engineering Projects • Young Designer, Detailer or Tradesperson

We are also introducing a new category this year: Cold Formed Precision Buildings in recognition of the enormous expansion in that space.

I encourage all ASI members to start shortlisting projects for entry, and to encourage your customers and clients to enter their projects. Further details around the submission process and deadlines will be made available as soon as possible.

ASI's CHAIR

I'd like to welcome Tony Schreiber (General Manager, Orrcon Steel) as the new Chair of the ASI Board of Directors.

Tony has extensive experience in the industrial and FMCG industries across areas such as manufacturing, distribution, product development and innovation. Having worked in Australia, the United States, and across Asia, Tony has held management positions with Smorgon Steel Tube Mills, LiteSteel Technologies and BlueScope. He joined Orrcon Steel as their General Manager over six years ago.

Tony has been a valued member of the ASI Board since 2017, and was appointed as the Vice Chair in 2021. I look forward to working with Tony in the coming months.

I'd also like to acknowledge our outgoing Chair, Bernie Landy. Bernie has been a Director of the ASI since 2017, and Chair

I'd like to thank Bernie for his dedication, sage advice, and service over the last five years, and beyond. With a career in the steel industry that spanned over 30 years, Bernie's contribution to the ASI, and broader Australian steel industry, has been invaluable.

I wish Bernie all the very best in the next phase of his non executive career.

UPDATES TO THE NATIONAL CONSTRUCTION CODE (NCC)

The National Construction Code (NCC) is updated every three years, based on industry research, public feedback and policy directions provided by governments to the Australian Building Codes Board (ABCB) between publishing cycles. The revised 2022 version of the NCC is nearing completion. It is expected that it will be published in mid 2022 and come into effect from 1 September 2022.

Updated content is included in the public comment draft (PCD). The ABCB is undertaking consultation, and seeking feedback, on the suggested amendments and inclusions. Some of the more significant amendments proposed in the final stage of the PDC include: • A stringency increase in the

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thermal performance of homes from the current level, equivalent to 6-stars NatHERS, to the equivalent of 7 stars Introducing whole-of-home annual energy use requirements (noting differences between Class 1 and 2 buildings) A new set of Deemed-to-Satisfy elemental provisions for Class 2 buildings New provisions designed to allow easy retrofit of on-site renewables and electric vehicle charging equipment for Class 2 to 9 buildings, and Enhanced condensation management provisions, including additional ventilation and wall vapour permeability requirements.

Over the last 18 months, the ASI has made many submissions to the various NCC working groups in order to provide feedback and recommendations on draft regulation on behalf of our members that service building products markets.

We are very appreciative of the considerable time and resources that members have committed to constructively engaging with the NCC review process.

NEW ASI WEBSITE

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.

As such, the ASI recently designed, developed and launched a new website.

One of the main objectives for the new website was to personalise the experience that ASI members (and registered guests) have when interacting with the ASI. Members 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.

Offering improved functionality and streamlined usability for members, the website will enable us to better tailor our services to member needs.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

since 2018. Prior to his posting in China, Bernie was also a valued member of ASI's Board. Bernie recently retired from his role as General Manager Australian Steel Markets at BlueScope Steel.

The look and feel of the website is vastly upgraded, modern and uncluttered. Once logged in to the members’ only area, the user dashboard provides a raft of additional features. There are also useful features for ASI member companies, such as the ability to update your Industry Directory records or manage your company contacts. Be sure to visit the new site soon: steel.org.au

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MEMBERS OF THE AUSTRALIAN STEEL INSTITUTE (ASI) RECENTLY GATHERED FOR THE POPULAR ECONOMIC BRIEFING SERIES. THE ONLINE EVENT COVERED THE SECTOR’S ECONOMIC OUTLOOK AS THE NATION ENTERS ITS POST-PANDEMIC RECOVERY. THE EVENT WAS DELIVERED WITH THE SUPPORT OF ASI’S CORPORATE PARTNERS, AUSTRALIANSUPER AND BANJO LOANS, AND ALSO SUSTAINING MEMBER, INFRABUILD. THE ANNUAL EVENT SEEKS TO HELP ASI MEMBERS ENHANCE THEIR DECISION-MAKING SKILLS AND REMAIN COMPETITIVE IN THE GLOBAL STEEL SECTOR. Delegates heard from a variety of speakers with knowledge from within, and outside the sector. The topics were wide ranging, including the challenges and opportunities during the COVID-19 health emergency; the ongoing crisis in Ukraine; and the economic outlook for small-medium sized enterprises (SMEs) in Australia for 2022.

According to Mark Tierney (Global Economist with AustralianSuper), Australia will leverage its investment

opportunities and expertise with a renewed ambition towards construction projects.

“This type of recovery that we’re going through at the moment, is going to be very different from anything that we’ve been through before,” Tierney said.

The Australian steel industry is the backbone of the nation’s economy and is vitally important for building the next generation of critical infrastructure.

However, the sector came to a grinding halt during the pandemic, which led to a large backlog of projects and a disrupted pipeline.

“Part of the problem is that there’s been a big dispersion between goods and services consumption. Goods consumption has roared, whereas services consumption has remained soft as a result of lockdowns,” Tierney said.

Analysts predict that when China eases several COVID-related policies, it will have a vital impact on global supply chains and steel demand.

“We do have these divergences between economies and these

imbalances, which have developed, and are causing inflationary problems around the world, with the crucial exception of Asia,” Tierney said.

China is responsible for over half of the world’s steel production. In 2019, China’s share of global steel jumped from 50.9 to 53.3 per cent—a global trend that has remained steady.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

RAISING BUSINESS POTENTIAL AT THE ASI'S 2022 ECONOMIC BRIEFING

Tierney gave an in-depth analysis of how the Australian economy has pivoted and recovered from the height of the COVID-19 crisis.

In comparison to other countries, Tierney said that policymakers have managed to steer the economy through an “exceptionally difficult period”.

“But that’s not to say that there aren’t problems developing,” Tierney explained.

He noted the three areas that will challenge the Australian steel and production sector in the next 12 months: 1. Energy transitions 2. China 3. Construction backlogs

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Tierney said the transition to clean and renewable energy is the most urgent challenge. He added that AustralianSuper is carefully considering a suite of innovation projects to overcome these obstacles.

The International Monetary Fund recently concluded that metals are a “potentially important input” for ongoing assessments and models of climate change.

“There is no historical precedent for this.

We could try to look at when oil took over from coal. There is nothing that we can compare it to.”

“Over the remainder of this decade, it is absolutely essential that China’s use of coal plummets,” Tierney explained.

Coal is embedded in China’s key industries, which requires a transition, rather than a complete phase-out.

“Inevitably, without the backup of infrastructure, we can understand why China’s steel production fell in the second half of last year… rarely do we see declines of that magnitude,” Tierney said.

GETTING EVERYONE ON BOARD THE RENEWABLES TRAIN

Presenters at the ASI’s Economic Briefing shed some light on China’s economic downturn, which was plagued by ongoing pandemic lockdowns and a COVID-zero strategy. However, Tierney believes the nation will use this economic slump to pivot towards more sustainable energy projects for the future.

“We are absolutely confident that the Chinese authorities are going to stimulate the economy aggressively through fiscal and monetary policy,” he added.

The recent assessment report by the Intergovernmental Panel on Climate Change (IPCC) recent assessment report concluded that average global greenhouse gas emissions reached their highest levels in human history between 2010 and 2019. However, analysts understand the rate of growth has slowed since the onslaught of COVID-19.

Hoesung Lee is the Chair of the IPCC, who said “we are at a crossroads”, and called on nations to make critical decisions to secure a liveable future.

“Having the right policies, infrastructure and technology in place to enable changes to our lifestyles and behaviour can result in a 40 to 70 per cent reduction in greenhouse gas emissions by 2050,” said Co-Chair Priyadarshi Shukla.

However, the global energy transition to renewable sources requires a global commitment.

China has recently announced several policies to support its transition to cleaner energy. For example, the nation of 1.4 billion people will delay steel curbs and peak carbon emissions for the steel industry by five years.

It has also set out green policies for steel scrap collection and electric arc furnaces. Interestingly, China also plans to significantly increase its domestic production of iron ore.

Mei Leong (Head of Market Analytics, InfraBuild) addressed the ASI Economic Briefing about the impacts of COVID-19 and supply chain shortages—from commodities to consumer goods.

Leong drew on the recent rainfall in the Brazilian iron ore hub of Minas Gerais, which led to a severe mining disruption for a range of international operators, including in China. Brazil is China's second-largest source of iron ore after Australia.

“Iron ore prices have been very volatile.

The prices are much higher than history shows,” Leong said.

Severe weather events across Brazil and Australia have historically led to lower shipments and availability of resources across the sector. Likewise, winter weather in Canada and Russia has also shifted operations in the first few months of each year.

The ongoing global supply chain crisis has drastically shifted the price and availability of raw materials like iron ore, scrap, hard coking coal and steel.

International transport costs are also expected to remain at an elevated level.

Container freight rates are around 79 per cent higher than this time last year, and analysts believe that will firmly hold.

In addition, Leong said the unfolding war in Ukraine has also disrupted steel raw materials and steel trade flows. “Russia is a big coal exporter. In terms of where they supply to, it’s certainly northeast Asia: Japan; South Korea; Taiwan and China, who make up about 54 per cent of their exports,” Leong said.

BRINGING IT ALL TOGETHER

Brendan Widdowson from Banjo Loans joined the ASI Economic Briefing to share his expertise on driving sustainable growth at a company-level.

Banjo Loans unlocks finances to help businesses achieve their goals.

Widdowson leads the company’s sales department, which has seen a 30 per cent increase in revenue targets among SMEs in the last 12 months.

Some of the actions undertaken by these companies include: • Investing in modern technology • Purchasing new assets • Increasing staff • Increasing marketing spend • Expanding existing and additional premises • Entering a new market Widdowson also spoke about the barriers to growth in some SMEs. Specifically, he divulged the data around Banjo Loans’ latest SME Compass Report, which focuses on the current challenges for business

growth in Australia. He encouraged SMEs to drop their existing ways of thinking and understand how to navigate the current economic environment of a tight labour market; restricted supply; and rising inflation.

He reported that economic, or market conditions are the key challenge for business growth (33 per cent).

Meanwhile, recruitment (28 per cent) and consumer confidence (22 per cent) were also crucial concerns for survey respondents.

“There’s some uncertainty around inflation… and obviously the situation in Ukraine are causing some economic challenges,” he said.

Recent data from Banjo Loans demonstrates that over half (55 per cent) of businesses are concerned that inflation will remain a barrier towards growth within the coming year. However, Widdowson said businesses have plans to mitigate these risks, including price increases (42 per cent), and reducing supply costs (37 per cent).

Despite the ongoing economic challenges for Australian businesses, Widdowson is hopeful for the future.

“There is really high optimism for the year ahead, 83 per cent of businesses are confident about the future of their business,” he explained.

As the sector recovers from the pandemic, analysts are encouraging increased resilience. Widdowson believes nearly two-thirds (63 per cent) of businesses are seeking to leverage funding to drive growth in the next 12 months.“There are a range of different means that

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INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

Prices skyrocketed when Russian forces entered Ukraine on 24 February 2022. Although, Leong said they appear to have stabilised to some degree. Leong concluded her keynote address with a check on how the residential construction market is performing. She said new housing development is being constrained by the increased costs of materials, labour shortages, and rising interest rates. However, she conceded there are positive indicators—like low mortgage rates and investor demand—that will continue to drive the domestic housing market.

There is really high optimism for the year ahead, 83 per cent of businesses are confident about the future of their business."

businesses are using to raise that capital,” he said.

Some of these measures include bank loans; founder investment; family and friends; or a capital raise. Meanwhile, the most important finance selection factors include: • Interest rates • Ease of application • Length of loan • Spend of obtaining funds • Customer experience or support • Existing relationships with lenders • Reputation of the lender • Security The 2022 ASI Economic Briefing concluded with an interactive Q&A session. The three speakers shared their thoughts about Australia’s economic forecast, which featured optimism and hope as the sector bounces back from the perils of COVID-19.

The Australian Steel Institute encourages its members to take part in future professional development and networking events. For more information about ASI membership, please visit: steel.org.au/become-a-member

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Moving business forward 1300 22 65 65 | banjoloans.com *Disclaimer: Fees, lending criteria, terms and conditions apply (including an origination fee on each advance). Actual fixed fee (or interest expense) and repayments will vary based on your individual circumstances. Advertised rates are subject to change at any time. Fixed fee (or interest expense) accrues upfront and is paid in instalments. While Banjo does not generally take security over assets, director guarantees may be required and a general security deed or other security may be required for larger loans or in respect of some loan types.

Statements regarding timing in relation to applications, approvals and funding are only indicative. Any advice given does not take into account your personal circumstances and you should carefully consider what products are appropriate for you and obtain professional advice where relevant.

BANJO'S ANNUAL SME COMPASS REPORT IS THE RESULT OF RESEARCH AMONG A WIDE RANGE OF SMALL TO MEDIUM ENTERPRISES (SMES) ACROSS AUSTRALIA. THIS YEAR'S REPORT PROVIDES RICH INSIGHTS INTO HOW SMES ARE PERFORMING IN 2022, THEIR VIEW OF THE NEAR FUTURE, AND HOW THEY WERE IMPACTED DURING 2021.

According to Guy Callaghan (Chief Executive Officer, Banjo Loans), "The SME Compass Report is released by Banjo Loans annually. We interview over 500 SMEs nationally—all different sized businesses, from various industries.

We work to have a minimum 30% female participation rate, as 30% of our borrowers are female. We ask a standard set of questions each year so that we can compare results year-on-year."

As the Compass Report indicates, in 2022, Australian SMEs are coming out of two years of the pandemic with an upbeat outlook and an eagerness to invest in the business. More companies have acquisitions in their sights. Yet many are frustrated by the traditional borrowing process and are not fully informed about the alternative options available to them.

"The results are really interesting.

Business confidence is still up. As we come out of the COVID-19 pandemic, business owners are really keen for their organisations to keep growing and moving forward. Business confidence is actually higher than it was at the same time last year, which is great," said Callaghan.

expansion post COVID-19."

Many are increasing investment in their businesses, with the biggest rises being in new technology (61% in 2022 compared to 51% in 2021) and marketing (50% in 2022 compared to 41% in 2021). At 55%, over half of SMEs are worried that inflation will be a barrier to growth this year. Despite this, there is high optimism for the year ahead, with 69% expecting their revenue to grow over the next 12 months, and 83% confident about the future of their business.

"There is still some concern out there about issues like inflation, and people are still wary about COVID lockdowns happening again. Another major challenge for SMEs at the moment is recruitment—getting the right people for the right job is really tough at the moment," said Callaghan.

Those who expect to grow intend to improve existing products, invest in new technology and spend more on marketing in 2022 than in 2021.

Banjo's new funding facility can help SMEs secure this growth.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

HOW BANJO SUPPORTS AUSTRALIAN STEEL MANUFACTURERS TO FINANCE THEIR GROWTH AND INNOVATION

"There are two key areas where Banjo Loans can help compared to a bank: speed to market, and, for working capital loans, we don't use security against the loan."

"Our customer service and ease of use makes us attractive. It's really exciting to see business confidence right up. While inflation and recruitment issues might persist, market optimism will outweigh those challenges. I think we're set to have a great year," said Callaghan.

This article was supplied as part of a paid advertising package.

CLICK HERE TO LEARN MORE AND DOWNLOAD A COPY OF BANJO'S SME COMPASS REPORT 2022 >>>

In a strong sign of the health of the SME sector, significantly more Australian businesses (55%) achieved or exceeded their revenue targets in 2021 than the previous year (45%).

Those who invested in new technology, purchased new assets and increased headcount were most likely to achieve success, with the 30% who outperformed their revenue targets up a healthy 5% on last year.

"It is the businesses that have constantly invested in their business that have grown significantly more.

These businesses have invested in new systems, new technology, new equipment, and hired new staff. It is the businesses that have borrowed and invested that are best placed for

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WITH CYBER CRIME RATES HEATING UP, ARE YOU PROTECTED? THE PATTERN IS CLEAR. EVERY TIME THE WORLD FACES HEIGHTENED VOLATILITY, CYBER-CRIME RATES SURGE TO UNPRECEDENTED HEIGHTS. FROM WAR-TORN EUROPE TO THE PROSPECT OF CONFLICT IN THE INDO-PACIFIC, 2022 IS RAPIDLY SHAPING UP TO BE ONE OF THE MOST VOLATILE YEARS IN RECENT MEMORY. ALL THIS VOLATILITY MAKES ONE THING CERTAIN - THE CYBER THREAT LANDSCAPE IS HEATING UP LIKE NEVER BEFORE. With cyber now an integral theatre in warfare, experts are warning that malicious actors are targeting organisations around the world with increased sophistication. And it’s not just nation-states that are engaging in offensive cyber activities. Increasingly, we are seeing governments working in concert with criminal syndicates to wreak havoc by overwhelming organisations with cyber-crime acts.

One reason governments may choose to work alongside criminal syndicates when targeting other countries is that it allows them to cover their tracks and claim plausible deniability.

One result of this unholy alliance between offensive state and non-state actors is that financially motivated attackers can leverage the expertise and computing firepower of governments to exponentially increase the number of organisations they target.

That is why you cannot afford to be complacent, especially at a time of

heightened volatility. Any organisation may be targeted at any time. Those supplying essential inputs to critical infrastructure, such as the steel industry, are particularly at risk of finding themselves in the firing line. When it comes to protecting your organisation from cyber-crime, one attack vector is surging more than any other: Business Email Compromise, or BEC.

have the ability to verify that the Account Name you entered corresponds to the BSB/Account Number entered. This verification gap opens up an opportunity for cyber criminals. If they can manipulate the BSB/Account Number, whilst leaving the correct Account Name in place, accounting staff are unlikely to notice that fraudulent activity is taking place right under their noses.

In 2020-2021, over 4,600 BEC incidents were reported to the Australian Cyber Security Centre, far outweighing all other attack vectors. During the same time, only 500 ransomware incidents were reported. Organisations are far more exposed to a BEC attack than any other type of cyber-attack. At the same time, the average amount lost to a successful BEC attack has surged to over $50,600 – a whopping 54% increase over the previous year.

WHO IS BEHIND BEC ATTACKS?

WHAT IS BUSINESS EMAIL COMPROMISE?

In short, financially motivated cybercriminals hack into an executive’s email account and issue fake payment instructions to accounts payable staff.

Attackers can also hack into a supplier’s email account and manipulate the payment details in invoices. When your accounts team processes the invoice, they inadvertently send the funds to a bank account controlled by the attacker.

WHY ARE BEC RATES SURGING? When processing online banking transactions, Australian banks don’t

Foreign criminal syndicates are masterminding this threat. To facilitate their activities, stolen funds are sent to Australian bank accounts controlled by local money mules, who rapidly disperse the proceeds of crime to a range of international bank accounts or convert the funds into cryptocurrency.

HOW CAN WE PREVENT BEC ATTACKS?

When it comes to protecting your organisation from BEC, you need to leverage your people, make sure you have the right processes in place and embrace the right technology that can assist you in the fight.

Staff need risk awareness training, so they are equipped to identify a potential attack. Processes and internal controls need to be robust, so supplier banking details can be regularly verified for suspicious anomalies. Technology solutions need to be adopted that will help you automatically identify suspicious outgoing payments.

Eftsure is a unique solution that aggregates banking and corporate data from over 2.5 million Australian organisations, including 85% of active Australian companies. Sitting on top of your accounting processes, Eftsure ensures that you are processing payments to the correct recipient, by verifying that others have paid the same supplier using a matching BSB/Account Number.

This is the most effective and efficient way to mitigate your organisation’s risk of falling victim to BEC. Speak with us today to safeguard your financial assets at this time of heightened volatility and risk.

This article was supplied as part of a paid advertising package.

15

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

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MANUFACTURERS ARE FACING INCREASED GLOBAL PRESSURES AND ARE DESPERATE TO FIND NEW EFFICIENCIES FOR BUSINESS CONTINUITY AND GROWTH. PRICE SENSITIVITY, VOLATILE RAW MATERIAL COST, SHORTER PRODUCT LIFECYCLES, AND ADOPTION OF QUALITY AND VALUE-ADDED SERVICES CONTINUE TO ERODE ALREADY THIN MARGINS. WITH THE ADDITION OF GLOBAL SUPPLY CHAIN CHALLENGES AND A PANDEMIC, IT IS A TOUGH TIME FOR ALL.

In response, many are expanding their traditional businesses and looking for new opportunities—some in new and unknown markets, and others centered in business performance.

Lean initiatives are driving many to re-engineer business processes from the plant floor to the top floor to the extended supply chain. These same businesses are enjoying cost savings, reductions in raw materials, improved throughput, better utilisation of existing resources, and improved customer satisfaction.

Epicor understands the demands placed on manufacturers today and is uniquely positioned to manage the requirements of these industries. Epicor supports simple-to-complex build plans, make-to-order, make-to-stock, or mixed-mode environments with a single, comprehensive solution.

We’ve collected some of the crucial tips and solutions to keep in mind and help manufacturers in the steel and metal industries: •

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Improve Operational Visibility Improve bottom line revenues through greater visibility of office and plant floor operations.

Learn how to remove redundant processes and improve accuracy of information to deliver better customer service and centralise operational management.

Make Your Customer the Focus of Your Business Ensure you’re meeting customer demands and fostering a closer relationship resulting in more profitable jobs.

Reduce Cost Without Compromising Quality Good forecasting and demand requirements provide better buying power. Critical to the process are strong indicators of cost and postproduction cost analysis.

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Produce Timely and Accurate Quotes Learn how to improve quote confidence and accuracy and avoid financial loss and jeopardise customer relationship.

Manage Increasing Complex Product Builds Enable your business with the latest innovation to engineer modern and complex products, multiple level of assemblies, within a single engineering structure.

Cradle-to-Grave Product Traceability Many industries today require strong process control with lot and serial controlled inventories throughout. A robust solution helps to track materials as well as finished and semi-finished products.

Maintain Supplier Status Through Delivery Performance Enable your business to offer true capable-topromise capability that absorbs the requirements for the sales order into the schedule using appropriate finite capacity and MRP rules to offer an accurate delivery date.

Maximise Equipment Effectiveness Enable automatic production monitoring, empowering your business with production data and the ability to eliminate inaccurate and time-consuming manual data collection; so operators can stop measuring and monitoring, and focus on making quality products.

Use Lean Methodology and Demand Pull Systems to Improve Lead Times and Reduce Waste Integrated systems will streamline business processes for manufacturers looking to reduce wasted processes from the office to plant floor.

Regulatory Compliance Offer a comprehensive approach to automating the compliance processes, from Sarbanes-Oxley to ISO/AS/TS/QS standards to adhere

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with regulatory requirements and strict business practices.

Reduce Waste in the Supply Chain As global competition continues to drive costs down, supply chain partners are playing a larger role than ever before and proximity to suppliers can be a benefit. Many businesses are looking for ways to collaborate with suppliers more seamlessly for optimum results.

Support Extended and Global Operations Achieve maximum efficiencies across your globally extended enterprise, bridging geographic and strategic diversity and eliminating supply chain inefficiencies.

Robust Technology Framework Outside of all the reasons organisations look to web services for deployment; speed, stability, reusability, and more; for midsize manufacturers, the incentive is imminent to drive electronic collaboration more firmly into their supply chain.

Flexible Deployment Options As your business grows and changes, you will need a solution that can grow and change with you.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

LEAN INITIATIVES HELP RE-ENGINEER PROCESSES

Epicor has 50 years of experience delivering industry focused, world-class solutions, and ongoing customer care and service to over 20,000 customer installations. It is a true global solutions partner with support offices worldwide.

The key vehicle that transforms Epicor Kinetic into a successful business solution is our Signature Implementation Methodology. Epicor delivers one of the most cost effective and efficient techniques to plan, design, validate, and deploy your Epicor solution. Visit www.epicor.com or reach out on info. anz@epicor.com today to learn more.

This article was supplied as part of a paid advertising package.

17

NCI supports $2Bn+ of trade credit sales in the steel industry.

We specialise in all things trade credit related. We’re here to help your business grow and to protect you from potential bad debts.

35 years of experience

Australia wide coverage

Want to talk? Contact us at 1800 882 820, info@nci.com.au or visit nci.com.au.

ADELAIDE

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BRISBANE

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CANBERRA

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MELBOURNE

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PERTH

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SYDNEY

BY KIRK CHEESMAN (GROUP MANAGING DIRECTOR, NCI)

I’m finding myself increasingly being asked to address questions along the lines of: If I have a Purchase Money Security Interest (PMSI) registered on the Personal Property Securities Register (PPSR), do I really need to worry about credit insurance?

And, its alternative: If I have credit insurance in place, do I really need to worry about registering my PMSI? In return for payment of premium, credit insurance can provide trade credit suppliers with protection of around 90% of any loss suffered should their buyer go insolvent, or otherwise default on their payment obligations.

However, if you have sold your goods subject to a Retention of Title (ROT) clause and your customer collapses before they can make payment, a timely $6 registration on the PPSR of that ROT will ensure the return of your goods (or their cash equivalent).

If this is the case, do you really need to pay substantially more in credit insurance premiums for bad debt protection?

Unfortunately, registration of a ROT will NOT ensure the return of your goods (or their cash equivalent). Registration might result in the return of goods, and registration certainly won’t hurt recovery prospects, but it isn’t a miracle cure.

Goods that remain unpaid may have been on-sold, consumed or ‘mislaid’ by the time a liquidator is appointed and what goods can be recovered may no longer be worth their original invoice value, either through

use, damage, or merely by the passage of time.

Because the Personal Property Securities Act 2009 focuses on property being used as collateral in a security interest, its effectiveness is wholly dependent upon the continued presence of that particular property and the value of the property continuing to be sufficient to cover the value of the outstanding debt for which it acts as security.

Credit insurance, however, focuses on what is actually owed, what has been invoiced and what remains outstanding. It doesn’t concern itself with any fluctuating value relating to the goods supplied nor with their continued presence postdelivery, only with what is owed under the invoices issued.

If someone goes bust owing you money, a credit insurance policy will, invariably, pay you the lion’s share of your loss, regardless of what happened to the goods you supplied.

Does this mean that credit insurance is the miracle cure and PPSR registration of ROT/PMSI rights is not necessary?

Well…

While I’m an enthusiastic advocate for trade credit insurance, it is nonsense to suggest that other risk mitigation strategies should be ignored merely because there’s an insurance policy in place. You wouldn’t decide against having window locks in your house just because you have a home and contents insurance policy, nor would you be casual with your car’s security because it’s insured against theft.

Not only do credit insurers require that the policyholder (the ‘supplier’ in our context) maintain a financial interest in the underlying transaction (the supplier will usually have to bear at least 10% of any loss), they also set their premium rates based (in some part) on the supplier’s history of bad debts and the claims they’ve already had to pay.

Just as a car insurer will take note of whether the insured vehicle is garaged overnight or parked on the street, so a credit insurer will look at the extent to which suppliers mitigate the potential for losses by including security rights in their trading terms and perfecting those rights by registration on the PPSR.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

PPSR REGISTRATION VERSUS CREDIT INSURANCE

Who would a credit insurer be happier with as a policyholder? A supplier who suffers a loss but is able to recover half its value by exercising their PPSR registered security rights, or a supplier who is unable to offset any of their loss because they weren’t prepared to spend $6 on a PPSR registration?

While both suppliers will get their claims paid, one will likely find their premium rates ‘adjusted’ far more than the other.

So while a credit insurance policy is more likely to keep your business afloat when beset by bad debts, a PPSR registration will likely help keep the cost of that insurance policy as low as possible.

This article was supplied as part of a paid advertising package.

19

MEASURING THE PERFORMANCE OF YOUR SUPER THE MAIN OUTCOME YOU LOOK FOR WHEN INVESTING IS TO GAIN A RETURN ON THE INVESTMENT, AND THE SAME APPROACH APPLIES WHEN INVESTING MEMBERS SUPER AT AUSTRALIANSUPER. THERE ARE MANY WAYS TO MEASURE RETURNS AND COMPARE PERFORMANCE WHEN LOOKING INTO HOW YOUR SUPER IS INVESTED.

DIFFERENT TYPES OF RETURNS Your investment return is the amount that an investment earns over time.

When looking at the performance of your super, knowing the different types of returns helps you to compare returns to a benchmark or to compare investment options.

is delivering returns for you over time compared to similar investments in the market, it can be helpful to compare performance to a benchmark. Similar to types of return measurement, there are different types of benchmarks to help you compare. These include peer, goalbased and market-based benchmarks.

A key difference between common return measurements is the treatment of fees. Fees are very important to understand when it comes to investing as they can reduce your return, for example: • Gross Investment Return is the return of an investment before investment fees, administration fees or taxes are deducted.

• Net Investment Return is the performance of the investment after investment fees, transaction costs and taxes are deducted.

• Crediting Rate Return provides the rate for investment earnings that are credited to your account and used for calculating your estimated balance.

• Net Benefit is the return after investment fees, transaction costs, administration fees and taxes.

REGULATOR ASSESSMENTS One of the aims of Australia’s regulators is to improve visibility of poor member investment returns and assist consumers to make informed choices about their superannuation product.

To achieve this, APRA assesses performance using the Performance Test and the MySuper Product Heatmap. AustralianSuper supports mandatory performance assessment.

This helps to address poor fund performance in the industry.

To read more about the different types

of returns used by the super industry, the regulator performance test and AustralianSuper, and how you can use them to make informed investment choices, visit australiansuper.com/ investment-articles.

Investment returns aren’t guaranteed. Past performance isn’t a reliable indicator of future returns.

Sponsored by AustralianSuper. This information may be general financial advice which doesn’t take into account your personal objectives, financial situation or needs. Before making a decision about AustralianSuper, you should think about your financial requirements and refer to the relevant Product Disclosure Statement at australiansuper.com/PDS or by calling 1300 300 273. A Target Market Determination (TMD) is a document that outlines the target market a product has been designed for. Find the TMDs at australiansuper.com/TMD. AustralianSuper Pty Ltd ABN 94 006 457 987, AFSL 233788, Trustee of AustralianSuper ABN 65 714 394 898.

This article was supplied as part of a paid advertising package.

COMPARING THE PERFORMANCE OF DIFFERENT INVESTMENT OPTIONS To compare investment options, looking at returns after all fees (Net Return or Net Benefit), provides an equal comparison. To see how an investment option has performed, a look at the net returns over 3, 5 or 10 years will highlight the longer-term return including the impact of fees over time.

HOW PERFORMANCE CHANGES THE BALANCE OF YOUR ACCOUNT Performance figures that are published for the investment options show the return for a period of time. These returns can grow your super balance when investment markets are rising or lower your balance during market declines.

COMPARING PERFORMANCE TO BENCHMARKS To see how your investment option

CLICK HERE TO LEARN MORE ABOUT THE DIFFERENT TYPES OF RETURNS USED BY THE AUSTRALIAN SUPER INDUSTRY >>>

SINCE COMBILIFT LAUNCHED ITS FIRST C4000 MODEL IN 1998, MULTIDIRECTIONAL CAPABILITY HAS BEEN ONE OF THE MAJOR HALLMARKS OF THE COMPANY’S WIDE RANGE OF HANDLING SOLUTIONS. TWENTY FOUR YEARS AND THOUSANDS OF R&D HOURS LATER, ITS LATEST PRODUCT TAKES MULTIDIRECTIONAL CAPABILITY TO THE NEXT LEVEL.

The Combi-MR4 is a 4-wheel electric powered multidirectional reach-truck, which incorporates Combilift’s new Dynamic 360°™ steering, which provides rotation on each wheel, enabling seamless directional change of the truck while on the move. The system allows this extremely agile forklift to work in forward, sideward and crab steer mode, guaranteeing swift operation and excellent manoeuvrability. Hence the full name of the new model: the Combi-MR4 Dynamic 360.

trucks. Driver comfort and safety are also major considerations, and this new truck definitely delivers the goods from an ergonomic point of view: a high visibility operator cabin, multi-function control joystick, AC-electric power steering and joystick operated hydraulic mast functions all make for a smooth ride and straightforward operation. The articulated rear axle with two rear rubber drive wheels provides optimum traction for outdoor use, while still ensuring nimble and accurate truck placement.

The impetus for the development of this latest addition to Combilift’s portfolio was to develop a multi-directional truck, with a very low platform to maximise storage density within racking. The Combi-MR4 is available in two unique models, with capacity ranges of 2,500kg to 3,000kg, and 3,500kg to 4,500kg. It can operate in aisles as narrow as 2,265mm when guided (based on 1,200mm deep material). To maximise all storage space in racking systems, the wheel configuration of two drive wheels at the rear and two sets of smaller dual front wheels provides a platform height as low as 380mm, allowing otherwise redundant areas towards the floor to be used.

To achieve this level of manoeuvrability, Combilift utilised its newly developedin-house Dynamic 360°™ steering.

This novel steering concept enables operators to manipulate the truck’s positioning and orientation without the need to stop and change driving mode.

Intuitive and easy-to-operate, this is achieved by simply twisting the control joystick right or left to adjust the wheel positions simultaneously – providing crab steering and allowing direction change on-the-go.

In keeping with Combilift’s common overall design ethos, the highly versatile Combi-MR4 can handle long loads as well as palletised goods with ease, and can load and offload from delivery

Combilift always likes to ensure that any new product has been thoroughly tried and tested in the field to make certain that it is 100% fit for purpose.

Following the initial operation of 3,000kg Combi-MR4 units, a 4,500kg model was developed after receiving a request from Combilift’s dealer in the BeNeLux region - Mabo BeNeLux, for a larger capacity

unit for their customer TABS (Timber and Building Supplies Holland).

One of the Netherlands’ leading suppliers of timber products and building materials, with 104 outlets across the country, TABS has partnered with Combilift and operated its multidirectional trucks for more than 15 years. It now has MR4 trucks at several locations in the Netherlands and is about to take delivery of its 15th and 16th trucks, which will work at its distribution centres in Zaandam and Bleiswijk.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

THE NEW COMBI-MR4 WITH DYNAMIC 360°™ STEERING

Combilift CEO, Martin McVicar, said, “TABS are delighted with the ongoing successful implementation of their Combi-MR4s and the improved levels of efficiency thanks to the overall design and features such as low platform height as well as the advanced Dynamic 360°™ steering system. I have no doubt that this new additional electric model will grow Combilift’s customer base. We are looking forward to showcasing the Combi-MR4 to our existing dealers, and potential new customers during the LogiMAT Intralogistics exhibition in Stuttgart at the end of May”.

This article was supplied as part of a paid advertising package.

CLICK HERE TO LEARN MORE ABOUT COMBILIFT'S NEW COMBI-MR4 WITH DYNAMIC 360°™ STEERING >>>

21

ON THE BEAM EACH QUARTER, THE AUSTRALIAN STEEL INSTITUTE BRINGS YOU NEWS AND VIEWS FROM AROUND THE STEEL INDUSTRY IN OUR REGULAR COLUMN: ON THE BEAM. FROM PROJECTS WON AND COMPLETED, THROUGH TO NEW PRODUCT LAUNCHES AND COMPANY ANNOUNCEMENTS, YOU CAN FIND IT ALL HERE.

RAIL PROJECTS BACK STEEL MANUFACTURING JOBS IN SOUTH AUSTRALIA

Steelworkers in South Australia will manufacture 147,000 tonnes of steel for key rail projects across Australia, including the nation-building Inland Rail, providing an important economic boost for the state.

The Australian Rail Track Corporation (ARTC) recently signed a contract worth $292 million with Liberty Primary Steel for the supply of heavy duty rail that will support 1,500 jobs in the coming years.

The Whyalla-based business will soon start rolling more than 147,000 tonnes of steel rail under the contract, including more than 110,000 tonnes for the remaining sections of Inland Rail.

The contract will also support upgrades between Narrabri and Turrawan, a vital connection between Inland Rail and the Hunter Valley coal network, and the Southern Highlands line in New South Wales.

Deputy Prime Minister and Minister for Infrastructure, Transport and Regional Development, Barnaby Joyce, said the latest contract further highlights how Inland Rail is already benefitting Australia.“Rail infrastructure keeps

Safety Storage Efficiency Enhance the Safety, Capacity and Efficiency of your Storage Facility Combilift’s range of electric forklifts combine powerful multidirectional performance, emission free operation and a host of up to the minute technologies to offer the most efficient way to handle long Steel loads up to 12 tonne.

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Australia moving and our economy growing, which is why we’re getting projects like Inland Rail done."

"Inland Rail will further strengthen our freight network, keeping supply chains open, providing exporters with better access to international markets and creating jobs and economic opportunities for businesses."

“This $292 million contract is a vote of confidence in Australian manufacturing, ensuring the high-quality steel needed to bring Inland Rail to life is made by Australians for the benefit of Australians,” said Joyce.

Liberty Primary Steel has previously supplied steel for Inland Rail, including contracts worth $51 million for the Parkes to Narromine and Narrabri to North Star sections of the project.

Federal Member for Grey, Rowan Ramsey, said rail orders rolling into Whyalla is good news for the region.“Those orders in the period soon after GFG Alliance took ownership were vitally important to the survival of the steelworks. In recent times the facility has returned to profit and I am confident this profitability will result in the investment we require to ensure the steelworks’ long-term viability."

The Innovative Manufacturing Cooperative Research Centre (IMCRC) has granted cutting-edge fire rated and acoustic panel system manufacturer, Speedpanel, and Deakin University $100,000 in funding to refine Speedpanel’s steel panel manufacturing process.

During the 10 month research collaboration, the project team will use new steel forming and joining solutions to further enhance Speedpanel’s production technology, with a focus on reducing waste and optimising and strengthening panel design. This research will also support Speedpanel’s high-volume production output and enable the business to have a more refined platform for continued expansion locally and abroad.

Commenting on the project, Lindsay Evans, Speedpanel’s Sales and Operations Manager, said the IMCRC activate funding would assist Speedpanel to further revolutionise the way it manufactures its fire rated and acoustic systems.

“By streamlining manufacturing processes with innovative joining solutions and advanced techniques for material monitoring and process control, we’ll be able to evolve our product offering and bring a more environmentally friendly and sustainable panel system to market,” Evans said.

“Tapping into Deakin’s expertise in material analysis and forming process

(L to R): Peng Zhang (Deakin), Lindsay Evans (Speedpanel), Matthias Weis (Deakin), Buddhika Abeyrathan (Deakin) and Bob McArthur (Speedpanel).

control will enable us to assess and monitor material properties and key production parameters throughout the process to enhance process efficiency, enabling better quality control and reducing waste.”

Matthias Weiss, Senior Research Fellow at Deakin University, highlighted the importance of connecting with the manufacturing industry on research and development (R&D) projects.

“Manufacturing large hollow sections of steel represents a major challenge for industry. With Speedpanel and IMCRC, Deakin University is helping to solve this problem by providing extensive support in material parameter monitoring and process control solution development,” Weiss said. “We’re also taking the findings from a previous Deakin University industry collaboration which has established a new and structurally optimised wall panel design and applying them to adapt Speedpanel’s cutting-edge system.”

Dr Matthew Young, IMCRC’s Manufacturing Innovation Manager, said IMCRC was delighted to be cofunding the R&D required to advance Speedpanel’s manufacturing process to improve design, manufacturability, and performance characteristics of the wall system to help expand markets and profitability.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

SPEEDPANEL® EMBRACING INDUSTRY 4.0 TO STREAMLINE STEEL PANEL MANUFACTURING PROCESS

“Speedpanel has been a market leader in conventional panel manufacturing methods for the past 20 years.

In only 10 months, this research collaboration has the potential to deliver transformational change to the business and pave the way for future product developments,” Young said.

“Supporting small to medium manufacturing enterprises like Speedpanel to embrace new technologies and the application of Industry 4.0 remains central to creating an Australian manufacturing sector that is thriving and globally relevant.”

ABOUT SPEEDPANEL

An ASI member, Speedpanel is an Australian owned and operated manufacturer of cutting-edge acoustic and fire rated wall systems. Developed by a team with many years of construction industry experience, the innovation behind SPEEDPANEL® systems addresses the practical, real-world challenges faced by builders, contractors, architects and engineers alike. Speedpanel’s lightweight composition, ease of installation and superior acoustic properties has seen its wide uptake throughout the building industry. The unique manufacturing process of each panel involves the joining of two individual roll formed steel profiles, providing flexibility to the finish of each wall as each panel can be manufactured using galvanised and coloured steels, or combinations of both. Coloured steel walls come pre-finished for either internal or external use without any need for additional surface treatments.

CLICK HERE TO LEARN MORE ABOUT SPEEDPANEL >>>

23

INFRABUILD CONTINUOUS IMPROVEMENT: TEAMWORK POWERS UP SUCCESSFUL TRANSFORMER INSTALLATION

Two Electric Arc Furnaces (EAF) located at InfraBuild’s manufacturing sites in Sydney and Laverton are at the core of their steelmaking facilities. The seamless functioning of both EAFs is critical to operations and ensures InfraBuild customers are always supplied with quality steel products. Due to the critical nature of the EAFs, the installation of a new transformer has seen a major operational security risk eliminated at the Sydney Steel Mill.

During the Christmas/New Year shutdown at Sydney Steel Mill, the main transformer (TX1), which supplies power to the EAF transformer was upgraded.

With the transformer’s installation, the active power input into the Sydney EAF has increased from 56.2 MW to 61.5 MW. In production terms, this equates to an increase in billet production of around 45,000 tonnes per year.

Gilbert Du.“Replacement of the No.1 transformer before failure has provided the site with a spare transformer sized for present operations and also provided us with a dedicated spare for the No.2 transformer."

"It was a combined stellar effort,” Gilbert said. “The project team was able to navigate through multiple technical and logistical challenges and managed to complete the installation on time with a shortened shutdown timeframe.”

The main transformer’s installation was a large complex project requiring a team of people with highly specialised skills across a variety of engineering disciplines. The team required experience with heavy rigging, fit-up, cabling, isolation, instrumentation and PLC’s (programmable logic control).

The electricity which feeds the Sydney Steelworks is supplied at high voltage (132kV) and is stepped down, in two stages via large transformers, to the operating voltage of the EAF.

Along with the transformer changeout, the capacity of the high voltage switchgear was upgraded with improved safety features to handle increased loads (cabling, earthing, switchboard, protection panel and switches).

Multiple, significant long-term benefits to InfraBuild include lower costs, increased self-sufficiency and a lower carbon footprint achieved through making our own rather than sourcing billet externally.

One of the most challenging aspects of the project was the late delivery of several essential components. The project team managed the delays well with parts air freighted to meet the installation deadline.

The delivery of the disconnector switches, the HV Panel and the circuit breaker – manufactured in China, Italy and Germany, were all affected by COVID and difficult supply chains.

“By purchasing and installing a new, higher power No.1 transformer, the operational risk of an unplanned outage and having to operate at reduced capacity has been eliminated,” explained the Project’s Coordinator,

“It was ‘touch and go’ whether some of this gear would arrive in time and the team had to change plans a few times to cope with changing delivery dates,” said InfraBuild’s NSW Head of Rod and Bar Manufacturing, Steve Elliott.

Condition monitoring on the primary step-down transformer (TX1) showed it was approaching the end of its expected service life (30+yrs). The failure of the transformer without a spare would’ve led to unacceptable business impacts.

The secondary transformer (the ‘engine’ of the EAF) was upgraded a couple of years ago from 72MVA to 90MVA. However, the full benefit of this upgrade couldn’t be realised until now due to the limited capacity and age of the TX1 transformer.

INFRABUILD'S NEW BILLET MARKING IMPROVES TRACEABILITY InfraBuild is developing and implementing best-in-class traceability that will instil confidence in the design, quality, and sustainability of their steel products. Billet marking is one such example, providing traceability of steel heat numbers and safely confirming the right steel grade for the right endproduct.

At the Sydney meltshop, the billet stamper has been replaced with an automated laser marking system to improve the quality and consistency of the markings. Following extensive research, the Electrical and Maintenance team at the Sydney meltshop installed the fully automated laser billet marking system. This system is fully automated and interfaces with the caster PLC. Each billet is uniquely marked with the heat number, strand number, and billet number that can be read manually and by automated vision systems.

Furthermore, a complimentary vision system recently installed at the rolling mill is currently being commissioned to accurately verify every billet.

Image courtesy of InfraBuild.

Consequently, grade misidentification has been greatly reduced and the new vision system has resulted in the fully automated traceability of billets from the caster through to the reheat furnace.

In automating the marking process, operators no longer need to perform a manual update for each heat and the increased accuracy and quality of marking will result significantly reduced manual stamping.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

RESPONSIBLESTEEL™ CERTIFICATION FOR PORT KEMBLA STEELWORKS

BlueScope’s Port Kembla Steelworks and steel processing sites were recently awarded ResponsibleSteel™ site certification. ResponsibleSteel™ is the global steel industry's first sustainability standard and certification program. It has been designed by business, civil society, suppliers and consumers so they can be confident that the steel they use has been produced and sourced responsibly.

ResponsibleSteel™ site certification creates a valuable point of difference for the Port Kembla Steelworks, the first site in the Asia Pacific region, and the fourth steelmaker in the world to obtain certification. The independent, third-party site certification process has taken almost two years, involving multiple teams across the business. A rigorous audit of the 12 sustainability principles, which cover environmental, social and governance issues, has ensured that BlueScope is a world leader in steel sector sustainability.

BLUESCOPE IS COLLABORATING TOWARDS NET ZERO GOAL

BlueScope has commenced two important collaboration initiatives in the first quarter of 2022, signing memoranda of understanding with Rio Tinto to explore technological and process options for low emissions steelmaking, and with Shell Energy Operations (Shell) to explore and develop renewable hydrogen projects at Port Kembla. The projects will focus on piloting an industrial scale 10MW hydrogen electrolyser, hydrogen direct iron reduction furnace and iron melter, all powered by renewable electricity.

Working with Shell, BlueScope will also seek to collaborate further with governments, private enterprise and research institutions to develop a hydrogen hub in the Illawarra.

BLUSCOPE'S BLAST FURNACE RELINE PROJECT ENTERS FEASIBILITY ASSESSMENT

BlueScope expects that breakthrough steelmaking technology will continue to develop over the current and following decade, with significant take-up across the steel industry predicted into the 2040s. Given this timeframe, BlueScope is now transitioning to a full feasibility assessment of a reline and upgrade of the currently mothballed No. 6 Blast Furnace (6BF) at Port Kembla.

A relined 6BF will secure BlueScope’s domestic ironmaking needs from 2026. The blast furnace campaign life of up to 20 years aligns with

BlueScope’s decarbonisation strategy and 2050 net zero goal, and provides a challenging but credible timeframe for the development, scaling and commercialisation of new low emissions technologies. The reline does not lock BlueScope in to blast furnace steelmaking for the full 20 years if technology is ready earlier. However, achieving this will be dependent on several enablers including access to low cost green hydrogen, firmed and affordable renewable energy, the development of suitable raw material supply chains and appropriate policy settings.

The 6BF reline project scope is broader than a typical reline and the feasibility study will examine a comprehensive upgrade of the blast furnace facility and related infrastructure, including comprehensive technical and environmental upgrades. This includes improved environmental controls for water and air quality management and technologies that will be key enablers of medium to longer-term opportunities to reduce Port Kembla Steelworks’ greenhouse gas intensity.

These opportunities are part of a broader suite of climate-related projects at Port Kembla that have the potential to reduce greenhouse gas

emissions intensity by up to 20 per cent (percentage intensity reduction on 2018 emissions base). Partnerships and collaborations with governments, technology vendors and industry bodies will be crucial to making sure that they are ready to implement the best available technologies.

BlueScope now estimates the preliminary indicative cost for the reline and upgrade project at around $1 billion, up from the initial indicative range of $700 to $800 million. The increase is due to both a broadening of the scope, including environmental upgrades, and more refined costing of the required works. The estimate includes over $100 million of measures directed at environmental efficiency improvements.

Detailed design and execution will be progressed across the next 12 months at a cost of approximately $50 million.

Capital expenditure is expected to peak in the 2024 and 2025 financial years, with around 50 per cent of total spend during that period. BlueScope will also proceed to commit during the 2022 financial to around $120 million of spending on long lead-time items, which are critical to the availability of 6BF ironmaking capability from 2026.

25

SUPERIOR MACHINERY STRATEGIES

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+61 8 6500 6880

www.SMSales.com.au

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WORLD'S LARGEST MANUFACTURER OF OFFSHORE WIND TOWERS CHOOSES HAEUSLER AS THEIR TRUSTED KEY PROJECT PARTNER Haeusler offers flexible manufacturing facilities for all types of windmill projects, regardless of tower structure or foundation. The Haeusler plant allows you to carry out all your current and future wind farm projects.

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within the steel industry and steel

The value of engaging SMS support and

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steel packages located hundreds of kilometres from the workshop so avoiding costly rework on-site is critical to the projects overall success.

GLEN PAYNE CHIEF EXECUTIVE OFFICER AT DIAB ENGINEERING

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We encourage everyone to share your

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have encountered and how steel processing automation had helped achieved your business objectives.

ESTABLISHED IN 1970, DIAB ENGINEERING PROVIDES INDUSTRIAL MAINTENANCE, FABRICATION AND CONSTRUCTION SERVICES TO THE MINING INDUSTRY AND HAS A PROVEN TRACK RECORD IN SAFE, QUALITY EXECUTION OF MAJOR PROJECTS IN REMOTE AND DIFFICULT TERRAINS ON TIME AND ON BUDGET. DIAB'S GERALDTON FACILITY HAS ALMOST 9,000M² OF WORKSHOP SPACE AND IS THE LARGEST, MOST EQUIPPED MODERN FACILITY IN THE MID-WEST REGION OF WESTERN AUSTRALIA. STRATEGICALLY LOCATED IN CLOSE PROXIMITY TO THE NORTH WEST AND MIDWEST MINING AREAS, THEIR WORKSHOP PROVIDES A 'ONE-STOP' ENGINEERING AND FABRICATION FACILITY THAT CATERS FOR PRACTICALLY ANY PURPOSE A MINE SITE REQUIRES. During the COVID-19 pandemic, Diab had sold their fabrication workshop capacity for the seven months ahead.

According to Glen Payne (CEO, Diab Engineering), "At the outbreak of the pandemic, several mining companies reshored metalworking packages from low labour cost countries because they were concerned with supply and schedule issues; it was clear there would be delivery risks when purchasing products from overseas.

Our workshop capacity was already

sold out for seven months ahead, and we knew there had to be a better way in a cost constrained and labour competitive market," said Payne.

And so, Diab ordered the Zeman Compact Steel Beam Assembly Machine (SBA), which is ideal for structural steel robotic automation in fabrication and welding.

With international borders closed due to COVID-19 travel restrictions, the Diab team was unable to travel to view any installations of similar high-value machinery. "We did a fair bit of due diligence through references supplied

by Specialist Machinery Sales, and had a few calls with Zeman. Once Zeman explained their company background that was similar ours—a family business that had grown significantly—we were comfortable," said Payne.

"Due to the pandemic, we were unable to have a Zeman technician on-site for installation and commissioning. But, with the machine already delivered and in the country, we wanted to use it. So, we worked with Zeman virtually to get the machine up and running.

Given our guys install a lot of technical equipment, it wasn’t a difficult process, but couldn’t have done it without the support of Zeman."

"The Zeman offers us two distinct advantages: it can basically fabricate by itself without any mistakes; and it increases our fabrication capacity."

The average distance from Diab's

workshop to the mine sites on which the company works is 1,500km.

As Payne explained, in the mining industry, if rework has to be undertaken on-site there is a general rule of thumb for costing. Correcting mistakes costs $1 in drafting, $10 in the workshop, and $100 on a mine site. It's not surprising then that onsite rework is avoided at all costs; the Zeman SBA helps mitigate this risk.

"The Zeman has definitely reduced our overall cost per tonne. The Zeman doesn't make errors. It really helps from an accuracy and rework perspective," said Payne. "This year, we will start the largest fabrication project we’ve ever done: 2,000 tonnes in three months. This would not have been possible without the Zeman—we would not have even tendered for the project."

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

DIAB SECURES MORE TONNAGE FOR ITS WORKSHOP WITH A ZEMAN

"You can increase throughput by about 10% if you increase your labour—but you have to be able to find that labour first. In such a constrained employment market, it's almost impossible to find welders and boilermakers at the moment."

"With the Zeman, we can increase throughput by 30% to 40%. But, it's important to remember that technology is not about less people— it's about more throughput. It's not about having less staff—it's about securing more throughput at a lower cost per tonne to fabricate," said Payne.

This article was supplied as part of a paid advertising package.

27

MOLYCOP AWARDED INDUSTRY COMMERCIALISATION GRANT NEWCASTLE-BASED MINING CONSUMABLES PRODUCER AND STEEL MAKER, MOLYCOP, IS ONE STEP CLOSER TO IMPLEMENTING THE UNIVERSITY OF NEW SOUTH WALES (UNSW) PATENTED POLYMER INJECTION TECHNOLOGY (PIT) FOLLOWING THE AWARD OF A COMMERCIALISATION GRANT FROM THE AUSTRALIAN GOVERNMENT’S ADVANCED MANUFACTURING GROWTH CENTRE (AMGC).

T

he commercialisation grant was announced in late 2021 by the Acting Minister for Industry, Science and Technology, Angus Taylor.

The grant will be utilised to implement PIT at Molycop’s Waratah Electric Arc Furnace (EAF) steelmaking facility and support research to further develop the technology.

This innovative technology is also known as SMaRT@UNSW Green Steel technology. It provides a responsible and sustainable recycling solution for end-of-life polymer materials such as tyres, conveyor belts and other rubber products. Industrial rubber boot manufacturer, Crawford Boots, will also partner with Molycop and UNSW to further enhance the recycling capability of this innovative technology.

The technology enables the recovery and reuse of carbon and hydrogen from end-of-life rubber products in the EAF steelmaking process and the introduction of this technology simultaneously: • Reduces Molycop’s reliance on imported carbonaceous materials from China • Reduces the volume of problematic wastes going to landfill • Improves energy efficiency of the EAF steelmaking process • Further reduces the carbon intensity of Molycop’s steel products The total investment in this project is $2.4 million which includes the AMGC grant, Molycop’s capital investment and the funding of ongoing research and development activities and trials

ACCELERATING INNOVATION IN NATIONAL MANUFACTURING PRIORITIES THROUGH AMGC'S COMMERCIALISATION FUND

The $30 million Commercialisation Fund is designed to foster projects that bring industry and researchers together to commercialise new manufacturing products and processes. Consistent with all programs under the Modern Manufacturing Strategy, this fund is supporting projects within the Government’s six National Manufacturing Priorities. These priorities are: Medical Products, Food and Beverage, Resources Technology and Critical Minerals Processing, Recycling and Clean Energy, Defence, and Space. Commercialisation Fund grants are between $100,000 and $1 million and must be matched by industry. These smaller-sized grants will complement the larger projects that will be supported through the $1.3 billion Modern Manufacturing Initiative.

AMGC Managing Director, Dr Jens Goennemann, said that the AMGC Commercialisation Fund had been established with the express intention of commercialising and transitioning new manufacturing products and processes.

“For the past five years, AMGC has been working with our manufacturers to identify and support promising manufacturing projects. These projects have resulted in an uplift in jobs, skills and Australia’s global competitiveness and the latest round of funding will allow us to continue the good work,” Dr Goennemann said. “This funding supports AMGC’s vision to transform Australian manufacturing to be internationally competitive, dynamic and thriving, with advanced capabilities and skills at its core – in short, we want to help Australia move from being a lucky country to a smart one.”

Projects must include collaboration with a research partner and a minimum of one industry partner.

to further increase this innovative technology’s resource recovery and recycling capability.

Acting Minister for Industry, Science and Technology, Angus Taylor, said that the recipients of this grant are a testament to the ingenuity of Australia’s manufacturing sector.

“The Commercialisation Fund is about supporting businesses to bring their outstanding products and services to new Australian and international markets, which helps to grow our economy and deliver jobs for local workers,” Minister Taylor said.

“These grants enable businesses to undertake commercialisation activities such as research and development,

Molycop is already one of the largest supporters of investment in renewable energy in Australia through its offtake agreements with both Bowman Solar farm and Sapphire Wind farm. Its steel products have over 90% recycled content.

Molycop Australia President, Michael Parker said, “The implementation and further development of this green steel Polymer Injection Technology will further cement our position at the forefront of responsible and sustainable steelmaking."

"Molycop is committed to building the circular economy, recovering and reusing valuable materials from waste streams, reducing our carbon footprint and supporting customers’ sustainability goals."

Molycop is also licensed to commercialise the technology internationally and is currently in discussions with international steelmaking companies.

ESTABLISHMENT OF MOLYCOP 360 To further enhance the company’s resource recovery capability, in April 2021 Molycop acquired the assets

of waste management company JLW Services. This business has since been rebranded as Molycop 360.

JLW Services provided integrated logistics, waste management and resource recovery solutions for businesses, government, councils, and the community. The company specialised in waste management and resource recovery services for problematic waste streams, including end-of-life tyres, mattresses, conveyor belts and IBCs. In recent years, Molycop became a key customer of JLW Services, consuming the scrap steel generated from mattress and tyre processing in its EAF steelmaking process in Newcastle.

“Molycop has been manufacturing and supplying essential steel products to vital Australian industries, including mining and rail transport, in Newcastle for over 100 years and is very proud to be supporting regional employment through the acquisition of JLW Services," said Parker.

In October 2021, Molycop 360 became an accredited participant of Tyre Stewardship Australia in a commitment to developing sustainable markets and uses of end-of-life tyres and tyre derived products.

“

“With the launch of our resource recovery business, Molycop 360, we are committed to building the circular economy, liberating value from waste streams and supporting our customers’ sustainability goals.”

“With the launch of our resource recovery business, Molycop 360, we are committed to liberating value from waste streams," said Parker.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022

investing in technologies that will assist them to scale up their operations, and securing further investment to grow even more.”

“Our capability to collect and process end-of-life tyres (and other industrial rubber products) complements our integrated EAF steelmaking operation.

The steel, carbon and hydrogen content of end-of-life tyres can be recovered and reused in the EAF steelmaking process, thereby reducing the consumption of virgin raw materials."

29

WHAT IS POLYMER INJECTION TECHNOLOGY?

Polymer Injection Technology is a process that leverages high temperature reactions in electric arc furnace (EAF) steelmaking to transform waste tyres and plastics in the production of high‐quality steel. By focussing on the evolution of carbon properties at high‐temperature conditions.

Director of the UNSW Sustainable Materials Research and Technology (SMaRT) Centre, Professor Veena Sahajwalla, completely overturned how the properties of carbon‐bearing materials are understood, bridging the gap between both pure and applied research, as well as between research and application.

The operating efficiency of EAF‐steelmaking (responsible for 40% of global production) is largely dictated by carbon/slag reactions, associated gas evolution and slag forming. In Sahajwalla's world‐first patented Polymer Injection Technology process, a mixture of coke and recycled polymers have been shown to produce a more stable foamy slag compared to coke only – greatly improving furnace energy efficiency, and yield while reducing raw material cost (without detriment to furnace functioning or the finished product).

Steel produced through Polymer Injection Technology is in commercial production around the world – having been installed and commercially operated in EAF steelmaking processes in two domestic and five international sites (in five different countries), resulting in overall cheaper production costs.

Furthermore, Polymer Injection Technology’s steel has been named as an ‘Innovation that could change the way we manufacture’ by the US Society for Manufacturing Engineers.

The commercialisation and ongoing sub‐licensing of Polymer Injection Technology and the resultant steel, in Australia and overseas, has demonstrated the many benefits of considering the composition and behaviour of waste streams at their molecular level. Sahajwalla has subsequently opened up numerous new pathways for the transformation of complex waste streams into practical, commercially viable ‘green materials’ for production.

“Molycop’s goal is to continue to develop and expand its capability to provide resource recovery solutions for our customer’s problematic waste streams. In the case of tyres, such a solution is becoming critically important given the impending waste tyre export ban which came into effect in December 2021," said Parker.

Tyre Stewardship Australia is an industry-led initiative by major tyre importers and auto brands and was recognised as best practice product stewardship by the Federal Government in March 2021. The Tyre Product Stewardship Scheme recognises sustainable end-of-life tyre management through an accreditation and auditing system.

“Having Molycop 360 join TSA as an accredited recycler is a positive step for increasing resource recovery in regional areas. These are the areas that face the most challenges when it comes to sustainably managing end-of-life tyres."

"The fact that Molycop 360 can recycle all types of tyres including passenger, SUV, 4WD, heavy truck and, most importantly, off-the-road tyres is a real benefit to the recycling industry”, said Lina Goodman (CEO, Tyre Stewardship Australia).

ARC Laureate Fellow, Professor Veena Sahajwalla (Director, Centre for Sustainable Materials Research and Technology (SMaRT) at UNSW.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | AUTUMN 2022 SMART@UNSW CENTRE

Founded in 2008 by ARC Laureate Fellow, Professor Veena Sahajwalla, the Centre for Sustainable Materials Research and Technology (SMaRT) at UNSW works with industry, global research partners, not-for-profits, local, state and federal governments, on the development of innovative environmental solutions for the world’s biggest waste challenges.

Professor Sahajwalla, who invented the patented PIT, congratulated Molycop for its commitment to both implementing and further developing SMaRT@UNSW Green Steel technology as part of its sustainability leadership.

“The AMGC grant will enable Molycop to work towards fully operationalising our existing technology in its Newcastle facility,” Sahajwalla said.

“And what’s also exciting is that we are collaborating in developing our Green Steel 2.0 technologies, which we are confident will at some point in the future allow us to be able to fully replace coking coal in EAF steel making with a range of waste materials."

"Being able to release carbon and hydrogen from waste as a resource improves overall efficiency and helps us move towards decarbonisation because hydrogen is present in waste," Sahajwalla said.

The SMaRT Centre at UNSW is focused on the idea of materials being produced by using waste and end‐of‐ life products as raw materials and the concept of green manufacturing as value-adding.

Originally in partnership with OneSteel, the SMaRT Centre developed a process to make green alloys, using end‐of‐life rubber tyres and waste plastic as an alternative to coking coal.

Many millions of passenger vehicle tyres have been diverted from landfill in Australia, and the technology has now been commercialised here and overseas in countries including South Korea, Thailand, the United Kingdom and Norway.

The SMaRT Centre has shown that the technology of polymer injection into steel making is successful on a commercial scale and that has huge beneficial outcomes for the

manufacturing industry as a whole, while at the same time demonstrating the successful translation of research into industry.

The SMaRT Centre takes a holistic approach to manufacturing. Their aim is to take their research, which is making real-world impact, and to disseminate those ‘green social technologies’ to enhance sustainable economic growth – particularly in regional areas of Australia and developing nations internationally.

The SMaRT Centre is now carrying out new research into using waste bioresources like coffee grounds, plastics and rubbers, and their application in steel making.

This includes not just using more wastes with the aim of one day replacing the need for coke and coal in EAF steel making, but using waste resources as a source of the vital steel making ingredient of hydrogen for an overall more efficient process requiring less energy.

31

AUSTRALIAN STEEL CONVENTION

9 – 11 OCTOBER 2022

REGISTRATION OPEN

BE SURE TO REGISTER FOR THE DEDICATED FABRICATORS FORUM

The Australian Steel Convention 2022 brings together key industry leaders and innovators to discuss opportunities, showcase industry successes and examine what the future can and will look like.

Australian steel is vital to this country’s economy, stability, and growth. While the global stage is learning to adapt to an ever-changing landscape, Australia’s steel industry has an opportunity to thrive by delivering high-quality products through a robust and effective supply-chain.

As billions of dollars are being invested in both civil infrastructure and domestic homebuilding, the opportunities for the steel sector are immense.

From research to design, manufacturing, and fabrication, through to installation and construction, the future of Australian steel looks bright. Brighter still when consideration is given to the ever-growing dependence on steel across sectors and the burgeoning of a new era of endless innovative uses to propel Australia towards a new economy.

HONEST DISCUSSIONS

VALUE FOR MONEY PROPOSITIONS

OUTSIDE THE STEEL BOX THINKING

In an everchanging global landscape, the Australian steel industry needs to be prepared to adapt to advancing technologies, sustainability, and environmental concerns and a rapidly changing economic outlook.

As an industry, Australian steel has shown its ability to innovate and adapt. In today’s environment, these qualities have never been more important.

Honest discussions, value for money propositions and the ability to think outside the steel box, will all be on display at this year’s convention.

REGISTER AT WWW.STEEL.ORG.AU

FEATURE: INNOVATION IN FABRICATION | STEEL AUSTRALIA | AUTUMN 2022

INNOVATION IN FABRICATION AUSTRALIA’S STEEL FABRICATION INDUSTRY IS HIGHLY DIVERSE, WITH A LARGE NUMBER OF BUSINESSES PRODUCING A WIDE VARIETY OF STEEL FABRICATED PRODUCTS THAT ARE USED IN A RANGE OF ECONOMICALLY SIGNIFICANT DOWNSTREAM INDUSTRIES. WITH AUSTRALIAN FABRICATORS INVESTING IN INNOVATIVE TECHNOLOGY, PROCESSES AND COMPANY CULTURE TO INCREASE CAPACITY AND CAPABILITY, THE INDUSTRY IS POISED FOR GROWTH.

T

he Australian structural fabrication industry is comprised of hundreds of fabricators, most of which are small and medium enterprises (SMEs)—approximately 94% of market participants have fewer than 20 employees. Of the approximately 6 million tonnes annual capacity of Australian steelmakers, total market output of fabricated steelwork is approximately 1.6 million tonnes per annum. The medium and larger fabricators process approximately 1.1 million tonnes per annum, with the largest fabricators producing in excess of 20,000 tonnes per annum.

Three industries—the construction, manufacturing and mining industries— are the main consumers of steel fabricated products comprising almost 90% of demand for these products.

Australian fabricators also supply steelwork for industrial, commercial and residential buildings, bridges, towers.

In recent years, Australia’s imports of selected steel fabricated products have been historically high compared

to a decade earlier. In 2017, the Australian Government’s Anti-Dumping Commission found that imports of some steel fabricated products had increased following the imposition of measures on the primary steel input to their production (although data and analytical constraints meant that a causal link could not be established).

More than 50% of total steel fabricated imports came from China and Thailand.

Recognising the competitive pressures that the international procurement environment has brought to Australia’s doorstep, the industry has responded through innovation and investing in improved capability and mechanisms. This has increased effective capacity to help ensure the Australian fabrication industry secures sufficient project work to support what is a significant extended manufacturing community and Australia’s continuing manufacturing knowledge base.

Innovation in construction of steelwork

structures is endemic, driven by continual striving for cost-effective, time-efficient and risk-minimised solutions in a nationally and internationally competitive market.

Every steel structure is ultimately a bespoke design, responding to external environmental influences and complex user requirements. The power of bespoke design is evident in the Sydney Football Stadium (page 36), and the work undertaken by ASI members DBM Vircon and S&L Steel to bring this steel structure to life.

Australian fabricators are also innovating in different ways, diversifying their business into new sectors. For instance, NEPEAN Engineering & Innovation has branched out into additive manufacturing of medical devices (page 34), and ArmorGalv has developed a thermal diffusion galavnizing technology (page 41).

Others still‚ like Icon Metal (page 44) have invested in innovative approaches to company culture to shore up future success.

33

NEPEAN: AN INNOVATIVE CULTURE BREEDS SUCCESS OPENING ITS DOORS IN 1974, NEPEAN ENGINEERING & INNOVATION IS ONE OF AUSTRALIA’S LARGEST PRIVATELY OWNED ENGINEERING SERVICE PROVIDERS. WITH AN ELITE DESIGN AND PROJECT MANAGEMENT TEAM THAT UNDERSTANDS THE DIVERSE NATURE OF ENGINEERING, NEPEAN PRODUCES GOODS LOCALLY FROM THEIR STATE-OFTHE-ART FACILITIES IN SOUTH-WEST SYDNEY AND DELIVERS TO CUSTOMERS ALL OVER AUSTRALIA AND GLOBALLY.

O

ver 45 years in operation, NEPEAN has maintained a culture that recognises and respects the importance of all participants in the business, focused on building lasting relationships with employees, as well as customers.

According to NEPEAN Engineering & Innovation General Manager, Peter Buckley, “The organisation was founded in 1974 by David Fuller.

With humble beginnings, it grew from a small engineering company into a highly successful and respected integrated engineering business. Today, NEPEAN employs over 1,400 people across 12 countries worldwide, and is led by CEO Miles Fuller, son of David. NEPEAN Engineering & Innovation employs over 120 employees at our site in Narellan.”

AN INNOVATIVE CULTURE

NEPEAN takes an innovative approach to people and team culture.

As Buckley explained, “Our success is aligned with our customers’ success.

To ensure we can deliver successful outcomes to all our customers, we employ and train the best. To continually develop our organisation and deliver

quality project outcomes, it is vital to invest in our people.”

“Team members resourced to each job are hand-picked according to specific project requirements in terms of experience, specialist skills and problem-solving capabilities. We are proud of the deep relationships with our employees, with many engineers, project managers and tradespeople employed with our company for over 25 years,” said Buckley.

"We recognise the importance of innovative training and thoughtleadership in our people. A few years ago, we had only one apprentice; now we have 12. We are focused on employing people who are enthusiastic, who want to learn and grow within our sector."

"We also get really granular on each of our projects. Every job that goes through an Australian fabrication workshop has a limited number of hours, and a limited volume of resources. We do everything we can to achieve client targets in terms of hours and resources, while maintaining the highest quality focus possible."

"In order to achieve this quality standard, we felt that we needed to get granular

around planning and scheduling. So, we employed a production manager.

We also installed TV screens throughout the entire workshop. So the production manager can access all of the machines through a single computer interface.

NEPEAN Engineering & Innovation has approximately 600 live jobs every month across the company. Keeping track of every individual job and process was something we had to get innovative about. Otherwise, the time and cost blowout would be problematic for us as an organisation."

"In terms of other innovation, NEPEAN Engineering & Innovation has achieved certification to AS 5131 CC3, as well as AS/NZS ISO 3834. These were huge milestones for the company. We are only one of seven companies in New South Wales that have both certifications. The process was very much driven by our customers' needs: they were telling us that they wanted to award work to us, but couldn't because we didn't have the certification," said Buckley.

MAJOR CLIENTS AND INNOVATIVE PROJECTS

NEPEAN has worked on some of Australia's most iconic projects like

As part of the NorthConnex project— designed to link the M1 Pacific Motorway at Wahroonga to the Hills M2 Motorway at West Pennant Hills—integration work was essential along the Hills M2 Motorway. NEPEAN was awarded the subcontract for structural steel works through the head contractor, the Lendlease Bouygues Joint Venture.

With the project requiring approximately 300 tonnes of steel, NEPEAN met all project logistics and design development requirements, as well as tight scheduling, to deliver a highly successful project.

In 2020, NEPEAN Engineering and Innovation implemented a Site Services division to help diversify the services of the business. The team has grown to 5 members in the last 2 years and is consistently delivering innovative solutions to large customers such as BlueScope Steel, Manildra and Ixom.

‘We’ve always worked with the best customers, providing the highest quality services and solutions for some of the most complex projects’, said Buckley.

NEPEAN recently completed work on the Castle Residence project with Hutchinson Builders, supplying mega cantilever trusses that typically hold over 20 floors of the residences. The trusses vary in size from 5.8m to 7.1m wide and a height of 10.8m, with an average weight of 19 tonne for one assembled truss.

"As part of our work in the Defence industry, we are consistently providing high quality projects to valued Defence customers", said Buckley. NEPEAN Engineering & Innovation deliver prototypes, large production batch runs, special purpose machines, steel structures, blast doors, armoured vehicle components and associated metal products to several customers in the industry.

ADDITIVE MANUFACTURING AND MEDICAL DEVICES

NEPEAN recently expanded its capabilities into additive manufacturing.

As a result, they are now able to offer customers in the medical industry an extremely short turnaround for bespoke implants required for local patients.

“

We recognise the importance of innovative training and thought-leadership in our people. We are focused on employing people who are enthusiastic, who want to learn and grow within our sector."

FEATURE: INNOVATION IN FABRICATION | STEEL AUSTRALIA | AUTUMN 2022

NorthConnex and 60 Martin Place.

“We’ve always worked with the best customers, providing the highest quality products for some of the most complex projects. We regularly work with industry experts like Lendlease and Hutchinson Builders on projects requiring upwards of 2,000 tonnes of steel,” said Buckley.

Having gained certification to ISO 13485 Medical devices — Quality management systems — Requirements for regulatory purposes, NEPEAN recently collaborated with Osseointegration International to develop a bespoke medical grade titanium implant for a patient.

"We've recently gone down the path of additive and medical devices. Now that we have certification to ISO 13485, this sector is set to become an innovative and growing part of our business. We have manufactured hip replacements and titanium rods for implants that are already improving patients' lives," said Buckley.

"We can achieve tremendous results— whether it's 2,000 tonnes of structural steel, or an additive manufactured hip joint. With over 600 very different jobs running through our workshop every month, we need to continually evolve— you cannot be focused on just one sector or just one process within the manufacturing industry."

CLICK HERE TO LEARN MORE ABOUT NEPEAN ENGINEERING & INNOVATION AND THEIR CAPABILITIES >>>

IMAGES Far Left: NEPEAN Engineering & Innovation undertook detailing, supply, fabrication and installation of the HS01 Substation and Southern Vent Facility for the NorthConnex project.

Left: A welder working at NEPEAN’s facilities in south-west Sydney.

Above (Left): NEPEAN Engineering & Innovation is providing structural steelworks for the Castle residencies project with Hutchinson Builders.

Above (Right): A large scale mining conveyor supplied by NEPEAN to Narrabri mine in New South Wales.

35

PROJECT CASE STUDY: SYDNEY FOOTBALL STADIUM THE NEW SYDNEY FOOTBALL STADIUM WILL BE A MODERN, WORLD-CLASS VENUE THAT PROVIDES SYDNEY WITH A SPORTING AND ENTERTAINMENT PRECINCT OF AN INTERNATIONAL STANDARD FOR DECADES TO COME. AS SUCH, IT’S LITTLE WONDER THAT THE STADIUM WILL BE HOME TO THE SYDNEY FC FOOTBALL CLUB, THE NSW WARATAHS RUGBY UNION TEAM, AND THE SYDNEY ROOSTERS RUGBY CLUB. The New South Wales Government is investing $830 million in the development of the new 42,500 seat Stadium on the site of the now-demolished Allianz Stadium, which was completed in 1988 as one of Sydney’s major bicentennial projects.

The 62,000m2 Stadium is part of the broader development of the 8.7 hectare recreation and sports precinct at Moore Park, which encompasses a light rail line, walkways from central station, and revitalised community areas. The project will create new active spaces for patrons and the community, and increase New South Wales’ ability to host international, national and local events.

Demolition of Allianz Stadium

commenced in March 2019, with construction of the new Stadium beginning in April 2020. By mid-2021, nearly 1,500 pile foundations were installed to support the structure, and 200,000 tonnes of earthworks had been completed. The concourse structure was complete, and the structural roof steel was being installed.

In December 2021, construction had reached the 80% mark. Most of the structural roof steel was lifted into place and work started on the installation of the roof fabric. The stadium façade was almost complete, with 325 precast concrete panels and 980 curtain wall panels installed around the stadium.

The Stadium’s official opening is scheduled for September 2022, in time to host the NRL Rugby League Grand Final in 2022 and the 2023 FIFA Women’s World Cup. STADIUM DESIGN

The Stadium was designed by Cox Architecture. According to Pete Sullivan (Director, Cox Architecture), "Creating something that both ‘fits in yet stands out’ in that part of Sydney is obviously a tough ask for any design team, as is the task of creating a piece of sevenday civic infrastructure that provides

superior amenity and services to multiple specialist and public groups."

"More than this, these services must be provided in a way that doesn’t detract from what a stadium needs to do well; provide a superior platform for sports and events spectacle for teams, performers and fans. And of course, there was the added responsibility to craft a form which progresses the elegance, balance and recognition of Philip Cox’s original design," said Sullivan.

Cox Architecture contends that the new Stadium design builds on the legacy of the original. Its sweeping roof floats over the seating bowl and will cover all patrons with 100% drip line roof coverage. To achieve this result, the roof structure is shaped in the form of a diagrid net. This is being supported by four corner ‘super columns’, otherwise known as Derricks. Spanning between the Derricks is an inner space frame truss that measures approximately 140m in length, connected by four large pins.

An outer tension ring supports the outer side of the diagrid.

A sculptural, ribbon facade draws on elements of technology, engineering and art. Covered in a delicate veil of bronze

BY DAVID DAWSON (GLOBAL GENERAL MANAGER, DBM VIRCON) 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 is being used.

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.

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.

The Australian steel industry has embraced technology, but there is still much more that can be achieved going forward.

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 backmodel using existing drawings and laser scan information to provide an up to date model of the facility.

In Australia, early examples of the steel industry transitioning towards 3D models started to emerge in the early 1990s. 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.

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 and, combined with non-3D model data, provide early material information to allow for earlier planning and ordering of materials.

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

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

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.

FEATURE: INNOVATION IN FABRICATION | STEEL AUSTRALIA | AUTUMN 2022

TRANSFORMATIONS AND INNOVATIONS IN STEEL DESIGN PROCESSES

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fins, the façade forms an environmentally responsive skin that enhances patrons’ sense of connection to place. The new Stadium will have substantially improved sightlines—there won’t be a bad seat in the house. It will also feature world-class amenities and food and beverage outlets, improved corporate entertainment facilities and greater accessibility.

ENVIRONMENTAL SUSTAINABILITY

The Stadium has been designed with environmental sustainability in mind, achieving a US Green Building Council LEED gold rating. For instance, the roof structure was designed to require 40 per cent less steel in its construction when compared to the reference design. The Stadium will feature solar panels and water harvesting systems on its roof, while its carefully designed profile will reduce the building’s overall impact on its parkland location.

The new landscape surrounding the Stadium will double the number of trees on the site, creating new habitats for native wildlife. The design of the roof will provide containment of noise, as well as protection from rain and sun for patrons.

DBM VIRCON’S SCOPE OF WORK

DBM Vircon was engaged initially by S&L Steel to supply shop detailing services for the stadium roof structure and site temporary works steelwork.

According to Pablo Santos (Director, S&L Steel), "S&L was contracted to supply, fabricate, paint and install the roof

steelwork for the Stadium. The success of delivering the project was the high level of teamwork within the whole supply chain. It is a credit that all fabrication was undertaken in Western Sydney."

"Trial assemblies of key sections such as derricks and trusses ensured installation issues were minimised. The interaction between S&L and DBM was excellent— both teams worked hard to ensure fabrication geometry on drawings was clear and provided in a timely manner.

Fun fact: approximately 17km of CHS and RHS were procured for the roof steelwork," said Santos.

DBM Vircon's works package comprised: • Four ‘super columns’, otherwise known as Derricks • Ten Arch truss sections spanning between the 4 x Derricks that measure approximately 140m in length on East and West side and spanning 90m on the North and South side • A CHS610 profile size outer tension ring • Inter connecting diagrid “net” steelwork • Temporary site works Structures Due to a tight construction schedule, DBM Vircon’s scope of works expanded to encompass an early Design Assist stage. This encompassed a period of collaboration with the project architect (Cox Architecture), structural engineer (Aurecon), main contractor (JHG) and roof fabricator (S&L Steel) to help fast track connection design, resolve constrctuability and erectability

issues, and streamline the process from engineering design to detailing to fabrication.

According to David Dawson (Global General Manager ‑ Industrial, DBM Vircon), "The design assist engagement ensured that potential fabrication and construction issues that are typically identified later in project execution were resolved collaboratively between all delivery parties to provide a more fast tracked fabrication and construction process."

CHALLENGES AND SUCCESS FACTORS

The biggest challenge on the project was the roof shape, which is in precambered form. The Arch Trusses were modelled over their length, which, once settled, will deflect up to 285mm and will effectively shrink by 90mm. However, the Outer Tension Ring was modelled 220mm short, which, once in the permanent state, will stretch. This gave a “lack of fit” element between the Arch Truss to Diagrid and the Tension Ring to Diagrid. All connections were one-offs and varied due to the structural layout complexity and radii. The complexity of connections flowed into challenges in the fabrication drawings where up to 10 ‘drawing sheets’ were required for certain assemblies.

PROJECT INNOVATION

DBM Vircon’s custom-built proprietary Job Management System (JMS) setup, along with drawing template smarts and the use of Tekla member UDAs, enabled a number of shop drawing automated outputs, text update efficiencies in the 2D production, and the issuing of drawings. 3D modelling of etching marks on pipe sections was also provided and outputted on .stp deliverable files to assist workshop fabrication on complex pipe to pipe welded connections.

TEAMWORK AND COLLABORATION

DBM Vircon is proud of the teamwork and collaboration displayed by all project stakeholders, particularly in the wake of the major disruptions caused by the COVID-19 pandemic. Tekla played a major role in enabling this collaboration.

Team members from two separate DBM Vircon offices (Chennai and Perth) worked collaboratively with the project stakeholders. The Perth team was in daily contact with the Sydney based engineering and fabrication teams to resolve design issues, progress the model and feedback information to DBM Vircon team members. This efficient collaborative methodology was made possible through the use of Trimble Connect, which was used to exchange project information by tagging the relevant members in the Tekla model.

FEATURE: INNOVATION IN FABRICATION | STEEL AUSTRALIA | AUTUMN 2022

“

Once a digital asset has been created, there is an extremely powerful model that not only provides a fabricationready model for any structural remediation work but also provides a visual platform to support efficiently capturing new data and information."

PROJECT TEAM • • • •

CLICK HERE TO LEARN MORE ABOUT HOW DMB VIRCON IS MAKING DESIGN CONSTRUCTIBLE >>>

• • •

Client: Infrastructure NSW Main Contractor: John Holland Group Architect: Cox Architecture Structural Engineer: Aurecon Fabricator: S&L Steel Temporary Engineering: Robert Bird Group, BG&E Detailer: DBM Vircon

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ARMORGALV: THERMAL DIFFUSION GALVANIZING

FEATURE: INNOVATION IN FABRICATION | STEEL AUSTRALIA | AUTUMN 2022

IMAGE: Caption TBC.

BASED JUST OUTSIDE OF NEWCASTLE IN THORNTON, ARMORGALV AUSTRALIA IS THE FIRST PLANT OF ITS KIND IN THIS COUNTRY. THEIR ARMORGALV® COATING TECHNOLOGY IS THE TRADE NAME FOR THERMAL DIFFUSION GALVANIZING. DURING THE PROCESS, A UNIFORM, SACRIFICIAL, ZINC-IRON COATING IS APPLIED TO ANY FERROUS ITEM USING A METALLURGICAL VAPOUR DIFFUSION. ARMORGALV® IS A CORROSION RESISTANT AND ABRASION RESISTANT COATING SOLUTION THAT HELPS INCREASE PART LIFE, EVEN IN THE WORLD’S HARSHEST MINING AND MARINE ENVIRONMENTS.

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n English metallurgist named Sherard Cowper-Coles invented thermal diffusion in the early 1900s.

He discovered that heating a special blend of dry zinc dust with steel parts in a closed cylinder to at least 343°C resulted in a uniform corrosion-resistant zinc-iron alloy coating. In honour of his discovery, the term for the process became known as ‘Sherardizing’. Difficulties controlling thickness and lengthy processing times saw Sherardizing fall out of favour by the 1950s.

Fast forward 40 years to 1995, and Israeli-based metallurgy company, Distek, discovered and patented modifications to the zinc powder formula that reduced time and improved consistency. That process became known under the trade name ArmorGalv® and is now licensed for use in over 45 sites across Europe, Africa, the United

States of America, and Australia.

WHAT IS ARMORGALV®?

ArmorGalv® is the trade name for a thermal diffusion galvanizing technology. It is a method of applying a uniform, sacrificial, zinc-iron alloy coating using a metallurgical vapor diffusion process. ArmorGalv® can be applied on many surface types including powder metal, steel, stainless steel and castings and forgings. Using a thermal diffusion galvanizing process, multiple layers of zinc‐iron alloy are formed, from a super corrosion resistant gamma layer to a compact delta layer and then the zeta layer.

Clive Jones (General Manager, ArmorGalv Australia) said, "Think of an onion, with each layer harder and more corrosion-resistant than the previous one—that's basically what

the ArmorGalv® process achieves.

ArmorGalv® is tough—it's very hard. This toughness comes from the fact that it is a baking process.

The zinc bakes, turns into a vapour, and then bonds onto the metal. The toughness is then locked in, with the component's service life increased by as much as 10 times."

"It's high corrosion and abrasion resistant. It's just about impossible to chip it, or crack it, and its easy to crimp and bend. So, it's great to use on spring steel—it bends, rather than cracking. Threads are a particular area where you really need reliable tension. Anything that is under tension or stress is perfect for the ArmorGalv® process."

"High tensile metals are prone to embrittlement when they're affected

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by too much heat. With our process, this isn't a factor. So we specialise in high tensile materials. Plus, if you need to apply a top coat, no other preparation is required. It is an excellent substrate for paint, e‐coat and over-moulding with rubber or plastic."

"ArmorGalv® is green, environmentally friendly, totally heavy metal free, and non-toxic. In addition, ArmorGalv Australia recycles as much as we can, and we use solar power. We're doing as much as possible to reduce our environmental footprint."

"ArmorGalv® is very economical for the right product," said Jones.

Thermal diffusion galvanizing is backed by a range of technical standards, including ASTM A1059, ISO 17668, BS EN 13438, ISO 14713-1, ISO 14713-3 and EN 15773.

THE GROWTH OF ARMORGALV AUSTRALIA

As the only company offering the ArmorGalv® process in the country, this industrial galvanizing method is exclusive to ArmorGalv Australia.

"We have been in business for just over 12 years. We started out protecting flexible roadside markers.

Our client needed something to protect the markers, and discovered the ArmorGalv® process. We quickly realised that there were many other industries in Australia that could benefit from the use of the process," said Jones.

"Today, we predominantly serve the mining industry, but also the rail industry, the construction industry,

civil contracting, and the renewables industry, supplying anchor bolts for wind towers. There are also multiple applications for the process in the marine industry, power lines, solar power, hydrogen, gas, oil and even fastenings. We are constantly growing—we're open to any weird and wonderful project that comes our way," said Jones.

THE ARMORGALV® PROCESS

"When we first started out in Australia in 2000, we were located in a small premises, and quickly outgrew it. Our new plant in Thornton has given us a lot more room to grow and enabled us to install bigger, better equipment.

Until we moved into our new premises, ArmorGalv® had been Australia's best kept secret—we just didn’t have the room to do any more work than we already had on the books. Today, we've got much more capacity in the workshop."

Diffusion: The products are heated in batches with ArmorGalv's magic mixture and zinc powder in closed rotating drums. The diffusion process starts taking place at 320°C, where the powder gets converted to vapours and form multiple zinc and iron alloy layers. Working temperatures range from 350°C to 450°C, so that high strength steels can be processed at lower temperatures.

"We like to think of ourselves as a solution provider. A lot of people don’t know about the process, so we're happy to educate people about how it all works. We’re firmly focused on improving the total lifespan of metals. If we can help materials last longer, this can drastically reduce maintenance costs and the total cost of asset ownership. It is also better for the environment because there is no need to dispose of a product that has gone rusty. The innovative nature of our product is very useful for the future of our industry," said Jones.

Pre-treatment: Pre-treatment is often unnecessary provided the products are a bright metal. ArmorGalv believes in providing a high quality finish so, where required, degreasing or shot blasting (or both) may be required to remove any contamination or oxidisation that would affect the final outcome.

Finishing Treatment: Once the container has cooled sufficiently for safe handling, the product is unloaded for finishing. The followup treatment requires a thorough wash to remove excess dust and then ArmorGalv adds a chrome-free passivation and a clear sealer to give a clean and long lasting finish. Where clients require an epoxy top-coat, ArmorGalv must be advised prior so that the sealer is left off.

Packing: Finished goods are packaged for shipment.

CLICK HERE TO LEARN MORE ABOUT ARMORGALV® AND THE BENEFITS IT HAS TO OFFER >>>

Environmental Sustainability ArmorGalv® thermal diffusion galvanizing provides important environmental benefits, including: • Low emissions • No chemical pre-treatment • Entirely closed zinc process • No dangerous gases • No chemical waste flows ArmorGalv® is a completely non-toxic and heavy metal free, environmentally responsible protection against corrosion and wear and tear. Thermal diffusion galvanizing is a cost-effective investment. The long service life has been proven for decades in industrial and marine applications and is testament to its sustainability.

The service life of several zinc coatings in a variety of atmospheric environments is described in EN ISO 14713. The expected service life of a thermal diffusion galvanized coating of, on average, 35 µm is more than twenty years if used in an urban environment. The corrosion resistance can be substantially increased through the application of a thicker coating to over 100 µm or top coating to a diffusion galvanized surface.

In salt spray tests, the ArmorGalv® system produces results of more than 2,000 hours.

No Hydrogen Embrittlement ArmorGalv® products are guaranteed free of hydrogen embrittlement. This is particularly important in the case of safety components and products made from spring steel, hardened or high-strength steel.

Hydrogen embrittlement is caused by the diffusion of atomic hydrogen in the steel. Thermal diffusion galvanizing is a dry galvanizing process, and this means hydrogen embrittlement is technically impossible. The pretreatment means there is no chance of hydrogen embrittlement because it involves blasting. Any hydrogen

present in products will disappear during the process of heating to 300°C, before the zinc iron alloy layers are formed.

By comparison, other methods, such as electrolytic and hot-dip galvanizing, involve the products being pretreated by acid dipping. During such a process there is a chance that products will absorb atomic hydrogen.

Temperature Resistant The stable zinc-iron alloys formed by thermal diffusion galvanizing are diffused 10 micron into the base material and can be used at high temperatures without the zinc diffusing into the steel. This prevents any liquid metal embrittlement. The coating is heat resistant to temperatures more than 600°C. The zinc-iron alloy does not melt but will burn at temperatures of approximately 1,000°C. Thermal diffusion galvanizing is ideal for ensuring that connecting components in engine rooms and exhaust systems are protected from corrosion at high temperatures.

Thermal diffusion galvanized valves and flange connections in the offshore oil and gas industries are used at operating temperatures of more than 400°C. Tough and Wear Resistant ArmorGalv® applies a uniform, tough and wear resistant zinc layer, even if the product has a complicated shape.

The zinc layer protects against, among other things, damage caused by mechanical stress.

The zinc-iron alloy is metallurgically bound by diffusion into and onto the base material. The hardness of the zinc-iron alloy is approximately 40 to 45 HRC which exceeds the hardness of the steel to be galvanized. This produces an extremely high resistance to wear and tear. Connections for steel and wood constructions, scaffolding and formwork are protected against corrosion and wear and tear, even after frequent assembly

and dismantling. Gear wheels, shackles, locking pins and shafts used in machine, bridges and mining engineering are precisely thermal diffusion galvanized and therefore protected in the long term against mechanical stress and corrosion.

Adhesive Surface The ArmorGalv® surface structure is micro-crystalline and has a natural roughness and unevenness. A surface structure like this is the perfect basis for lubricants, lacquers, coatings, adhesives, and rubber (vulcanisation).

This has several benefits.

Lubricants are absorbed by the microcrystalline surface, leading to longterm lubricating properties.

Lacquers and coatings acquire special mechanical bonding qualities on an ArmorGalv® surface.

Application by spraying, dip spinning, electrostatic or catophoresic processes is possible without pretreatment. Thanks to the bonding surface, adhesive connections form an inseparable, rigid connection.

Vulcanisation on ArmorGalv® products can be achieved by applying the binding primer directly to the diffusion galvanized surface.

FEATURE: INNOVATION IN FABRICATION | STEEL AUSTRALIA | AUTUMN 2022

THE BENEFITS OF ARMORGALV® CORROSION PROTECTION

Uniform Application Thermal diffusion galvanizing is a dry galvanizing process which involves zinc being vaporised at high temperature and diffusing into steel.

The zinc-iron alloy layers formed follow the product contours exactly. The layer thickness can be set precisely to between 20 µm and more than 120 µm.

Strong profiled components, products with an internal thread and the inside of hollow products are galvanized with a coating of the same thickness.

Flat products such as rings, discs and sheets are galvanized uniformly irrespective of whether they are thick, thin, or vulnerable parts weighing just a couple of grams or more than 100kg each.

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AN ICONIC APPROACH TO INNOVATIVE FABRICATION PROJECT MANAGING SOME OF THE LARGEST DEVELOPMENTS IN SYDNEY, ICON METAL TAKES GREAT PRIDE IN ITS DYNAMIC TEAM AND THEIR CAPABILITIES. THE COMPANY SPECIALISES IN THE FABRICATION AND INSTALLATION OF METALWORK, INCLUDING BALUSTRADES, GLASS AND CLADDING. WITH 35 YEARS EXPERIENCE IN CONSTRUCTION, ICON OPERATES ACCORDING TO THREE CORE COMPANY VALUES AND TAKES AN INNOVATIVE, QUALITY-FOCUSED APPROACH TO ALL OF THE PROJECTS IT DELIVERS.

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con Metal Fabrications was established in 1996. Founder, Michael Pribula, utilised the experience he had gained in the industry over 20 years to launch the company. Icon started out with five employees, an office and workshop in Granville, western Sydney, specialising in miscellaneous metalwork.

"It was around this time that Michael Pribula's brother Stephen got involved in the management of Icon. Together, Michael and Stephen started working on larger projects. Around 2007, Icon secured the Queens Square Law Courts project, which is the first project I worked on with Icon."

According to Chris Farmer (General Manager, Icon Metal) Icon quickly built a reputation for excellent service and quality, and expanded rapidly. "When Icon was first established, the company focused on smaller jobs. We evolved slowly to begin with. Then, in the late 1990s, when construction was taking place in preparation for the Sydney Olympics, we won a significant contract with Multiplex to undertake works at the stadium. This contract catapulted Icon into the next tier," said Farmer.

"As the company grew, it became apparent that the future growth of the company required further expertise. In 2016, Icon Metal became part of the Teaminvest Private Group of companies, and in 2018, the company was floated on the Australian Stock Exchange. Since 2016, we have tripled in size, revenue and staff," said Chris.

In 2021, Icon moved from its longtime headquarters in Granville to a more spacious premises just around the corner, in Silverwater. In their new

7,000m2 facility, Icon is able to accommodate their ever-growing team of designers, drafters, project managers and admin staff. Their skilled tradespeople have plenty of room to fabricate even the most complex of designs. Now, with 35 years experience in construction, Icon employs 65 staff, offering a range of services including structural steel, architectural feature stairs, glass, cladding, rigging and project management.

"We service tier one construction companies like Multiplex, Lendlease, Watpac, and Laing O'Rourke. We work across a wide range of products within the steel industry, from architectural metalwork to balustrades, and we also do structural steel and architectural feature stairs, as well as miscellaneous metalwork," said Chris.

Despite their rapid growth, Icon maintains a small-company culture.

Their people are their most valued asset. Icon invests in skill-building such as training and apprenticeships, and supports the development of all staff, right throughout their careers.

Icon has three core company values: mental health awareness, women in construction and reconciliation.

According to Bethan Farmer (Media Relations, Icon Metal) "Mental health is core to our values. The statistics for poor mental health outcomes for construction workers are extremely sobering and stubbornly high. Icon is a stigma-free company, where it is OK to not be OK, and where we challenge the culture of silence that surrounds mental ill health."

"By partnering with external workplace consultants, Mental Health Movement, we ensure that all our staff have access to training and workshops. We just recently ran training with our supervisors on mental health response. The training covered how to recognise the signs and symptoms of someone suffering poor mental health and how to talk to someone to help them get the help they need."

"We are also focused on improving opportunities for female participation in the construction industry. At the moment our female participation is 17%. We’re focusing on building that up through a targeted recruitment strategy, with a focus on female apprentices. If we get

female candidates, we make sure they all get a fair go", explained Bethan.

Icon is a Silver members of the National Association of Women in Construction (NAWIC), and encourages all their female staff to take advantage of the benefits this membership can offer, from seminars and site visits to mentoring.

"We were finalists for two NAWIC awards this year, which was a massive achievement for us. We’ve basically made ourselves as attractive a prospective employer for women as we can be. We celebrate female gains on social media and our website. When recruiting, we make sure that Icon is appealing to female candidates. We work with our managers on unconscious bias and compensating for ingrained thoughts and views in decision making processes."

"Our vision for the future of Icon Metal is one where traditional notions of what is acceptable in the construction industry are replaced by diversity, inclusiveness and equality of opportunity."

FEATURE: INNOVATION IN FABRICATION | STEEL AUSTRALIA | AUTUMN 2022

ICONIC VALUES

~ Stephen Pribula (CEO, Icon Metal)

"We really are aiming to counter the prevailing masculine culture in construction. It's an issue that we talk about quite a lot at Icon. As an industry, we all need to call out behaviours that are not serving our values and purpose," said Bethan.

The third and final core value by which Icon operates is reconciliation. In May 2021, Icon Metal had its first Reflect Reconciliation Action Plan endorsed by Reconciliation Australia.

"Reconciliation is really important to us.

Having our first Reconciliation Action Plan endorsed by Reconciliation Australia was a long-held ambition for

IMAGES Left: Icon Metal boilermaker works on a complex geometric spiral stair at AMP Capital's Quay Quarter Tower Precinct.

Right: Quality control checks by Icon Metal at AMP Capital's Quay Quarter Tower Precinct.

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Icon, and one that we are committed to fulfilling. We're focused on ensuring that all our staff are educated and informed about issues like NAIDOC Week and Reconciliation Week."

Icon Metal has an ongoing charitable partnership with The Settlement, a charity based in Chippendale, Sydney, that supports predominantly Aboriginal and Torres Strait Islander families and young people through the provision of social housing, after-school and school holiday care, and leadership training.

AN INNOVATIVE APPROACH

Icon Metal has invested in innovation on several fronts, helping to accelerate the company's expansion. From improved processing capabilities, through to the introduction of a new digital quality control system, innovation is a key ingredient to their success.

"It’s a very interesting time in the Australian manufacturing industry as a whole. On the back of COVID-19 and the resultant changes to supply chain reliability and transport costs, Icon has changed the way it views and operates its business. As a result, we are looking to advance our processing capabilities quite significantly, with a greater focus on our capacity to manage fabrication in-house," said Chris.

"We are constantly working on continuous improvement within the organisation, including a strong focus on quality control processes and compliance according to AS/NZS 5131 Structural steelwork fabrication. We're also accredited to AS/NZS 4801, ISO 9001 and ISO 14001."

"Icon is taking on more and more technically advanced projects, as well as government funded projects, that have higher benchmarks for compliance. So a focus on quality assurance is essential. We're also in the process of introducing a digital control system that has 100% traceability for all the components we manufacture. The system will register all necessary quality documentation that we're required to present to clients at the end of a project.

It will greatly improve accuracy and reduce wastage," said Chris.

Icon Metal is also a member of the ASI's Environmental Sustainability Charter (ESC), which demonstrates a commitment to sustainable business practices, taking environmental responsibility and sharing their

knowledge of sustainability with others.

In addition to their certifications, Icon upholds socially responsible values, recycling all their scrap metals and buying materials only from suppliers with certified sustainable practices.

"The standards to which we hold ourselves are demonstrated by our high incidence of repeat clientele – we deliver quality results without compromising on safety or consideration for sustainability," said Chris.

Chris believes that innovation is essential to the future of the Australian steel industry. "Australia's competitiveness with overseas markets depends upon innovation. Here in Australia, we pay a lot of money for labour compared to some other countries. The introduction of specialist equipment and investment in innovative systems, processes and training can help reduce these labour costs while improving efficiency, accuracy and quality control. All these efforts make Australian fabricators not only more competitive with international markets, but within local markets as well."

CLICK HERE TO LEARN MORE ABOUT ICON METAL AND THEIR INNOVATIVE OPERATIONS >>>

SYDNEY OPERA HOUSE CONCERT HALL REFURBISHMENT The Brief: To increase the load-bearing capacity of the stage from 8 tonne to 38 tonne by reinforcing the main stage and choir stall area.

Challenges: • Difficult access • Working in confined spaces • Working safely at height • High fire danger To fulfil the brief required the installation of 180 tonne of steel inside the cavity between the outer shell of the Opera House and the internal wall of the auditorium, and 25m above the auditorium in the Tech Zone from where the stage is suspended.

Without using a crane, up to 2 tonne of steel at a time was brought into the building in stages using pulleys to lift and trolleys to move the steel around inside the cavity. In places the space inside the cavity was less than a metre wide.

Quay Quarter Tower

A complex geometric spiral stair with glass balustrade and stainless steel handrails Quay Quarter Tower is a 200m high skyscraper located at 50 Bridge Street in Sydney. Originally built as the AMP Centre in 1976, the structure underwent a redevelopment from 2018.

The redevelopment is scheduled for completion later this year. Designed for AMP Capital by Danish architects 3XN, the new building comprises a series of shifting glass volumes stacked upon each other to provide a striking façade and an atrium that cuts all the way through the building. The tower features the latest in commercial office technology and is targeting 6-star Green Star and 5.5 Star NABERS ratings. There have been a number of 'construction firsts' with the building, including the tallest cranes in Sydney and the highest erected scaffolding in Australia.

Spanning 48 floors, the spiral stairs at Quay Quarter Tower are Icon Metal's largest and most ambitious project to date. Icon Metal was part of the delivery team led by contractor Multiplex. The project encompassed 35 sections of steel spiral stairs, painted pure white.

The stairs will become a major public feature in this iconic building.

FEATURE: INNOVATION IN FABRICATION | STEEL AUSTRALIA | AUTUMN 2022

ICON METAL'S PREVIOUS PROJECT EXPERIENCE

Wynyard Station

Balustrade and glass screen works in Icon Metal's first project with Transport for NSW Wynyard railway station is a heritagelisted underground rail station in the north-west precinct of the Sydney central business district. The station opened on 28 February 1932 to coincide with the opening of the Sydney Harbour Bridge. As Sydney’s third busiest station, Wynyard recently underwent redevelopment, increasing the station's capacity to 150,000 people per day and improving links to Barangaroo and Sydney’s financial district. The project established Wynyard station as a modern Australian rail benchmark for comfort, safety and efficiency.

The Wynyard Station upgrade was delivered by Novo Rail, an alliance of Transport for NSW in partnership with Aurecon, Laing O’Rourke and RCR Infrastructure O’Donnell Griffin.

Novo Rail commissioned Icon Metal to undertake the balustrade and glass screen works. Icon Metal delivered high quality certified and compliant product solutions that supported the architectural intent. All of this work was completed either after hours or as the station was operating, which demanded a high level of pedestrian control and safety.

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STRENGTH IN AHRENS’ STEEL AHRENS’ SOLID INVESTMENT DECISIONS HAVE LED THE NATIONALLY RECOGNISED BUSINESS TO CEMENT ITS FUTURE AND POSITION AS A LEADER IN STEEL FABRICATION IN THE GLOBAL MARKET. THE FIFTH-GENERATION FAMILY-OWNED SOUTH AUSTRALIAN COMPANY, WITH FOOTPRINTS ACROSS THE NATION AND OVERSEAS, ATTRIBUTES ITS VERTICALLYINTEGRATED BUSINESS, COMPLETE IN-HOUSE CAPABILITIES AND WORLD-LEADING TECHNOLOGY AS ITS CORE STRENGTHS. COMPETITIVE ADVANTAGE

Ahrens Managing Director, Stefan Ahrens, says for more than 100 years – even through tough times – Ahrens has always maintained steady sustainable growth.

“Our vertically-integrated set up continues to enable us to remain as a one-stop company for our clients’ project needs from concept to completion,” said Stefan, a fourth generation Ahrens.

Ahrens’ broad range of in-house capabilities includes construction project management, design and construct, engineering services and infrastructure, procurement and steel fabrication and installation.

“By managing all these capabilities inhouse, we have superior control over cost savings and time above all others, on every project we undertake,” said Ahrens.

“We have the expertise to successfully deliver projects in any location, from complex inner-city footprints to remote outback regions. Our significant in-house labour, trades, plant and equipment enable us to mobilise at short notice and meet the tightest deadlines.”

Ahrens Steel and Site Services General Manager, Nick Pizzino, said the move into the expansive steel manufacturing facility, just north of Gawler in 2009, was

a big catalyst for company growth. He said their forward planning led to their custom-engineered building (CEB) line.

“The fit out involves a workshop featuring an overhead crane for each welder and a side-lift which was introduced to eliminate turning of long beams,” Pizzino said.

The CEB line and flange materials are safely handled by electromagnetic grab cranes, and steel plates are handled by vacuum suction cop lifting attachments.

Its tapered web welded beam technology has provided Ahrens the ability to undertake CEB building design for more cost-effective and large-span build work.

Today, Ahrens’ products and services are used in commercial construction, refurbishment, mining services, structural steel, agriculture and more.

“Importantly, the CEB’s capability has continually enabled our team to have that highly competitive edge against industry competitors to manufacture full turnkey projects,” Pizzino said.

INFRASTRUCTURE SOLUTIONS

Among the robust Ahrens family of brands is their rural division’s statebased flat silo bottom factories and their transportable silo line. General Manager of Ahrens Rural, Aaron Bain, also credits the manufacture of quality steel and complete in-house services as major

strengths. “The roll form line for our flat bottom silos has led us to heavily reduce lead times, which gives us greater control in a competitive market,” Bain said.

Ahrens’ world-leading technology also enables their silos to be engineered to Australian Standards for rural and commercial applications, making them a trusted Australian silo manufacturer.

“Having our silos delivered either fully assembled on site or ready for site construction by our team also make us competitive,” Bain said.

To date, their transportable silos range from 31 to 126 tonne, with core options, and the flat bottom silos range from 800 to 3,000 tonnes.

“Our in-house capabilities also provide us greater versatility – especially as demands increase – for individual silos or complete grain storage systems to suit all types of grain fertiliser, dairy and seed and feeds,” Bain said.

Similarly, Ahrens sheds division operates under the same principles of complete in-house capabilities, with all sheds manufactured and installed using the highest quality steel. Ahrens Group Manager for Sheds, Amanda Armistead, said the quality and workmanship that goes into their Australian owned and made sheds are second to none.

INNOVATIVE INVESTMENTS

Ahrens Water Storage Group General Manager, Alistair Johnston, says their innovative and cost-effective water solutions make Ahrens trusted leaders in Australia and overseas. Overseeing benchmark brands, Pioneer Water Tanks, Southern Cross Water and Altanks, Johnston said each business answers all water storage needs for farming,

domestic and industrial applications.

“At Pioneer Tanks, we have made significant investments to our plant and equipment to create the most technologically advanced tank manufacturing facility in Australia,” Johnston said.

Pioneer’s world first antimicrobial tank liner, scientifically proven to keep tank water fresher for longer, is a great example of their innovation. Southern Cross introduced prefabricated, modular steel bolted tanks to the Aussie water market 50 years ago to supply water storage solutions to commercial and industrial sectors, and rural and agriculture sectors. Altanks' recent procurement by Ahrens has led to a range of modular steel bolted tanks for

the commercial and industrial water storage market; primarily servicing the Australian fire sector.

COMPANY ALIGNMENT

The design and construct and delivery of Ahrens' steel products and services relies on the execution of detailed planning, says Ahrens Construction Director, Mark Smeaton.

FEATURE: INNOVATION IN FABRICATION | STEEL AUSTRALIA | AUTUMN 2022

“Our in-house production and design capabilities, combined with a loyal pool of subcontractors, mean we can control costs and quality above all others to provide a cost-effective turnkey solution to suit client needs,” Armistead said.

The range includes hay sheds, machinery sheds, workshops, open end sheds, fertiliser and grain sheds, barns, equestrian arenas and shearing sheds.

“Ahrens’ family of brands have prospered due to the creation of a full breadth of steel fabrication services backed by best project delivery principles, technology and Ahrens’ people,” he said. “We are continually growing our vertically-integrated business model, and it’s also about having quality products to cross-sell between the divisions.”

Ahrens is further focussed on removing the 'middle dollars' to provide their clients with value for money. “We are situated in a competitive market and still riding a global pandemic, so we clearly need to be diverse and dynamic with our approach to business,” Smeaton said.

Ahrens’ current approach has given the company the confidence and reputation for future growth – geographically and product wise.

IMAGES Top Left: New facility built for Viterra by Ahrens Design & Construct.

CLICK HERE TO LEARN MORE ABOUT THE STRENGTH IN AHRENS' STEEL AND INNOVATION >>>

Top Right: CK Tremletts flat bottom silos completed by Ahrens rural division.

Left: Ahrens' roll forming machine.

49

ASI LIBRARY & BOOKSHOP UPDATE MULTI-USER EBOOK SETS NOW AVAILABLE

The Australian Steel Institute (ASI) is pleased to announce that our eBooks can now be purchased as multiuser subscriptions. These multi-user subscriptions can be accessed by all employees linked to an ASI account.

This update means that you'll receive generous discounts when you purchase our sets of eBooks.

In 2020, the Australian Steel Institute (ASI) launched its first eBooks. Since then, the ASI has rapidly expanded its suite of ebooks to over 30 titles, including: • Handbook 1: Design of Structural Steel Connections • Design Capacity Tables for Structural Steel (Volume 1): Open Sections • Design Capacity Tables for Structural Steel (Volume 3): Simple Connections - Open Sections • Design Capacity Tables for Structural Steel (Volume 4): Rigid Connections - Open Sections • Design Guide 1: Bolting in Structural Steel Connections

NEW ASI MEMBERS

• • • • • • • • • • • • • • • •

Design Guide 2: Welding in Structural Steel Connections Design Guide 3: Web Side Plate Connections Design Guide 4: Flexible End Plate Connections Design Guide 5: Angle Cleat Connections Design Guide 6: Seated Connections Design Guide 7: Pinned Base Plate Connections Design Guide 10: Bolted Moment End Plate Beam Splice Connections Design Guide 11: Welded Beam to Column Moment Connections Design Guide 12: Bolted End Plate to Column Moment Connections Design Guide 13: Splice Connections Steel Detailers Handbook Economical Structural Steelwork Worked Examples for Steel Structures Standardised Structural Connections Australian Steelwork Corrosion and Coatings Guide The complete set of eight books in the Structural Steel Tubular Connection Design Guide series

Bespoke Engineering Solutions T: 07 3801 4449 E: admin@bespokeeng.com.au W: bespokeeng.com.au A: Unit 1, 3974 Pacific Highway Loganholme, Queensland

THE AUSTRALIAN STEEL INSTITUTE (ASI) WOULD LIKE TO WELCOME SEVERAL NEW MEMBERS WHO JOINED OVER THE LAST QUARTER.

Lendlease Building T: 02 9236 6111 W: lendlease.com/au/ A: Level 14, Tower Three, International Towers Sydney Exchange Place 300 Barangaroo Avenue Sydney, New South Wales

PROFESSIONAL MEMBERS

WalkOn Drafting T: 0414 310 645 A: 47 Minda Crescent, Oaks Flat New South Wales

3D Engineering Global T: 0455 598 423 E: info@3deglobal.com W: 3deglobal.com A: Level 1, 100 Havelock Street West Perth, Western Australia Austfield T: 02 9687 7677 E: info@austfield.com.au W: austfield.com.au A: 316/33 Lexington Drive, Bella Vista New South Wales

HOW DO ASI eBOOKS WORK? There are flexible options for access to ASI eBooks: •

An individual user licence; or

•

An annual, multi-user subscription that can be accessed by employees within your company via their ASI Dashboard.

ASI eBooks are accessed via your personal Dashboard, when logged into the ASI website, from a state of the art eBook reader called tekReader.

Navigation within the eBook is optimised with contents, tables, figures and references all linked.

You can add notes to your publication and access it from any device.

FURTHER INFORMATION

To purchase any of the ASI's eBooks, simply click here.

FABRICATOR MEMBERS AM Metal Group T: 03 9336 9300 E: office@ammetal.com.au W: ammetal.com.au A: 42 McIntosh Street, Airport West Victoria Knox Engineering T: 02 9829 5858 E: info@knoxeng.com W: knoxeng.com A: 9 Devon Road, Ingleburn New South Wales

MANUFACTURER MEMBERS

Livingstone Engineering T: 07 3277 5499 E: info@liveng.com.au W: liveng.com.au A: 63 McCarthy Road Salisbury, Queensland

Spantec Systems T: 02 4860 1000 W: spantec.com.au A: 17 Drapers Road, Braemar New South Wales

Motion Group T: 02 4067 3718 W: motiongroup.net.au A: Unit 14/33 Kyle Street Rutherford, New South Wales

CLICK HERE TO LEARN MORE ABOUT ASI MEMBERSHIP AND JOIN THE ASI TODAY >>>

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. AS SUCH, THE ASI RECENTLY DESIGNED, DEVELOPED AND LAUNCHED A NEW WEBSITE.

to become a central place in which the ASI community can come together to be informed, educated and record their journey with steel.

One of the main objectives for the new website was to personalise the experience that ASI members (and registered guests) have when interacting with the ASI.

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

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

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. 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.

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.

INSIDE THE ASI | STEEL AUSTRALIA | AUTUMN 2022

NEW ASI WEBSITE LAUNCHED

Keep in mind that in order to view your Member Dashboard, update the Industry Directory, manage company contacts, and so on, you need to be logged in with your email and password.

CLICK HERE TO VISIT THE AUSTRALIAN STEEL INSTITUTE'S BRAND NEW WEBSITE AND TAKE ADVANTAGE OF ITS NEW FEATURES >>>

UPCOMING ASI EVENTS THE ASI HAS SEVERAL EXCITING EVENTS ON THE HORIZON, WITH SUBJECT MATTER RANGING FROM STRUCTURAL BOLTING THROUGH TO THE DESIGN OF STEEL BRIDGES, PORTAL FRAME BUILDINGS, AND ROLLER DOORS IN STEEL SHEDS. BOOKINGS WILL BE AVAILABLE ON OUR WEBSITE AS SOON AS DATES ARE CONFIRMED. VISIT STEEL.ORG.AU FOR FURTHER INFORMATION. Event Title

Event Format

Introduction to Construction Modelling and Steel Detailing – the millimetre perfect solution

2 hour webcast plus Q&A

The updated Australian Wind Code AS 1170.2 and its impact on the design of structures

2 hour webcast plus Q&A

Effective Design of Steel Bridges

4 hour webcasts plus Q&A

Design of Portal Frame Buildings

4 hour webcast plus Q&A

Design & Construction of Temporary Works

1 hour webcast plus Q&A

Design of Roller Doors and Supporting Structures

2 hour webcast plus Q&A

2022 ASI Australian Steel Convention on 9 to 11 October 2022 in Sydney

2 day face-to-face conference

51

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

1

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

2

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

3

Regular industry news & steel Australia magazine and Steel Construction journal

4

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

5

Member discounts on ASI bookshop publications and eLearning packages

6

Superior technical advisory services, delivered by experienced industry experts

7

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

8

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

www.steel.org.au | +61 2 8748 0180 | enquiries@steel.org.au