steel Australia (Vol 34 No 2) Winter 2021

TECHNOLOGY, RESEARCH & DEVELOPMENT

PLUS

LYSAGHT AUSTRALIA CELEBRATES 100 YEARS OF LOCAL MANUFACTURING Winter 2021 Vol. 34 | No. 2 ISSN 2208-7486 (online) ISSN 1447-5359 (print)

CHESS ENGINEERING CELEBRATES 50 YEARS IN BUSINESS COVID-19 SURGE CENTRE DELIVERED IN RECORD TIME WITH PRE-FAB STEEL

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Working hard for a future you can be proud of Like millions of us across this nation, we’re working hard for a future we can all be proud of. A fund that puts members first, gives you and your employees the freedom to move forward with confidence.

With more than $200 billion in members’ assets, our size and scale allow us to invest for you like no other fund can. And whilst we always look to the future, it’s reassuring to know we’re Australia’s top performing fund over the past 15 years.*

*Based on the SuperRatings Fund Crediting Rate Survey — SR50 Balanced (60–76) Index for the 5, 7, 10 and 15 years to 31 December 2020. This may be general financial advice which doesn’t consider your personal objectives, situation or needs. Before deciding on AustralianSuper read the Product Disclosure Statement available at australiansuper.com/pds. AustralianSuper Pty Ltd ABN 94 006 457 987, AFSL 233788, Trustee of AustralianSuper ABN 65 714 394 898.

A134 04/21

Visit australiansuper.com

Vol. 34 No. 2 | Winter 2021 ASI HEAD OFFICE

20 CONTENTS INDUSTRY INSIGHTS

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

Message from the Chair

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 Julie Fidler on (02) 8748 0104

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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

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

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Combilift Delivers its 60,000th Truck

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SMEs Set for Growth & Ready to Drive Up Revenue

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FICEP's Secret to Success

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Protect Your Organisation from EFT Payments Fraud

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What is the Real Cost to Being Underinsured

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On the Beam

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Lysaght Australia Celebrates 100 Years of Local Manufacturing

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Chess Engineering Celebrates 50 Years in Business

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Pacific Industrial Company: A Western Australia Success Story

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Australian Pipe & Tube: The Independent Choice

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Dunsteel Invests in Kaltenbach System

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FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT

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Molycop: Automation Builds a Better Working Environment

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DSI Underground: A Holistic Approach to Lean Manufacturing

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idec's Automation Journey: Increasing Competitiveness, Productivity and Innovation

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Celebrating 30 Years of Continuous Casting at Whyalla Steelworks

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ACT COVID-19 Surge Centre Delivered in Record Time with Pre-Fab Steel

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Steel Research Hub: Creating a Globally Competitive, Sustainable and Resilient Steel Industry

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Protecting & Improving Steel: New Galvanizers Design Manual

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New ASI Members

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How AustralianSuper Invests Members' Super

INSIDE THE ASI

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

Message from the Chief Executive

Exclusive ASI Member Offers

Cover image: Steel Research Hub: Creating a Globally Competitive, Sustainable and Resilient Steel Industry.

Story on page 46.

CONTENTS | STEEL AUSTRALIA | WINTER 2021

steel Australia

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AUSTRALIAN STEEL CONVENTION

12–14 SEPTEMBER 2021

REGISTRATION OPEN

The Australian Steel Convention 2021 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

INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

MESSAGE FROM THE ASI CHAIR A few months back, we were talking about the post-pandemic recovery in various economies around the world, including Australia.

However, as the 2020-2021 financial year came to a close, we were once again experiencing disruptions.

While we had become somewhat accustomed to these, to a certain extent, we thought they were behind us.

While these disruptions have hit certain sectors of the economy quite hard, our industry has been able to maintain momentum. This is a result of the continued strong growth in the infrastructure and residential construction markets, driven by the stimuli initiated by state and federal governments over the course of the last financial year.

The booming construction markets we are experiencing in Australia— coupled with similar conditions in other major economies around the world—have led to substantial shortages of construction materials, steel included.

Steelmaking capacity in some countries that was idled in the early stages of the pandemic has been very slow to come back online. In addition, major exporting countries, such as China, have either made the decision to reduce export steel trade or, in the case of India, have had their supply chains interrupted due to new COVID-19 outbreaks.

The massive worldwide demand for materials has also put pressure on the availability and cost of sea freight. These freight shortages have consequently created inflationary pressures, which have increased the price of most construction materials.

Bernie Landy Chair, Australian Steel Institute

Again, steel is included in this dynamic.

There is no doubt that the efforts by our state and federal governments to stimulate construction activity have successfully delivered increased demand to suppliers throughout the construction sector. ASI’s members have experienced this first-hand.

However, the rapid increases in the price of materials are possibly an unintended consequence of this booming demand, which could still run on for some time.

It is difficult to predict when a turning point might come.

The new financial year is therefore likely to once again bring significant opportunities for our industry but, as usual, there will also be some challenging risks ahead that we will need to manage.

“

The booming construction markets we are experiencing in Australia— coupled with similar conditions in other major economies around the world—have led to substantial shortages of construction materials, steel included."

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MESSAGE FROM THE ASI CHIEF EXECUTIVE The feature of this edition of steel Australia is Technology, Research and Development. The advent of more sophisticated technology and automation is enabling the Australian steel industry to augment and improve its production processes. From investments in technology at the Whyalla Steelworks

by Liberty Primary Steel (see page 38), through to idec's automation journey (see page 36) and DSI Underground's process advancements (see page 34), this uptake is improving efficiency and capacity throughout the steel supply chain.

In the realm of Research and Development, the Steel Research Hub at the University of Wollongong is leading the charge in Australia (see page 46). Having just received an additional $28 million in funding, the Hub is set to embark on its second phase of operations, which will investigate projects in areas such as process integration and sustainability, product innovation and technology, advanced corrosion performance and operational efficiency and steel supply chain transformation.

2021 AUSTRALIAN STEEL CONVENTION

Planning is well underway for the upcoming 2021 Australian Steel Convention. With the theme of Vital and Adaptive, the Convention will be held at the Four Seasons Hotel in Sydney from 12 to 14 September.

We are monitoring the continually evolving COVID-19 situation and will keep members informed of any updates.

Our first priority is the health and safety of attendees, presenters, sponsors and stakeholders.

The program will bring together key industry leaders and innovators to discuss opportunities, showcase industry successes and examine what the future can, and will, look like. Just some of our speakers include Professor Veena Sahajwalla (Director, SMART at University of New South Wales), Vik Bansal (CEO, InfraBuild), Dr Paul Pietro (Director, Facility for Intelligent Fabrication), John Nowland (Chief Executive Steel Products, BlueScope), Davina Rooney (CEO, Green Building

Council of Australia), Des Watkins (Director, Watkins Steel), and Mark Campbell (CEO, DBM Vircon).

I urge all ASI members to register now.

Further information is available via https://www.steel.org.au.

YEAR IN REVIEW

ASI recently released its 2020-2021 Year in Review. This document provides an overview of our activities and achievements across the last 12 months. To access a copy of the 2020-2021 Year in Review, scan the QR code below.

ASI COMPLIANCE SOLUTIONS

The supply of non-compliant, unsuitable, and often faulty building products is increasingly being seen in building, infrastructure and resources projects in Australia, ranging from small local developments to major projects involving international teams. Buying Australian manufactured and processed steel brings many advantages to customers beyond the broader economic benefits, from reduced delivery times and freight costs, to greater reliability of supply.

The ASI has produced a range of solutions and tools to help our stakeholders ensure cost-effective, compliant outcomes, and structures that are resilient and achieve the intended design life. These steel compliance solutions include: the National Structural Steelwork Compliance Scheme (NSSCS), the Environmental Sustainability Charter (ESC) and ShedSafe. The ASI's recently released Steel Compliance Solutions document outlines these three schemes. To access a copy, click on the links below.

ASI eLEARNING RESOURCES

Mark Cain Chief Executive Australian Steel Institute

both a major Australian university (using the eLearning portal to support their Masters coursework), and international consulting engineering firm, ARUP. Universities and engineering consultants alike are realising the benefits of the ASI's eLearning courses to support the education and training of the next generation of steel experts. For further information on the eLearning platform, visit: https://learn.steel.org.au.

NEW CORPORATE PARTNERS I'd like to welcome the ASI's new corporate partners. In recent months, we've had Banjo (an innovative online lender for SMEs), eftsure (for protection against payment fraud and errors) and NCI (a leading provider in trade credit services) partner with the ASI to support the Australian steel industry.

Launched in mid-2020, the ASI’s eLearning portal brings together highly relevant, quality learning material for all steel industry stakeholders.

Month-on-month, course uptake by has increased. Over 560 course seats have been sold to date. This uptake has been bolstered by subscription models with

We also recently announced our Exclusive ASI Member Offers program.

To kick off the launch of the program, we've created a 'Motoring Package'.

Whether you're looking to purchase a luxury Lexus, fill up your tank with WEX Motorpass, or hire a Europcar vehicle, the ASI's motoring package has got you covered (see page 51).

CLICK HERE TO DOWNLOAD ASI'S 2020-2021 YEAR IN REVIEW >>>

CLICK HERE TO DOWNLOAD ASI'S COMPLIANCE SOLUTIONS >>>

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INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

HOW AUSTRALIANSUPER INVESTS MEMBERS' SUPER AUSTRALIANSUPER INVESTS WITH ONE GOAL IN MIND: TO HELP MEMBERS ACHIEVE THEIR BEST POSSIBLE RETIREMENT. SO MEMBERS CAN ENJOY A BETTER FUTURE, AUSTRALIANSUPER FOCUSES ON MAXIMISING INVESTMENT RETURNS OVER THE LONG TERM. THEY INVEST IN A MIX OF QUALITY ASSETS TO GROW MEMBERS’ SAVINGS OVER TIME AND BALANCE THIS WITH AN UNDERSTANDING OF THE RISKS TO ACHIEVE THIS GOAL. FOUR INVESTMENT BELIEFS

Four core investment beliefs are the foundation of AustralianSuper’s investment approach. These are supported by a rigorous governance framework and disciplined investment process.

1. Aim to enhance member returns.

2. Active management across both asset allocation and stock selection.

3. Use scale to reduce costs and better structure investments.

4. Awareness of their responsibility to the broader community, consistent with their obligations to maximise benefits to members.

INVESTING FOR MEMBERS

Super is the largest asset most people will ever own, after the family home.

AustralianSuper invests to help make sure members are going to get the most out of their money. This is achieved by using AustralianSuper’s size and scale, in-house investment expertise, active management and global investment.

USING SIZE TO BENEFIT MEMBERS As Australia’s largest super fund, AustralianSuper takes advantage of opportunities that aren’t available to smaller funds. These include large unlisted assets like Kings Cross, Ausgrid and WestConnex.

Strong cashflows enable AustralianSuper to allocate funds to different asset classes without selling valuable long-term investments. This

also helps keep transaction and tax costs low, which benefits members’ returns.

IN-HOUSE INVESTMENT EXPERTISE AustralianSuper’s in-house investment team of more than 170 people invest members’ assets, and almost half of them are managed by internal teams.

This gives AustralianSuper increased access to investments and saves millions of dollars in costs every year.

Good returns and lower costs have resulted in a better ‘net benefit’ for members*.

ACTIVE MANAGEMENT

AustralianSuper believes an active management approach delivers the best long-term returns. They select specific sectors, assets and stocks that have the potential to outperform the broader market and use index managers in some options to lower overall portfolio costs, or where active management opportunities are smaller.

INVESTING GLOBALLY FOR MEMBERS

With teams in Australia, Beijing, London and soon New York, AustralianSuper is able to access insights and opportunities in targeted global investment markets. AustralianSuper’s on-the-ground presence also allows them to efficiently monitor their global investment portfolio and make timely investment decisions.

To read more, please visit australiansuper.com/how-we-invest *Investment returns are not guaranteed.

Past performance is not a reliable indicator of future returns. Sponsored by AustralianSuper. This may include general financial advice which doesn’t take into account your personal objectives, situation or needs. Before making a decision consider if the information is right for you and read the relevant Product Disclosure Statement, available at australiansuper.com/pds or by calling 1300 300 273.

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.

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INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

COMBILIFT DELIVERS ITS 60,000th TRUCK THE IRISH MANUFACTURER COMBILIFT RECENTLY MARKED A FURTHER MILESTONE WHEN ITS 60,000th UNIT CAME OFF THE PRODUCTION LINES AT THEIR HEADQUARTERS IN MONAGHAN AND WAS SHIPPED TO THE OTHER SIDE OF THE WORLD. THE CUSTOMER TAKING DELIVERY OF THIS SPECIAL FORKLIFT IS METROLL, A LEADING AUSTRALIAN MANUFACTURER AND SUPPLIER OF STEEL BUILDING PRODUCTS INCLUDING ROOFING, CLADDING, RAINWATER, STRUCTURAL AND FENCING.

Metroll has branches across the country, and the new Combi-CB3000 will be a further addition to its fleet of 13 Combilifts that are operating throughout the Metroll Group, with another 10 already on order. These range from 3 tonne multi-directional units to a highly customised 10 tonne model.

Combilift number 60,000 will be working at the site in Toowoomba and has been fitted with features such as 4.9m triplex mast with a 3,050mm spreader to safely and easily manage the long loads that are typically handled by Metroll.

According to Metroll Operations Manager, Vic Josephs, “Like most businesses we are very busy and we’re also growing at a significant rate, so space has become a premium resource.

With this unit we can utilise our space more efficiently whilst at the same time operating safely. Safety is of paramount importance. This forklift allows our machinery to get into tighter spaces and

for us to space our racks more closely together to maximise factory floor space.”

Combilift CEO and Co-Founder Martin McVicar commented, “This is a great achievement for Combilift, particularly as almost every truck we manufacture is a one-off, designed for specific and individual requirements. There are very few other companies, if any, that can offer this level of customisation whilst manufacturing in such volume. The first half of this year has been by far the best in our 23 year history for the number of orders we have received – not just for Combi-CB models but across our complete product range.”

Chris Littlewood, Country Manager of Combilift Australia said: “The Combi-CB 3 tonne model is the most popular unit

in the Australian market and accounted for 50% of the machines we sold in the year ending March 2021. So we are particularly pleased that it is one of our customers in this country that has been able to receive this landmark machine.”

Following the successful collaboration with Metroll in Australia, Combilift now also supplies its trucks to the company’s Californian based operations too. “We have often found that a recommendation from one country leads to sites elsewhere adopting the same material handling processes with our products,” said Martin McVicar. “So we’d like to congratulate Metroll on taking delivery of our 60,000th truck, and thank them for their continued support over the years.”

This article is part of a paid advertising package.

CLICK HERE TO LEARN MORE AND WATCH A VIDEO ABOUT COMBILIFT'S DELIVERY OF ITS 60,000TH TRUCK TO AUSTRALIA >>>

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If you’ve got the opportunity, Banjo Loans will help transform it into an outcome. Our local experts will find the right loan to help your business take the next step.

So if you’re ready, we’re ready.

1300 22 65 65 | banjoloans.com

SMEs ARE RECOVERING WELL FROM A DIFFICULT YEAR, AND SIGNS ARE POINTING TO A POSITIVE ECONOMIC ENVIRONMENT FOR THE 2022 FINANCIAL YEAR. IN THE NEXT 12 MONTHS, NEARLY TWO-THIRDS OF SMEs ARE PLANNING TO BORROW TO DRIVE GROWTH FOR THEIR BUSINESSES. BUT THERE ARE STILL TOO MANY PAIN POINTS AROUND GETTING THE APPROPRIATE FUNDING.

These are some of the many findings in the Banjo SME Compass report 2021.

The report reflects a recovering SME sector, many of which are feeling positive about the year ahead and planning for growth. Yet barriers to growth remain, and a surprising number are lagging in getting their businesses online.

Banjo’s SME Compass report is based on research commissioned by Banjo, to analyse how the engine room of the Australian economy is going. A broad cross-section of SMEs across Australia was surveyed earlier this year by Honeycomb Strategy for Banjo.

TOP FACTORS THAT HELPED DRIVE SMEs’ REVENUE

Not surprisingly, just a quarter of SMEs said that they exceeded their revenue targets last year. There was a common factor among the 25% who recorded strong performance: all of them invested for growth by implementing new technology, improving products and buying new assets or equipment in 2020. Those who leveraged debtor or supply chain finance were significantly more likely to exceed revenue targets.

MANY BUSINESSES ARE POISED FOR GROWTH

Nearly seven in 10 SMEs are expecting an increase in revenue over the next 12 months. With close to one third having

let staff go during the pandemic, employment prospects are also set for growth with 46% intending to increase their headcount in 2021.

However, many have a lot of catching up to do in online business. With only 28% of SME revenue currently generated online, businesses are more aware than ever that on the back of pandemic restrictions, online needs to be a key component of their growth strategy.

More than half (52%) propose to increase the proportion of their sales generated through online channels in 2021. For 14% of SMEs, this year will mark the first time they begin to earn revenue online.

DEMAND FOR FUNDING – AND WHAT SMEs NEED RIGHT NOW

With nearly two thirds of the approximately 1.2 million SMEs in Australia intending to borrow in 2021, this means approximately 750800,000 SMEs seeking funding.

The sector had $146 billion of funding lines in June 2020, which declined during the pandemic to $141 billion in March 2021. Based on this research, and the upswing Banjo is seeing in demand, this suggests lending to the SME sector will increase by around $5 billion between now and the end of the year.

A significant proportion (59%) of SMEs experience challenges when looking to secure funding to grow.

Chief among the pain points are lenders who require property or assets as security, and lengthy loan approval times.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

SMEs SET FOR GROWTH & READY TO DRIVE UP REVENUE

Drawn-out approval processes are undoubtedly prevalent in some parts of the banking sector. However, lenders with the right technology can give a small business owner an answer either way, within 24 hours.

The opportunity cost of not being able to secure funding when a business needs it – now – is too big to ignore. After a competitive interest rate, SMEs find the most attractive feature in a lender is a simple application process.

FEMALE BUSINESS OWNERS TAKE A DIFFERENT APPROACH

Female business owners are much less likely than their male counterparts to borrow to fund growth, preferring to self-fund from operations. This is, in large part, because they are more averse to providing personal assets as security – regardless of how large or small their business is. There is also the question of where to turn for funding.

MERGERS, ACQUISITIONS AND EXPANSIONS

Acquiring another business (or being acquired) to grow is on the cards for 42% of those surveyed. SMEs chiefly turn to business advisors/ consultants and accountants for advice on mergers and acquisitions, with other advisers coming a distant third or later.

CLICK HERE TO FIND OUT MORE AND DOWNLOAD YOUR COPY OF THE BANJO SME COMPASS REPORT 2021 >>>

Where expansion is concerned, New South Wales is the target for most.

Interestingly, Queensland is on par with Victoria as a target, despite having a much smaller SME footprint than the southern, more heavily populated state.

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

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FICEP'S SECRET TO SUCCESS: EXPERIENCE, KNOW HOW, RESEARCH & DEVELOPMENT, EDUCATION & LOCAL PRESENCE FICEP’S GOAL IS TO SATISFY THE REQUESTS OF THE GLOBAL STEEL CONSTRUCTION MARKET. THIS MISSION IS GUIDED

BY A CLEAR STRATEGIC VIEW. THE KEY FACTORS IN FICEP'S SUCCESS ARE EXPERIENCE, KNOW HOW, RESEARCH AND DEVELOPMENT, EDUCATION AND A STRONG LOCAL PRESENCE.

FICEP is an Italian company with almost a century of experience. Today, the company is a leading partner for the production and supply of complete steel solutions. FICEP offers a wide range of highly advanced technology and machines for the steel construction, forging and stamping industries.

Australasia represents an important market for FICEP. The company operates through the synergy of an experienced Sales Area Manager and a prominent agent – Ron Mack Machinery. A dynamic commercial network ensures that FICEP is able to deliver fast and effective results for this dynamic and growth oriented market.

A STRONG LOCAL PRESENCE

Throughout its global operations, FICEP is focused on establishing a strong local presence to enable the delivery of superior quality after sales service development. To date, FICEP boasts a worldwide network across 17 countries and 100 agents.

Highly qualified employees and local structures equipped with state-of-the-art offices and showrooms, replicate the Gazzada Schianno headquarter model.

They also guarantee the ultimate in technical assistance, as well as tools and consumables supply.

FICEP's success and penetration in all the geographical markets is driven by constant and important investments.

RESEARCH AND DEVELOPEMENT

FICEP has always believed that Research and Development is essential in maintaining a strong position within the global market.

Their team of 50 engineers, specialised technicians and CAD/CAM operators has access to the direct support of the production office, and regularly develops prototypes and undertakes in-depth research.

All this allows the management team to look towards the future, equipped with

a deep technical knowledge and the capabilities required to anticipate market needs and trends.

EDUCATION, EXPERIENCE AND KNOW HOW

FICEP invests heavily in education, which plays a key role in the growth of the company. Employee education, experience and know how are essential in achieving customer satisfaction.

FICEP has followed this philosophy for many years, constantly demonstrating its commitment to upskilling its entire team. Just one tangible example of this commitment is the FICEP Academy of Technology and its associated 2,400m2 showroom.

One of the main trends emerging across worldwide markets, including Australia, is the need to design and build complete productive lines. FICEP is able to manage every step, offering the widest range of hardware and software solutions to cover the whole production process.

FICEP's CNC line is engineered and designed for milling, drilling and scribing steel plates specifically for the wind tower construction industry. FICEP Energy is a powerful and innovative solution that achieves high productivity, versatility and performance, and meets the elevated quality standards required by regulations associated with the wind tower industry.

FICEP Energy satisfies the wind tower construction processes requirements, and also meets the energy sector needs (such as those associated with heat exchangers), as well as the requirements of the oil and gas and civil construction

industries, and shipyards. FICEP Energy’s technological focus is the chamfering of large and thick plates. But thanks to its versatility, the CNC system is able to drill, mill and scribe plates of different shapes and thicknesses, from a minimum of 6mm up to a maximum of 140mm. The plate width ranges from a minimum of 100mm up to a maximum of 4,500mm, and the maximum length is 30,000mm. The gantry system and the two different working areas allow a continuous working cycle without machine stoppages, which helps to maintain high productivity rates.

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

FURTHER INFORMATION

FICEP www.ficepgroup.com Area Sales Manager, Francis Lee on +64 (0) 21 448 568 or francis.lee@ficep.it

INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

FICEP ENERGY

Ron Mack Machinery Australia www.ronmack.com.au Darryl Mack on +61 (0) 419 383 376 or dmack@ronmack.com.au David Sharp on + 61 (0) 439 901 646 or david@ronmack.com.au Andrew Barker on + 61 (0) 400 219 634 or andrew@ronmack.au

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PROTECT YOUR ORGANISATION FROM EFT PAYMENTS FRAUD WITH CYBER CRIMINALS NOW TARGETING AUSTRALIA’S STEEL INDUSTRY, NOW IS THE TIME TO PROTECT YOUR ORGANISATION FROM EFT PAYMENTS FRAUD. Nobody would deny the past year presented unprecedented challenges.

Despite it all, demand for steel is starting to bounce back strongly following the COVID-19 downturn. Additionally, a renewed focus on onshoring supply chains means the outlook for Australia’s steel sector looks promising.

But even as the heat rises in the furnaces at Port Kembla and Whyalla, new challenges are emerging. Last year’s cyber incident at BlueScope Steel is an important reminder that criminals are actively targeting the sector. Now is the time to make sure your organisation has the right systems in place to stay secure.

Among the most common threats Australian organisations face is Business Email Compromise (BEC) fraud. According to the Australian Cyber Security Centre (ACSC), there were 4,255 reported instances of BEC fraud in the 2019-2020 financial year, with losses exceeding $142 million. That figure is steadily rising year-on-year.

compromise the email accounts of an organisation’s CEO or CFO. Fake emails are then sent to the accounts team, instructing them to wire funds to the fraudster’s bank account.

If all that weren’t worrying enough, criminals have even been known to manipulate supplier banking records by hacking into ABA files or ERP systems.

Once again, the accounts payable team ends up transferring the payments directly to the fraudster.

Once your accounts team processes an EFT payment, there’s no retrieving the funds.

Relying on manual verification procedures, such as calling back suppliers before paying, is both timeconsuming and prone to error. For any organisation that is processing hundreds, if not thousands, of invoices each year, having your accounts team constantly calling suppliers to verify their details over the phone is hardly the most productive use of their precious time. And with criminals also known to manipulate supplier contact details, there’s no guarantee your accounts staff are even calling the legitimate supplier.

match account names with account numbers. Which makes it hard for people to spot whether payments are going to the right bank account.

Sitting over your banking platform, eftsure gives your accounts team realtime intelligence via ‘green-thumb’ or ‘red-thumb’ signals. These indicate whether the banking details you are using to process an EFT payment match the details used by other companies to pay the same supplier.

Recently, eftsure helped one of Australia’s largest diversified food and dairy companies avoid a $200,000 fraud attempt. Cyber criminals had breached a supplier’s email system and manipulated an invoice, changing both the banking information and the office contact details. Knowing that the supplier’s staff were all working remotely due to the pandemic, the fraudsters gambled that conducting call-back verifications would be difficult, if not impossible. However, what they didn’t gamble on was eftsure.

With eftsure integrated into their systems, the food and dairy company was alerted to the fact that the banking details in the invoice couldn’t be positively verified against our unique database.

This critical red-flag ensured that the payment was put on hold pending further investigations, which revealed the fraudulent activity.

Similar scams see fraudsters

eftsure has pioneered a unique fraudtech solution to address the challenge of EFT payment security. By aggregating banking and other corporate data from nearly 2 million Australian organisations, eftsure has built the nation’s largest independently verified database. Each time your accounts team processes an EFT payment, the banking details are cross matched against this database.

This process solves the fundamental security flaw where the banks don’t

What’s the most common method to get defrauded?

Do banks protect my business against payment fraud?

Why do you need eftsure to protect payments?

The ‘most-popular’ method is business email compromise (BEC). It’s an easy way to impersonate someone in a digital world so cyber fraudsters can pretend to be supplier, customer or partner to your business.

The Australian Banking system has a flaw: it cannot match Account Numbers to names – so all fraudster have to do is switch bank details, but keep the entity name on the invoice.

Making it hard to detect fraudulent invoices.

Payment controls have not kept up with a digital world – even in some Top 50 ASX companies, you’ll find they check vendors/ supplier with people checking people – that will fail at high volume and over time.

Typically, in BEC fraud, cyber criminals hack into your suppliers’ email systems.

When a supplier sends you an invoice, the criminals manipulate the banking details in the email. Without knowing it, your accounts payable team processes an EFT payment to the fraudster’s bank account.

Visit eftsure.com.au today to learn how we can also help your organisation avoid costly EFT payments fraud.

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

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INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

Understanding your risk to create tailored solutions

Gow-Gates Insurance Brokers At Gow-Gates we are a long serving risk advisor for Australia’s Steel industry. Our experience and competitve pricing has earned us the unwavering reputation for being a leading broker in this sector.

We know the Steel industry has a unique operating environment and risk profile.

Our designated service team can provide peace of mind through developing and implementing tailored insurance and risk programs and provide the support you need to protect your workers and reduce the complexities associated with Work Health and Safety.

1300 165 116 | gowgates.com.au | info@gowgates.com.au Gow-Gates Insurance Brokers Pty Ltd | ABN 12 000 837 785 | AFSL 245432

IT IS CRUCIAL TO ASSESS IF YOUR PERSONAL AND BUSINESS ASSETS HAVE HAD A COMPREHENSIVE REVIEW OF THEIR INSURANCE COVER. AS SEEN IN RECENT TIMES, AUSTRALIA HAS EXPERIENCED EXTREME WEATHER CATASTROPHES SUCH AS DEVASTATING BUSHFIRES AND FLOODS. THESE EVENTS HAVE HAD MAJOR IMPACTS ON PEOPLE’S PROPERTIES AND LIVELIHOOD. In some cases, the road to recovery after a natural disaster is not as direct as it could be due to personal and business assets being underinsured.

Many individuals and businesses can be considerably affected due to underinsuring and underestimating the potential impact of their risks. Such impacts can come at a cost of security for the future.

WHAT IS UNDERINSURANCE?

Underinsurance is when you do not have adequate insurance to cover the cost of loss, damage, business disruption or legal liabilities. This can unfortunately lead to the increased risk of a business having to close if something goes wrong.

WHAT ARE THE RISKS ASSOCIATED WITH UNDERINSURANCE?

There are many threats that can endanger individuals and businesses who don’t have the right insurance coverage, these include: • Financial impact: It is very difficult for you to financially recover from unexpected events.

• Legal action: Clients, suppliers and employees can take action against your business, and lawsuits are financially draining without the right insurance.

• Damage to your reputation: Your business may not have the right cover to assist in the payout of customer/client complaints. With the right coverage individuals and businesses can avoid negative public perceptions.

• Loss of business: Catastrophic

•

•

events can damage equipment, infrastructure and property, directly affecting your business productivity and ultimately profit without appropriate cover.

Non-compliance: Law requires you to have insurance coverage. If your business doesn’t have insurance in place you could be at risk of penalties and fines.

Delays and disputes: Delays arising from insurance claims can inhibit the recovery of your business.

It is common to misjudge the reinstatement or replacement costs of business or personal assets, after a destructive event. If the sum insured doesn’t reflect an up to date reinstatement or replacement cost, owners will consequently be underinsured and face significant expenses when needing to make a claim.

WHAT DIFFERENCE DOES INSURANCE MAKE?

Heatwaves, bushfires, and severe storms can have a major impact on your business and personal assets.

Insurance plays a critical role in promoting recovery and providing incentives for investments in hazard mitigation. The role of insurance in the recovery from natural disasters can be seen in three ways: 1. Encouraging mitigation to reduce losses of future weather events 2. Providing financial protection for property owners in the event of loss 3. Reducing financial uncertainty in the event of a disaster, allowing for

more efficient use of capital by individuals and businesses.

HOW CAN GOW-GATES HELP?

At Gow-Gates we do the hard work to protect you and your business with the level of insurance that is right for you, to help you continue to operate smoothly, even if the unexpected happens.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

WHAT IS THE REAL COST TO BEING UNDERINSURED?

We review your insurance strategy, adapt your cover as your business and personal needs change to give you peace of mind that you are properly insured. Our team of expert professionals can tailor a competitively priced policy to protect against the major risks your business faces.

If you are uncertain about your current insurance policy or have questions about your cover, please don’t hesitate to contact us.

Joe Zammit (Director - Head of Corporate, Health, Sport) E: jzammit@gowgates.com.au P: 1300 165 116 This advice has been prepared without taking into account your objectives, financial situation or needs. You must therefore assess whether it is appropriate in light of your individual circumstances, to act on this advice. If this advice contains information about a financial product, you should ensure you obtain a Product Disclosure Statement in respect of that product prior to making a decision to acquire the product. .

This article is part of a paid advertising package

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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.

INFRABUILD APPOINTS VIK BANSAL AS CEO AND EXECUTIVE DIRECTOR

BLUESCOPE COMMITS TO WORKPLACE GENDER EQUALITY

Australia’s largest integrated manufacturer and supplier of steel long products, InfraBuild, recently announced the appointment of Vik Bansal as its new CEO.

BlueScope is proud to be a signatory to 40:40 Vision, an initiative led by members of Australia’s investor and business community to achieve gender balance in executive leadership across all ASX200 companies by 2030.

Bansal joins InfraBuild from Cleanaway, Australia’s leading waste management company, where as CEO he oversaw its significant growth during his approximately six-year tenure.

He has held a range of executive roles across Australia, Asia, and the United States over the last 20 years. This includes three years as General Manager of the OneSteel (now InfraBuild) business responsible for steel distribution and metal processing services.

Executive Chairman, Sanjeev Gupta, said,“Vik knows our industry very well and has runs on the board as a successful chief executive of an ASX100 company, successfully creating value and driving business transformation."

"He is aligned with our plans for InfraBuild, and the board is pleased to have him joining us to build on the exceptional work of Dak Patel and the team," said Gupta.

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40:40 stands for 40% women, 40% men and 20% any gender. 40:40 Vision seeks to achieve this goal by encouraging companies to set and publicly report on progress against targets for the composition of their executive leadership teams.

Committing to 40:40 Vision demonstrates BlueScope's long-term commitment to workplace gender equality and aligns with the company's purpose: to strengthen our communities for the future. According to BlueScope, a diverse workforce and inclusive culture are competitive advantages that lead to sustained business success and make BlueScope a better place to work.

BluScope has already reached the 40:40 Vision target of 40% women on both its Executive Leadership Team and Board of Directors, but recognises that there is work to do to reach 40:40 in business leadership teams and at other levels.

Bisalloy Steels recently announced the receipt of a significant order from Rheinmetall for highly specialised Australian Made BISALLOY® Armour steel. The steel, developed by Bisalloy to meet the protection levels required for the BOXER 8×8 Combat Reconnaissance Vehicles (CRV) and tested and certified by the German Government and the BAAINBw (German Government testing authority) in collaboration with Rheinmetall Defence Australia, will be used for Rheinmetall’s Australian-built BOXER 8×8 CRV in the LAND400 Phase 2 program.

Bisalloy and Rheinmetall began collaborating in 2017, strengthening their relationship through a teaming agreement that enabled the two companies to work together on R&D, reciprocal technical visits, various plant and production tours, technical discussions, and information sharing.

Rheinmetall Defence Australia Managing Director, Gary Stewart, said, “I am impressed by Bisalloy Steels’ people, capability and their outstanding product.

I am grateful for Bisalloy’s hard work to achieve this significant outcome.”

Glenn Cooper (CEO and Managing Director, Bisalloy) said, “This is an important milestone for Bisalloy as

a supplier to Rheinmetall, and as a supplier to the LAND400 Phase 2 program. Rheinmetall is an important and strategic customer for Bisalloy, and the engagement between our two companies over the past years is a testament to the commitment our company has to these important defence programs and demonstrates our commitment to building sovereign capabilities within Australia."

"Congratulations to the Bisalloy team who have worked for so long behind the scenes to get to this point, and we look forward to working with Rheinmetall for many years to come.”

Operating for 40 years, Bisalloy is Australia’s only manufacturer of high strength and high hardness quenched and tempered steel plate used for armour, structural, protection and wear-

resistant steel applications. Bisalloy has a long history of collaboration with the Australian Defence Force. Originally developed in the 1980s for use in the hulls of the Royal Australian Navy’s Frigates, BISALLOY® Armour steel has since been used in many domestic defence projects, including the Collins Class Submarines, Bushmaster Infantry Mobility Vehicles and the Hawkei Protected Mobility Vehicles (Light).

INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

BISALLOY RECEIVES FIRST ARMOUR STEEL ORDER FROM RHEINMETALL FOR LAND400 PHASE 2

BISALLOY® Armour steel has a global reputation as a high-quality material and has become the product of choice for defence applications in international markets, being specified for projects in North America, Thailand, Turkey, UAE, South Korea, Israel, Slovenia, Indonesia, and many more.

BISALLOY INTRODUCES BISALLOY BUILT Australia’s only manufacturer of quenched and tempered steel plate, Bisalloy recently launched their Bisalloy Built customer initiative.

Showcasing Bisalloy’s commitment to clients that depend on high quality performance steel, businesses will bear the stamp of quality on their respective products, including truck bodies and earthmoving attachments, indicating they are made of genuine BISALLOY® steel.

The BISALLOY® range is renowned for its hardness, impact and abrasion resistance combined with improved wear life designed to perform in the world’s toughest environments. The Bisalloy Built badge is a representation of these attributes providing an unrivalled choice for customers considering their next quenched and tempered steel plate purchase.

Andrew Egan (National Sales and Marketing Manager, Bisalloy), highlighted what the Bisalloy Built initiative means to its industry leading customer and dealer network.“When you choose businesses and products displaying this badge, you can be assured you’re getting quality Australian made BISALLOY® high performance steel. This badge serves as a quality guarantee the steel is manufactured locally, meets strict Australian standards, and delivers cost and weight savings without compromising strength,” said Egan.

“Our innovative steel range is backed by over 40 years of world-class technical expertise and product development experience. When you see the badge, you will know the product contains BISALLOY® steel. There is a sense of pride among our customers in that they understand what it takes to achieve this level of product quality.”

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LYSAGHT AUSTRALIA CELEBRATES 100 YEARS OF LOCAL MANUFACTURING LEADING AUSTRALIAN STEEL BUILDING PRODUCTS COMPANY, LYSAGHT, IS CELEBRATING 100 YEARS OF LOCAL MANUFACTURING— AN IMPRESSIVE ACHIEVEMENT THAT GOES AGAINST THE TREND OF OFFSHORING, WHICH HAS PREVAILED IN AUSTRALIA DURING RECENT DECADES. WHILE THE CURRENT LYSAGHT RANGE COVERS ROOFING AND WALLING, ARCHITECTURAL CLADDING, GUTTERING, FASCIA AND RAINWATER GOODS, FENCING AND SCREENING, STEEL SECTIONS, FORMWORK AND FRAMING, PATIOS, CARPORTS AND STRUCTURES, IT’S UNDOUBTEDLY CORRUGATED IRON THAT IT’S LONG BEEN KNOWN FOR. THIS STEEL BUILDING PRODUCT HAS BEEN USED ON EVERYTHING FROM THE ROOFS AND BULL-NOSE VERANDAS OF HERITAGE HOMES, THROUGH TO SHEARING SHEDS AND OUTBACK DUNNIES, AND MORE RECENTLY IN EN VOGUE ARCHITECTURAL BUILDINGS.

REVOLUTIONARY BEGINNINGS

For any lover of history, the 1850s was a pivotal and powerful decade.

From a manufacturing perspective, the era marked the end of the industrial revolution, where production methods changed from manmade to mechanised, and mass production.

With this insurgency came innovation and visionaries. One of these was a 25-year-old ardent Irishman by the name of John Lysaght. As demands for factory and warehousing needs grew in England, John developed his expertise in galvanizing and corrugating iron sheeting in Bristol during 1857. Durable, versatile, lustrous and resistant to rust, the product was trademarked as ORB. At the same time, Australian immigration boomed due to the gold rush era.

The influx of people hoping to find their luck as prospectors created the beginnings of modern cities and a need for construction – both residential and commercial. That’s why, after satisfying demand in the United Kingdom which was being fuelled by the Industrial Revolution, Lysaght turned his attention

to export markets, namely Australia.

John saw huge opportunities arising from the gold rush of the late 1800s, and he began exporting to the colony soon afterwards.

Initially ORB was sold across Australia through independent merchants until John established his own distribution company, the Victorian Galvanised Iron and Wire Company. By 1913, some 80,000 tonnes of ORB had found its way across the Equator to our shores from Bristol, England.

NAVIGATING THE WORLD WARS

The next challenge the company encountered was World War I, which saw compulsory redirection of production capacity to assist the war effort. This devastated local supply and highlighted the need for a local production presence in Australia.

Within three months of the war commencing, the company (now under the direction of John Lysaght’s nephew Herbert Royse Lysaght in Australia) was making arrangements to purchase 24 acres of land in Newcastle, New South

INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

Wales, adjacent to a site already owned

by Broken Hill Pty Co (BHP).

By the following year in 1917, John Lysaght (Australia) Pty Ltd was formed with the intent of establishing a manufacturing site in Australia.

Approximately four years later, in April 1921, the new Lysaght company commenced manufacturing at its purpose-built site in Newcastle. From that date, Lysaght has remained intrinsically Australian-made.

EXPANSION AND GROWTH THROUGHOUT THE 20TH CENTURY In 1961, Lysaght became a public company, issuing three million shares (20%) to the Australian public. Since then, the company has experienced exponential growth.

Some of this growth was made possible through acquisitions, such as those of the steel building products division of Brownbuilt, Melbourne-based structural steel manufacturer Metalform, roof installation business Kiteleys, and Tasmanian steel distributor The Roofing Centre. All of these acquisitions expanded Lysaght's footprint, capacity and skills base.

However, much of Lysaght's success can be attributed to continual improvement and refinement in product development. All of Lysaght's products meet the most stringent of industry standards and are designed for optimum performance and durability.

According to Blake Tasker (Marketing Manager, BlueScope Building Components), "Product testing, compliance and meeting Australian Standards is at the heart of Lysaght's business model. Thoroughness and performance are integral to everything we do."

KLIP-LOK®

The first such example of innovative product development was the launch of KLIP-LOK® in the 1970s. KLIP-LOK® enabled commercial building designers to develop roof systems that offered larger water carrying capacity and concealed fixing to help the weather resistance of these larger structures.

It also allowed roof structures with gentler slopes, while providing excellent water carrying capacity and fewer joins because of its longer length.

The evolution continued with KLIP-LOK® 700 in the 1990s. This wider profile increased manufacturing efficiencies by using the same steel feed width as popular, high volume profiles such as CUSTOM ORB®.

Then came the current profile, KLIP-LOK 700 HI-STRENGTH®, which improved sheet strength and water capacity while providing longer sheet lengths. The introduction of a new clipping system, LOK-KLIP®, also solved problems caused by sheet lapping.

A major leap in roof design and integrity was then achieved by rolling the KLIP-LOK® profile on site and ‘straightto-roof’, meaning roof sheet lengths of up to 100m became possible thereby eliminating joins.

Above (Top) Corrugating Galvanised Iron at Lysaght's original Newcastle works.

Above (Bottom) LYSAGHT CUSTOM ORB® roofing.

Left L-House featuring LYSAGHT LONGLINE 305® cladding.

BONDEK®

In the structural field, Lysaght also enabled building efficiencies and cost savings with new formwork solutions.

BONDEK® was introduced in the 1960s as a permanent formwork system to replace timber. It provided savings in reinforcement requirements as the BONDEK® system forms part of the steel reinforcement and it also assisted fire ratings.

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In the late 1980s, a quantum leap was achieved with the introduction of BONDEK® II. The new design dramatically improved the interaction between steel and concrete, resulting in further reductions in steel reinforcing requirements and further improved fire ratings. The latest advancement to the range is BONDEK PLUS®, which provides greater spanning capabilities.

All Lysaght product breakthroughs and enhancements are made possible through the work of their Product Innovation Group. This team of dedicated engineers is responsible for bringing ideas to life, and ensuring all products meet Australian standards and equally importantly, the lofty standards of Lysaght's parent company BlueScope.

Using its NATA-accredited testing facility, the Product Innovation Group is able to undertake critical bespoke product development tasks including prototyping, product development, building system design, global and Australian standard compliance testing, cyclonic testing conditions, design software development and installation and usage guides.

TODAY'S STRENGTH

Lysaght General Manager, Peta Renkin, said the company was extremely proud to reach the important milestone.

“For Lysaght to have reached 100 years of manufacturing in Australia is an extremely satisfying achievement for our company,” Renkin said.

“It’s proof that there’s viability in local production – Lysaght has worked hard to develop new product lines, to innovate and to make manufacturing processes as efficient as possible while still providing premium quality products and offering superior support."

“Of course, this achievement would not have been possible without the dedication of Lysaght employees and the ongoing support of our business partners and clients, so to all of you we say ‘thank-you’ and we look forward to the future,” said Renkin.

Service Excellence Service excellence is one of the values on which Lysaght was founded, and remains one of the company's key ingredients for success.

“

It’s proof that there’s viability in local production – Lysaght has worked hard to develop new product lines, to innovate and to make manufacturing processes as efficient as possible while still providing premium quality products and offering superior support."

"An emphasis on service excellence started with John Lysaght back in the early 1800s—at the time, the concept was quite a new thing in business," explained Tasker.

"This focus on customer service excellence has carried all the way through to today. Our customer service

Below LYSAGHT LONGLINE 305® cladding.

Penrith Anglican College Performing Arts Centre is a Major Award winner in the annual Lysaght Inspirations Design Awards, the program that celebrates outstanding Australian architectural work incorporating LYSAGHT® steel building products.

The Performing Arts Centre entry constituted the first stage of a broader transformation of Penrith Anglican College and featured one of Lysaght's most popular products, LYSAGHT KLIP-LOK 700 HI-STRENGTH® cladding across its expansive roof area.

LYSAGHT KLIP-LOK® roofing has long been a design favourite for prestige architectural projects. With a substantial, bold rib rising from wide, fluted pans, this profile creates a dynamic linear visual and uses a concealed fixing system for uninterrupted lines and superb watertightness.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

PENRITH ANGLICAN COLLEGE PERFORMING ARTS CENTRE

The design of the Performing Arts Centre cleverly exploits the product’s geometric possibilities allowing the roof to become a key design feature of a building that points to the creative endeavours that take place within, just as it asserts the school’s broader learning possibilities.

and sales teams deliver the best service possible, in what can be quite a complicated manufacturing process and supply chain."

which helps us to create regional employment opportunities—not just for direct employees but throughout the downstream supply chain as well."

A National Network "In terms of manufacturing capability, Lysaght has a true national network.

Regardless of where you might be located in Australia, you can get hold of Lysaght products. Lysaght has grown as Australia has grown—both in terms of our manufacturing footprint and our product offering. So, whether you need products delivered in regional, rural, outback or metro locations, Lysaght can help," said Tasker.

Throughout Lysaght's strong history, one thing has remained a constant – and that’s Lysaght’s commitment to putting customers, shareholders and communities at the centre of their operations.

A strong local manufacturing industry is clearly important to Lysaght. "From a transactional perspective, our product needs to be manufactured and supplied on a short lead time. Industry demands our product quickly, so we need to make locally," said Tasker.

"But, more than that, a strong local manufacturing industry supports local jobs. We have operations in regional centres all around Australia,

So as part of their ongoing commitment then, now, and into the future, Lysaght aims to help communities to rebuild and recover when times get tough through the Build Up community support fund. Community groups impacted by natural disaster, or unforeseen events or circumstances, are encouraged to apply to receive assistance through the supply of LYSAGHT® steel building products.

GAME CHANGING INNOVATION

Today, Lysaght’s parent company, BlueScope, supplies it with Australianmade steel, with manufacturing (customising, forming and profiling) of the Lysaght products overseen by skilled production technicians at over 40 Lysaght branches nation-wide.

Along with products like CUSTOM ORB® – whose heritage can be traced back to ORB – Lysaght has continued to innovate and lead the industry, introducing many game-changing products to market including KLIPLOK® and BONDEK®.

If John Lysaght was here today to witness the achievements grown from his ingenuity and foresight, we're certain he would be proudly sipping tea under a corrugated bull-nose roof, listening to the sweet drumming of the rain above.

CLICK HERE TO LEARN MORE AND WATCH A VIDEO ABOUT LYSAGHT'S 100 YEARS OF MANUFACTURING IN AUSTRALIA >>>

23

CHESS ENGINEERING CELEBRATES 50 YEARS IN BUSINESS ESTABLISHED IN THE LATE 1960s, CHESS ENGINEERING WAS ORIGINALLY BASED IN SYDNEY'S INNER-CITY SUBURB OF ALEXANDRIA, SPECIALISING IN FABRICATION, MACHINING AND FITTING. OVER THE YEARS, CHESS ENGINEERING HAS GROWN, MOVING ITS SYDNEY OPERATIONS TO THEIR CURRENT PADSTOW LOCATION IN THE EARLY 1970s and OPENING FACILITIES IN PERTH IN 2014. PURCHASED BY STEVE FACER IN 2002, CHESS ENGINEERING BOASTS AN IMPRESSIVE ROSTER OF CLIENTS AND PROJECT EXPERIENCE. THE COMPANY RECENTLY CELEBRATED 50 YEARS IN BUSINESS.

Chess offers leading engineering solutions in Sydney and Perth. Their 8,500m2 Sydney facility caters to a broad spectrum of needs, while their largest cranes and machines are located at their 6,000m2 facility in Perth.

Their mechanical engineers specialise in fabrication, machining and fitting.

In terms of fabrication, Chess has experience in everything from heavy boiler shops through to sheet metal, with materials including mild steel, stainless steel, exotic steels and other materials.

One of their highly specialised fields is flame proofing equipment and parts.

According to Steve Facer (CEO, Chess Engineering), "When I first bought the business, its operations were dominated by food manufacturing. We had a permanent site crew at Kellogg's, undertaking equipment design, repair and maintenance works. We still have a site crew at Kellogg's today, but the

company has grown to encompass more than just food processing and general engineering."

"The company's expertise spans various industry sectors, from structural steel to specific parts for rail, mining, food and defence. In Sydney, our biggest market is infrastructure, followed by rail rolling stock.

We’re an OEM on some of those parts too.

We also have a dedicated stainless steel shop and undertake machining, blasting, fitting and painting in Sydney."

"In Perth, we concentrate on machining and fabrication, particularly for the mining industry. Both our Sydney and Perth facilities are certified to CC3 under AS/NZS 5131 by Steelwork Compliance Australia."

"We've also just started moving into the defence industry. We are close to securing certification to DIN 2303 Welding and allied processes - Quality

requirements for production and maintenance companies for military products. We've also applied for some grants and invested in capex," said Facer.

PREVIOUS PROJECT SUCCESS

Chess boasts an impressive roster of previous project success.

"We've worked on some of Australia's most notable projects, including the Eastern Distributor, the M5 and the Sydney Harbour Bridge," said Facer.

"One of the most notable projects we've worked on was the replacement of Sydney’s historic Meccano Set intersection structure. As proud members of the Sydney community, we are happy to have worked on such an iconic and familiar roadside structure. Trusted by Transport for NSW to complete work on time and within budget, we gave the Meccano Set a new lease on life that motorists will enjoy for decades to come.”

Gantry Toll Structure on Sydney Harbour Bridge.

Land Bridge for WestConnex 3B Rozelle Interchange Project.

Chess Engineering's Perth facilities.

The Western Australian arm of Chess Engineering recently delivered 39 conveyor drive bases for the BHP South Flank Project.

This was a demanding project, with a combination of heavy fabrication and machining required to very exact specifications. A rigorous inspection was followed by a robust test plan and fully compliant product meeting. The client had very stringent quality benchmarks, including a fully plumbed fluid overflow system to meet environmental standards.

The BHP South Flank Project is an example of demanding and highly specialised mining engineering. The Chess Engineering team is always ready to rise to the challenge, with the project completed beyond expectations on time and within budget.

MECCANO SET

Originally installed at Lansdowne in June 1962, motorists have long used the Meccano Set as a point of reference when travelling through Sydney. After years of neglect, the 25-tonne structure was replaced and restored in 2019 to cement the legacy of what is a unique and functional traffic light system.

Chess Engineering replaced the entire structure over a four-week period to minimise the impact on the local area.

With around 88,000 vehicles using the intersection each weekday, there were obvious complexities to be solved. The new parts for the updated Meccano Set structure were fabricated off-site at our world-class facilities and then transported to the site. The individual parts were installed in place, with the existing footings strengthened, and traffic lights and signs attached. Each side of the structure was replaced one at a time before being tested to ensure integrity and alignment.

"At the moment, we're working on the steelworks for Barangaroo Station on behalf of Transport for NSW, as well as two projects that will form a substantial portion of the walkways along the new harbour tunnel from Chatswood to Marrickville."

in six different countries, working in the agriculture sector.

"One of our current projects that I'm most excited about is a series of agricultural robots, which are mechanical weeders that drive up and down crop rows and, when finished, drive themselves back to the shed.

We're working for Agerris—a field robotics start-up based on technology created by the University of Sydney's Australian Centre for Field Robotics.

Chess is undertaking the mechanical manufacturing and the electrical fit out," said Facer.

"We have three rules at Chess Engineering. Number one: deliver superior customer service at all times. Number two: no idiots—this applies equally to staff, suppliers and clients. Number three: innovation. This is often the hardest to manage, because the day-today operations and jobs always get in the way. Also, we take safety seriously. At Chess, safety is not just a goal—it's a value," said Facer.

This foray into the world of agriculture is not a first for Facer. He has spent a considerable portion of his career living

THE WINNING CHESS FORMULA For Facer, there are three key elements to the Chess formula for success.

BARANGAROO STATION

Barangaroo Station is a new underground metro station being built to serve the inner-city Barangaroo precinct in Sydney.

With an estimated investment of A$217 million, the project is expected to be completed in 2023. The new station is part of the Sydney Metro City and Southwest project which includes five other new metro stations and 66km of railway tracks, making it the largest public transport project in Australia.

INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

BHP SOUTH FLANK PROJECT

Situated 10m above the rail track level, Barangaroo Station's concourse will be split into three main areas, north, south, and central. The crossover cavern at the new underground metro station in Sydney will facilitate the crossing of trains from one track to another.

Chess Engineering is providing the structural steel for the over track exhaust and lift structure.

A FUTURE POISED FOR SUCCESS

The future looks bright for Chess Engineering. "We're on track to nearly double our turnover this year compared to last," said Facer. "When I bought the business, our turnover was around $7.5 million, and it's a lot more than that now. Infrastructure is driving our Sydney operations strongly, while mining drives our Perth business."

"With this strong base, we will spread our wings and get into defence. In the shorter term, we're also trying to improve our equipment to elevate efficiency and quality and keep driving our conscientiousness as a competitive edge. Our future is one focused on continuous growth," said Facer.

CLICK HERE TO LEARN MORE ABOUT THE CAPABILITIES AND PROJECTS OF CHESS ENGINEERING >>>

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PACIFIC INDUSTRIAL COMPANY: A WESTERN AUSTRALIAN SUCCESS STORY PACIFIC INDUSTRIAL COMPANY (PIC) IS A WONDERFUL WESTERN AUSTRALIAN SUCCESS STORY OF VISION, HARD WORK AND COURAGE. FOUNDED IN 1969 BY ERASMO MOSOLE AND HIS PARTNERS, MUCH OF THE COMPANY’S GROWTH OVER THE LAST 50 YEARS HAS BEEN IN DIRECT RESPONSE TO DEVELOPMENTS IN THE OVERALL DOMESTIC STATE ECONOMY. FROM EARLY DAYS AS A PARTNER OF THOSE SERVICING THE WHEATBELT’S PRIMARY PRODUCERS, THROUGH YEARS OF RAPID EXPANSION IN THE RESOURCES AND ENERGY SECTORS TO THE LARGE SCALE COMMERCIAL CONSTRUCTION PROJECTS OF CURRENT TIMES, PIC HAS POSITIONED ITSELF AS A LEADING STEEL FABRICATION, MAINTENANCE, CONSTRUCTION AND MODULARISATION ORGANISATION.

PIC provides full design, engineering, procurement, fabrication, installation and commissioning to the commercial, infrastructure and resources sectors Australia wide.

Located in the Kwinana heavy industrial area, PIC’s workshops are equipped for all types of fabrication, construction and modularisation services. Their main Naval Base facility is situated just 5km from the Australian Marine Complex (AMC) Common User Facility and boasts over 43,000m2 of undercover fabrication facilities, as well as 120,000m2 of laydown area.

Their facilities are equipped with over 45 overhead cranes with capacities up to 100 tonnes, and a vast array of plant that ranges from a robotic profiling line and a band sawing line, through to plate punching and plasma pipe profiling lines.

OFFSITE MODULARISATION

With increasing reliance on modularised assembly, PIC offers extensive offsite modularisation capabilities. PIC’s extensive Naval Base workshops are key to the delivery of these services.

It is here that steelworks are assembled

into shippable packages to be installed economically and effectively at site.

Large modules of up to 300 tonnes are fabricated in controlled environments, where all trades have access to the full range of specialised equipment together with extensive overhead and mobile crane support.

The workshop location benefits from the existence of the high wide load corridor along Patterson Road to the AMC, meaning that assemblies can be freighted from the workshops to Jervoise Bay, and from there loaded onto ships for transfer to the North West or beyond.

According to Marco Mosole (Managing Director, PIC), modularisation affords clients a range of benefits.

"Modularisation offers higher productivity and an improved quality of work executed in a controlled and fully equipped fabrication yard. It all but eliminates inclement weather issues on-site, and it can reduce overall project delivery schedule through parallel schedule management."

"Modularisation helps PIC undertake complex multi-disciplinary engineering and construction services for resource,

energy and infrastructure sectors, comprising structural, mechanical, piping, electrical and instrumentation," said Mosole.

VALUES BASED DRIVERS

Mosole explains that PIC's values have been essential to the company's ongoing success over the last 50 years.

"At PIC, our values are integral to the organisation and act as internal drivers.

They shape how we conduct our business on a daily basis and ultimately drive our success," said Mosole.

"PIC's values include quality, safety, integrity, collaboration and innovation.

We are dedicated to continuous improvement through the provision of efficient, cost-effective services that ensure client satisfaction, driven by our collaborative approach to business."

"Through effective engagement with our people and industry, we better understand the challenges and obstacles they face. Our team works collaboratively in order to develop and implement the most effective solutions and improvements. We constantly look for improvement opportunities in order to

PROJECT SUCCESS

With such extensive capabilities, it comes as little surprise that PIC has been involved in some of the state's most high profile projects.

PIC won the 2020 Australian Steel Institute's Western Australia Steel Excellence Award in the category of Large Building Projects for their involvement in Perth’s New Museum Boola Bardip. PIC’s scope of work included the supply, fabrication and installation of more than 1,600 tonnes of structural steel, consisting of over 10,000 individual elements. All works were delivered in Perth's busy central business district, under strict heritage controls.

project, including 2,700 tonnes of welded beams, and primary members measuring 3.2m high x 42m long x 1.m wide, and weighing 80 tonnes.

Last, but by no means least, PIC was awarded multiple packages of work for the Tianqi Lithium Hydroxide Plant in Kwinana. This project included

fabrication, rubber lining and painting of 24 carbon steel tanks; fabrication and surface treatment of more than 4,200 tonnes of steelwork; fabrication and full off site modularisation, including piping, electrical cable trays and walkways of 50 pipe racks; and on-site structural, mechanical and piping installation.

PIC was recently awarded multiple modular steelwork packages for Rio Tinto's Robe Valley (Mesa J) and GudaiDarri (Koodaideri) projects, consisting of over 2,000 tonnes of supply, fabrication and assembly works.

PIC won the contract for the design, supply, fabrication and delivery of seven steel welded site tanks for ACCIONA Kwinana Waste to Energy Plant. The company also fabricated and assembled 16 road and rail bridge modules for Fortescue Metals Group's Eliwana Mine

INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

enhance our performance," said Mosole.

CLICK HERE TO LEARN MORE ABOUT PACIFIC INDUSTRIAL COMPANY (PIC) AND THEIR SERVICES AND CAPABILITIES >>>

FORRESTFIELD-AIRPORT LINK The $1.86 billion Forrestfield-Airport Link is jointly funded by the Australian and Western Australian governments and will deliver a new rail service to the eastern suburbs of Perth – with three new stations at Redcliffe, Airport Central and High Wycombe. The design, construct and maintenance contract was awarded to Salini Impregilo – NRW Joint Venture.

PIC was awarded the structural steelworks contract for the project in 2018. Works have progressed along the route of the tunnel from its start at Forrestfield Station to breaking the surface again at Bayswater. Along the tunnel route PIC has fabricated and installed three major stations (High Wycombe Station, Airport Central Station and Redcliffe Station), three emergency egress shafts (Abernethy, Airport West and Wright Crescent) and two Dive Portals (High Wycombe and Bayswater).

PIC's project engagement continues with the recent commencement of on-site electrical installation works, including cable installation, terminations, testing and commissioning, which is scheduled for completion later this year.

27

AUSTRALIAN PIPE & TUBE: THE INDEPENDENT CHOICE A PRIVATELY OWNED AND OPERATED COMPANY, AUSTRALIAN PIPE & TUBE SPECIALISES IN THE MANUFACTURE OF WORLD-CLASS TUBULAR STEEL. THEIR PRODUCTS ARE USED THROUGHOUT A RANGE OF INDUSTRIES, FROM MANUFACTURING, FABRICATION AND CONSTRUCTION, THROUGH TO AGRICULTURE AND FARMING. THIS YEAR MARKS THEIR ELEVENTH YEAR OF OPERATION—NO MEAN FEAT FOR A TRULY INDEPENDENT AND COMPETITIVE MANUFACTURER IN THE AUSTRALIAN MARKET.

Australian Pipe & Tube (APT) was established in 2010 by David Brandi, who is the company's Chairman.

According to Mike Doubleday (General Manger, APT), "Eleven years ago, when APT was established, it was a completely new start up. The business was set up on a greenfield site in Ravenhall in Melbourne's west, with a purpose-built 6,500m2 shed. The shed was fitted with brand new equipment, including an OTTO tube mill from Italy, which is the newest and most advanced technology in tubular manufacturing in Australia."

"APT grew out of the need expressed by the local market—there was a clear need for a truly independent, competitive and dynamic source of alternate supply for tubular steel sections in Australia, and specifically in Victoria. Our two competitors are based in Queensland and New South Wales," said Doubleday.

“

The more successful we are as a local manufacturer, the bigger we become.

The bigger we become, the more jobs we create for the local community and Victoria as a whole."

Today, APT supplies its products—in bulk—directly to the distribution market.

"Being a completely independent manufacturer within the Australian steel industry is quite unusual. Our competitors are all vertically integrated, with their own mills and distribution centres," said Doubleday.

"We support Australian made as much as we can. As a country, we need a level of self sufficiency. With so many businesses closing and going under, you can't rule your own destiny if you can't manufacture your own products for industries like downstream manufacturing, infrastructure and defence."

"After all, the more successful we are as a local manufacturer, the bigger we become. The bigger we become, the more jobs we create for the local community and Victoria as a whole."

John Egan (CEO, APT) emphasised the importance of local manufacturing for customers. "The flexibility for fabricators and manufacturers using our product comes from the fact that they can access our products with potentially short lead times, or order project-specific sizes and grades. Without a local manufacturer, our customers would be forced into a standard product offering from overseas.

We offer much more flexibility."

QUALITY AND CUSTOMER CARE

APT has built its success over the last 11 years on two key pillars: customer service and the provision of superior quality products.

"It’s hard to say what comes first: the customer or product quality. We produce everything to stringent Australian Standards and have an experienced quality manger on-site. All our testing is performed at an external lab, and

Australian Pipe & Tube hollow structural sections are manufactured in full compliance with AS 1163 Structural steel hollow sections, which is one of the world’s most advanced Standards. Used in industries ranging from mining through to agricultural, APT Painted and APT Galv products are backed by local technical support.

Painted Products

Galv Products

APT Painted is the newest tubular product in the steel industry, providing strength and ductility that meets and exceeds AS/NZS1163:2016.

APT Galv products build on the extensive groundwork of the Painted range, taking quality to new heights with improved corrosion resistance. Utilising a pre-galvanised source material eliminates any inconsistencies in applied coating and offers a superior level of protection against the natural elements.

APT Painted products can be manufactured in Grades up to C450L0, while providing an industry-high elongation percentage (typically 20% to 30%). Compliance with grade C350L0 or C450L0 requirements of AS1163. L0 grades ensure suitability for use in lower temperature requirements, as well as non-brittle behaviour when subjected to dynamic loads. Compliance with minimum mass per metre requirements ensures full loading capacity Put simply, APT Painted is one of the strongest and most workable products available in the tubular market.

End-users can be confident that APT Painted is the right product, whatever its intended use.

we also have ACRS accreditation," explained Egan.

When it comes to customer care, Egan believes that APT's combination of personal service and agility is a winning formula. "We’re very agile. We can change and react to the market and customer needs very promptly.

We pride ourselves on our personable service. These days, you can take automation too far, particularly when it comes to customer service—we like to add that personal touch," said Egan.

"We have two sales representatives who visit our customers regularly. We listen to what the market wants, and ensure we continue to meet our customers' needs and expectations."

By utilising a 200g per square metre Surface Coating Mass on both surfaces of the material, APT Galv tubular products offer excellent corrosion protection against white and red rust when compared to normal hot-dip galvanizing processes.

Superior paint and powder coat adhesion gives the visual appeal and combined corrosion protection (subject to adherence to the finished paint manufacturer instructions).

APT can also supply products without a clear coat layer to meet customer specific requirements.

"Our people are our strength.

Throughout the whole business, we’ve got a lot of people with years of experience in the steel industry, and specifically in tubular manufacturing.

Whether it's our management team, our sales staff or our operators, most of our people have had some level of experience within the tubular industry," said Doubleday.

It's these people who enable APT to deliver their superior quality products and customer service.

THE WAY FORWARD

APT is committed to the advancement of the Australian steel industry. With a successful 11 years of business under their belt, APT is looking forward

INDUSTRY INSIGHTS | STEEL AUSTRALIA | WINTER 2021

AUSTRALIAN PIPE & TUBE PRODUCT RANGE

to a strong future. "We constantly strive to stay ahead of the quality curve and develop a superior way of manufacturing the best quality tubular steel products in Australia—that's the holistic commitment we make to our industry," said Doubleday.

"We're growing the business, which covers a number of different things, from looking at a bigger greenfield site for future growth and development, through to a third shift for manufacturing."

"In the current market, trying to meet demand and remain competitive and profitable—while maintaining our commitment to quality and customer service—is keeping us busy," said Doubleday.

PEOPLE POWER

With a workforce of approximately 35 people, APT runs two production shifts each day.

CLICK HERE TO LEARN MORE ABOUT AUSTRALIAN PIPE & TUBE AND THEIR PRODUCTS >>>

29

DUNSTEEL INVESTS IN KALTENBACH SYSTEM IN 1964, NOEL DUNLOP STARTED MAKING SIMPLE STEEL PRODUCTS FOR THE LOCAL FARMERS IN THE SOUTHERN HIGHLANDS OF NEW SOUTH WALES. TODAY, MORE THAN 50 YEARS LATER, DUNSTEEL REMAINS A PROUDLY FAMILY OWNED AND OPERATED BUSINESS. DUNSTEEL SPECIALISES IN COMPLEX PROJECTS FOR LEADING BUILDING FIRMS AND ARCHITECTS, AND IS AT THE FOREFRONT OF PREFABRICATED STAIRWAY DESIGN FOR LARGE MULTI-STOREY BUILDINGS. THEIR 6,000m2 WORKSHOP IN MOSS VALE BOASTS STATE OF THE ART MACHINERY, INCLUDING A NEWLY INSTALLED KALTENBACH STEEL PROCESSING SYSTEM.

Dunsteel recently invested in Kaltenbach's first fully automated blasting machine and beam line in Australia. According to Dunsteel's Director, Jonathon Dunlop, they invested in the Kaltenbach steel processing system to help improve productivity and bolster efficiency.

"The outcome we were looking for was to automate our beam production, and to have reliable layout marking done by a scoring process," said Dunlop.

"We purchased a fully automated blasting, sawing, drilling and layout marking line. The truck is unloaded directly onto the in-feed of the machine and, from that point on, there is no human intervention until the fittings are welded onto the member by one of our boilermakers."

INCREASED PRODUCTION

"As a result, we have been able to increase production by around three times, when compared to our old machinery. It has also enabled us to deploy staff into higher skilled roles.

Our ambition is to have the machine working two shifts per day—to load it

up and then leave it alone. Depending on the complexity of job, this outcome is achievable and does happen."

"The machine is basically unattended most of the time. It needs attention when tools reach their end of life, and also when a different tool needs to be used.

However, there are 12 tool changes on the machine so 90% of work is catered for automatically. Really, the only time the machine needs attention is when the bed or scrap bin become full," said Dunlop.

LAYOUT MARKING

By automating layout marking, the fabrication schedule can be improved by as much as 30%, without increasing headcount or footprint. It also improves accuracy on-site, helping to eradicate rework.

"There are two sides to our business – structural steel and architectural steel like staircases. For our structural steel, about 75% is marked. Our goal is to reach 100%," said Dunlop.

EXTRA FEATURES

"A couple of the extra features that Kaltenbach offered were the additional

X axis on the drilling line, allowing for multiple operations to be conducted at once, and a function called AFC (Automatic Feed Control) on the saw line that enables a pivoting action on the band saw," said Dunlop.

In fact, Kaltenbach claims that theirs is the fastest band saw in the world.

CUSTOMER SERVICE TO COUNT ON

"We chose to partner with Kaltenbach because we felt that their culture was a good fit with our 'family business' style of operating. Kaltenbach felt like a small, tightly managed organisation, as opposed to some of the other players in the market that are much bigger," said Dunlop.

"It hasn't been an easy road. With the pressures of COVID-19 and the inability of technicians to travel freely, there have been times when we wondered if we'd made the right decision. But one thing that never changed was the Kaltenbach team's outstanding loyalty and devotion to their product and company."

This article is part of a paid advertising package

IN AUSTRALIA'S STEEL INDUSTRY The advent of more sophisticated technology and automation is enabling the Australian steel industry to augment and improve its production processes, delivering efficiency, safety and quality enhancements throughout the supply chain.

For instance, a series of major investments, technological advancements, and research and development projects at the Whyalla Steelworks by Liberty Primary Steel has resulted in the consistent manufacture of high-quality steel products over the last 30 years. (For further details, see page 38.)

Molycop's facility in Perth is fitted out with a SAG ball forging robot, a bolt grinding robot, and a bolt forging robot. These robots have enabled Molycop to reduce team members risk exposure, improve safety, and build a better working environment. (For further details, see page 32.)

Similarly, DSI Underground started their automation journey about seven or eight years ago, focused on productivity and competitiveness, as well as safety and efficiency improvements. Their holisitic program of process improvement, incorporating automation, Industry 4.0

and lean manufacturing processes has proved very effective. (For further details, see page 34.)

Brisbane-based fabrication company, idec recently received a Made in Queensland Grant. This Queensland Government initiative supports local manufacturers to increase their international competitiveness, productivity and innovation through the adoption of new technologies.

As a result, idec invested in the latest Voortman technology, including automated drilling and sawing machines, a robotic coping system, an intelligent infeed-outfeed system and industry leading modelling and control software. All of this has increased the overall quality of the steel coming off their processing line. (For further details, see page 36.)

21st century construction technologies, such as pre-fabrication are also helping the industry transform the way it builds.

This was illustrated by the COVID-19 Surge Centre, recently delivered by construction company Manteena and pre-fabrication specialists Austruss in Canberra (see page 42). The project team achieved practical completion of the 17,000m2 51-bed medical facility

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT | STEEL AUSTRALIA | WINTER 2021

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT after an initial design phase of seven days and a construction period of just 36 days—not only achieving the goal of a very tight program but delivering a facility built to Australian Standards.

In the realm of Research and Development, the Steel Research Hub at the University of Wollongong is leading the charge in Australia. Having just received an additional $28 million in funding, the Hub is set to embark on its second phase of operations, which will investigate projects in areas such as process integration and sustainability, product innovation and technology, advanced corrosion performance and operational efficiency and steel supply chain transformation. (For further details, see page 46.)

Research and development has also led to the release of a new and improved edition of the Galvanizers Design Manual by the Galvanizers Association of Australia. First produced in 1965 and available on CD since 2008, the Design Manual has undergone a major revision process to bring its contents in line with technical and technological innovations, as well as changes in Australian Standards.

(For further details, see page 48.)

31

MOLYCOP: AUTOMATION BUILDS A BETTER WORKING ENVIRONMENT MOLYCOP'S 100-YEAR HISTORY HAS BEEN BUILT ON PROVIDING THE MOST INNOVATIVE, HIGHEST QUALITY PRODUCTS AND DELIVERING OUTSTANDING SUPPLY ASSURANCE. THEIR EXPERIENCED AND HIGHLY TRAINED TECHNICIANS ARE CONTINUALLY DEVELOPING SUPERIOR TECHNOLOGY SOLUTIONS AND PUSHING THE BOUNDARIES OF MINING CONSUMABLE PRODUCTS, TO MAKE CERTAIN NO MINE EVER STOPS OVER MOLYCOP. MOLYCOP EMBARKED ON ITS AUTOMATION JOURNEY IN 2011 IN A BID TO IMPROVE SAFETY AND BUILD A BETTER WORKING ENVIRONMENT.

Towards the end of World War I, Australia found it impossible to obtain supplies of railway wheels, axles and other steel products previously imported from England who, due to the war, were no longer in a position to export steel products. Consequently, Molycop's Australian operations began with the formation of Commonwealth Steel Company (Comsteel), and the establishment of its steelmaking operation at Waratah in Newcastle in 1918. During the 1930s, Comsteel diversified into grinding media to support Australia’s burgeoning hard rock mining industry.

Molycop’s product lines include grinding media, fasteners and the Comsteel range of forged railway wheels and axles. The main markets for grinding media are copper and gold mines in the Australasian region. In terms of rail products, Molycop caters for passenger

and general freight, and their premium range of wheels is used in heavy haul in the Pilbara for iron ore - carrying the highest axle loads in the world.

The Comsteel range of products includes continuously cast anode pins for Australian and New Zealand aluminium smelters. Comsteel also supplies a range of ingots, from 1 tonne to 37 tonnes, for Australian forging operations. These forgings are used in applications like wind generation, heavy shafts and gears, and defence applications.

In addition, Molycop Engineered designs and manufactures a range of SAG and ball mill liner bolts for the mineral processing industry, Twistlock pins, and specialty fasteners.

THE AUTOMATION JOURNEY Molycop embarked on its automation journey back in 2011, with the installation

of a dual robot system for forging. This was quickly followed with the installation of a grinding robot in 2012. In 2017, both systems underwent capability improvements, before the installation of a second forging robot in 2018.

THE BENEFITS As Samuel Regan (Business Improvement Leader, Molycop) explained, Molycop's decision to invest in automation was driven very much by the idea of creating a better working environment for their team.

"At the heart of it, most automation is about reducing risk to operators. The business case for automation was built around the safety aspects. We were focused on removing people from risk, improving safety, and building a better working environment," said Regan.

The grinding wheel in particular presents

Molycop's SAG robot.

safety issues—running the grinding wheel over an extended period of time can cause RSI injuries due to the vibrations. Removing this was a real priority," said Regan.

The other clear benefit afforded by robotics is increased product quality and consistency. With the way the robotics work, they place the workpiece in the same place every time, which means that the final product is pressed perfectly every time."

IMPACT ON STAFF "Overall, our staff have found the automation process really positive.

A lot of our team members took the opportunity to upskill. Quite a few really embraced the changes and have become more involved in the business."

"A lot of the roles that get replaced or augmented by a robot are not necessarily what people come to work to do. You don’t get up in the morning and come to work wanting to use a grinding wheel for hours on end. People want to be in those higher-skilled, more interesting roles," said Regan.

THE CHALLENGES As with any major business improvement project, Molycop faced some challenges along the way.

"Being a bespoke manufacturer, many of our jobs are smaller batch sizes, particularly on the bolt side of business, which makes bolts to order. This type of manufacturing requires flexible robotic solutions with broad scope. The robots can cope with these sorts projects, but it needs to be allowed for in your original project scope."

"The other major challenge comes with automating a rigidly manual process, like programming a robot to operate a griding wheel. It's challenging but also very rewarding – the payoff is definitely worth it," said Regan.

Given the importance of project scope, Regan had this advice for other manufacturers considering embarking on the automation process themselves.

"The most important thing is to define the scope of the project well, and to make sure that scope is reasonable.

You need to know exactly what you want to end up with and be clear on the deliverables – they need to be specific and measurable," said Regan.

"It's best to focus on high volume products and processes associated with the core business. Later on, you can increase the scope of your automation with improvement projects. Starting with a project scope that is too broad can make it extremely difficult to get the right robot cell, or makes the robot really expensive and hard to implement."

Another key tip for a successful automation journey is to leverage the experience and knowledge that your operators have built, working with the machinery every day.

"It's so important to utilise the knowledge of the operators who use the machinery.

We learnt a lot talking with the operators.

We found out little things—like tricks they were using to ensure the machines worked at full capacity—that weren’t immediately obvious, but when pointed out made a lot of sense," said Regan.

CONTINUOUS IMPROVEMENT With technology ever evolving and improving, the automation journey is one that is never really complete. Molycop is already working on further improvements to their grinding robot, which was only upgraded a few years ago. Their team is also investigating the benefits of automating other processes within their facility.

“

At the heart of it, most automation is about reducing risk to operators.

The business case for automation was built around the safety aspects. We were focused on removing people from risk, improving safety, and building a better working environment.”

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT | STEEL AUSTRALIA | WINTER 2021

Molycop's griding media.

"Automation and investment in technology is really important—it's the key to being competitive in a global sense. Robotics are really where you can find an edge. Labour isn’t cheap in Australia and keeping the workforce safe is really important.

Robots can help to manage both of these aspects. Robots allow manufacturers to pay their workers a higher wage, to perform a higher function, in a working environment that is much safer," said Regan.

"Robotics offer a higher quality of product if set up properly and give you the market premium to stay competitive. If quality is the goal, and robotics are the pathway to that goal, then Australian businesses need to take that on-board and leverage the power of automation."

"Robots are the way forward," said Regan.

CLICK HERE TO LEARN MORE ABOUT MOLYCOP, AS WELL AS THEIR PRODUCTS AND CAPACBILITIES >>>

33

DSI UNDERGROUND: A HOLISTIC APPROACH TO LEAN MANUFACTURING DSI UNDERGROUND IS AUSTRALIA’S LARGEST MANUFACTURER AND SUPPLIER OF SPECIALIST STRATA REINFORCEMENT AND SUPPORT PRODUCTS TO THE UNDERGROUND COAL AND METALLIFEROUS MINING SECTORS. WITH OVER 2,000 EMPLOYEES WORLDWIDE, DSI UNDERGROUND BOASTS OPERATIONS IN OVER 70 COUNTRIES ACROSS EUROPE, AFRICA, ASIA-PACIFIC AND THE AMERICAS. OVER THE LAST EIGHT YEARS, DSI UNDERGROUND HAS INVESTED IN A HOLISTIC PROGRAM OF PROCESS IMPROVEMENT INCORPORATING AUTOMATION, INDUSTRY 4.0 AND LEAN MANUFACTURING PROCESSES.

Complying with all technical standards, DSI Underground's solutions cover just about every mining application, from shaft sinking and horizontal drift excavation, through to shaft rehabilitation and emergency support.

DSI Underground's largest volume, and longest standing, product is their friction bolt. The friction bolt is a ground support system that consists of a high strength steel tube with a slot along its entire length. One end of the friction bolt is tapered to assist insertion into the bore hole whilst the other end has a welded steel ring to retain a bearing plate when installed into the mine roof.

The company also boasts newer products like the Kinloc bolt—a fast installation, non-resin anchored 30 tonne rock bolt. The system develops significant additional point anchor capacity via a threaded non-rotating head. The Kinloc bolt’s ability to better

“

Our drive is keep to manufacturing in Australia. We could have offshored but, instead, we're investing in automation and are working with our suppliers to continue to be a low cost producer.

With the globalisation of products and supply chains, we want to ensure that we remain globally competitive."

endure shifting ground conditions creates a new option in ground support where loading after movement is important.

NATIONAL PRODUCTION FACILITIES

DSI Underground has three production facilities in Australia. Their head office and main facility in Newcastle manufactures rock bolts for the mining and tunnelling industries. In Brisbane, their workshop produces hard rock products for the gold copper, zinc, lead markets. In Western Australia, where DSI Underground services the hard rock space, their Perth facility is focused on the production of friction bolts, plates and mesh.

As Derek Hird (Regional Chief Executive Officer, DSI Underground) explained, DSI Underground started their automation journey about seven or eight years ago, focused on productivity and competitiveness.

"Our drive is keep to manufacturing in Australia. We could have offshored, but instead, we're investing in automation and are working with our suppliers to continue to be a low cost producer. With the globalisation of products and supply chains, we want to ensure that we remain globally competitive," said Hird.

"Automation and investing in technology is vital to the future of manufacturing in Australia. We need to preserve our in-country capability, particularly in the wake of COVID-19. We have seen massive supply chain interruptions, and massive issues with importing a range of products into the country."

Safety and efficiency improvements were also an important driver in DSI Underground's decision to invest in automation. "Our manufacturing processes were, and continue to be, very manual and repetitive, giving us a high conversion cost from a labour

"We made the decision to address these issues step by step, prioritising those with the greatest opportunities for safety and efficiency improvements."

"We picked a couple of processes and, initially, our approach was to select an external contractor who specialised in automation to deliver a scope of work as a turnkey package. Unfortunately, we had limited success; the end result was not quite what we were after."

"So, we decided to recruit in-house mechanical and electrical engineers to design processes, and build and program machines to our specifications.

Having internal capability has been more successful in our drive for automation.

Our in-house team has access to our equipment and operators, and understands the factors that influence our products," said Cox. "As a result, we've seen efficiency gains and improvements in the quality of our products. Automation drives a more predictable output."

"We’ve definitely seeing a decrease in working capital; there is less partially manufactured product sitting on the factory floor. This has allowed us to reduce our factory footprint," said Cox. Hird explained that there have also been benefits for DSI Underground's clients.

"Our agility, and therefore customer responsiveness, has improved. If we didn’t have the types of equipment we now have, things would take far longer to manufacture. When customers want

something unique, we can deliver far more effectively and quickly."

A HOLISTIC APPROACH

While DSI Underground has invested in robotic cells for packaging and palletising, as well as plate processing technology, their approach has not focused only on installing the newest, latest and greatest machinery. Instead, DSI Underground has improved its internal processes and Industry 4.0 methodologies.

"One thing we've found is that there are certain things you shouldn't automate. There will always be parts of your process that need the human touch. You should automate the things that make sense to automate— and that will have the largest possible impact—rather than the processes on the fringe that might give rise to reliability issues," said Cox. The company has also focused on lean manufacturing processes, training over 20 members of the team on the subject.

"The education of personnel within the business is vital. The whole business has to come along for the journey. We started a big education program around lean manufacturing with key individuals, which was a massive advantage. Without the buyin of your employees, automation will fail," said Hird.

THE CHALLENGES

The automation journey hasn't all been smooth sailing for DSI Underground.

"One of the main challenges we've faced has been obsolescence – the level and duration of support delivered by suppliers can be an issue. For instance, the controllers might not be available after a certain point in time, which means your investment is not as beneficial as first thought," said Cox. "Using external suppliers, who lack in-depth knowledge of your product and processes is also challenging."

Hird agreed. "It's essential that you put time into really defining the scope of what you're trying to achieve. If you involve external suppliers, without fully scoping the project, it's almost impossible to achieve the desired result. It's also vital to allow realistic timeframes— it will take a lot longer than you anticipate."

MORE THAN JUST AUTOMATION

DSI Underground is also embracing new and emerging technologies such as connectivity and ‘digital twin’ to drive cost-saving and efficiencies into their customers’ operations.

"The work we're doing in the digital space is really exciting. We recently launched a product app, which we're expanding to include a customer interface tool. Customers will be able to use the app to access product information and PDS. We're also looking at expanding the functionality of the app to include seamless product ordering. DSI Underground is also investigating digital warehousing solutions and the use of digital twins from design and installation, through to service life monitoring," said Hird.

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT | STEEL AUSTRALIA | WINTER 2021

perspective. This also gives rise to manual handling risks and hazards in the workplace," said Phil Cox (General Manager East, DSI Underground).

CLICK HERE TO LEARN MORE ABOUT DSI UNDERGROUND AND THEIR RANGE OF PRODUCTS >>>

35

IDEC'S AUTOMATION JOURNEY: INCREASING COMPETITIVENESS, PRODUCTIVITY AND INNOVATION BASED IN BRISBANE, IDEC SPECIALISES IN THE DESIGN AND CONSTRUCTION OF COMMERCIAL AND INDUSTRIAL BUILDINGS, AS WELL AS REMOTE INFRASTRUCTURE. THEIR IN-HOUSE CAPABILITIES INCLUDE WORKSHOP DETAILING, FABRICATION AND ERECTION. IDEC RECENTLY RECEIVED A MADE IN QUEENSLAND GRANT. THIS QUEENSLAND GOVERNMENT INITIATIVE SUPPORTS LOCAL MANUFACTURERS TO INCREASE INTERNATIONAL COMPETITIVENESS, PRODUCTIVITY AND INNOVATION THROUGH THE ADOPTION OF NEW TECHNOLOGIES. AS A RESULT, IDEC HAS INVESTED IN THE LATEST VOORTMAN TECHNOLOGY INCLUDING AUTOMATED DRILLING AND SAWING MACHINES, A ROBOTIC COPING SYSTEM, AN INTELLIGENT INFEED-OUTFEED SYSTEM, AND INDUSTRY-LEADING MODELLING AND CONTROL SOFTWARE. GLENN GIBSON (CEO, IDEC) ANSWERED SOME QUESTIONS FOR STEEL AUSTRALIA ABOUT IDEC'S AUTOMATION JOURNEY.

MADE IN QUEENSLAND GRANT Made in Queensland (MIQ) is a $61.5 million Queensland Government program helping small and medium manufacturers to increase international competitiveness, productivity and innovation via the adoption of new technologies, and to generate highskilled jobs for the future.

Since 2017, MIQ has supported 84 advanced manufacturing projects across the state. It is expected to create more than 1,100 jobs over five years and generate more than $100 million in private sector investment.

Of the 84 projects funded through MIQ, 40% are being delivered in regional Queensland. Eligible manufacturers can apply for grants between $50,000 and $2.5 million with matched funding.

TELL US ABOUT IDEC'S HISTORY.

The idec story has roots deeply planted in industry and agriculture. Over 40 years ago, one of our Directors—Peter Gartshore—began marketing off-theshelf building kits, and from this, grew Big Country Buildings (BCB). BCB specialised in the design, fabrication and construction of custom-engineered steel buildings including hangars, warehouses and commercial facilities.

In 2006, Big Country Buildings rebranded to idec – an anagram of ideas, design, engineering and construction. This emphasises our ability to provide fully in-house steel design solutions. idec continues to grow and tackle complex projects. We operate with a corporate structure in conjunction with the support of a family run organisation.

WHAT DO IDEC'S OPERATIONS LOOK LIKE TODAY? Today, idec is a multi-faceted design, fabrication and construction company that provides a true one-stop-shop solution. Our extensive in-house capabilities include design, processing, fabrication, rigging and construction across a multitude of sectors such as aviation, defence, local government, communications, energy, mining, education and major infrastructure.

WHAT ARE SOME OF YOUR MOST SUCCESSFUL MAJOR PROJECTS?

We have undertaken over 1,500 projects throughout our 40 year history, with each bringing its own challenges, learnings and rewards.

Notable projects include the VISY Can facility at Yatala which saw us deliver an 18,000m2 state-of-the-art facility as principal contractor in 2013. Moving away from the commercial space, we have been fortunate to work with numerous Tier 1’s on the delivery of Australia’s most well-known infrastructure projects, including the C-17 Hangar at Amberley, Land-121 Enoggera, Gold Coast University Hospital, AirportLink, Legacy Way and Cross River Rail.

WHAT IS THE SECRET TO IDEC'S SUCCESS?

Our secret to success is our people.

From the outset, our clients deal directly with a member of our team, whether that be our estimators, engineers, designers, project management team or riggers. At every step of the way, all works are undertaken by idec employees – ensuring the highest quality outcome. Second to this is our ongoing commitment to innovation and technological advancement.

The grandstand at Lawnton Aquatic Centre provides covered seating for 1,000 people, disability access, timekeeping facilities and storage areas. idec’s scope of works for the project included: structural design, steel fabrication and installation, civil works, pre-cast concrete seating, and cladding. idec engineered and built the structure to cantilever (using their built-up plate technology) over the bleachers for maximum visibility.

TELL US ABOUT IDEC'S RECENT INVESTMENT IN AUTOMATION AND TECHNOLOGY?

Our recent investment consists of three Voortman robots – the VB1050 Sawing Machine, V631 Drilling Machine, V807M Coping Machine – and an intelligent infeed-outfeed system. The utilisation of this robotic technology, coupled with our existing in-house design and detailing capabilities will ensure future competitiveness within the industry. This robotic steel processing line is currently the most advanced line in Queensland and is the first of a series of planned investments in automation.

WHY DID YOU DECIDE TO INVEST IN AUTOMATION?

idec has always been at the forefront of technological and industry advancement including the implementation of AS 5131 in 2016 as one of the first fabricators certified to Construction Category 3. Likewise, the conversation about investing in the emerging field of automation and robotics has been ongoing for a number of years. The Board and I could very clearly see the material number of improvements and opportunities which automation would bring our business including the creation of high-skilled jobs and

VISY WAREHOUSE

idec was contracted by VISY to construct a new large-scale warehouse to manufacture lightweight cans for the beverage industry. The facility included 18,000m2 of warehouse space and 1,000m2 of office space. idec's scope of works included concrete foundations and slabs, structural steel, precast concrete panels, cladding, building services, fire protection systems, internal office fitout and landscaping.

increased quality assurance.

WHAT IMPROVEMENTS HAVE YOU SEEN AS A RESULT? We are still in the commissioning phase, with the sum of improvements not yet clearly discernible. However, I will say that the overall quality of processed steel coming off our new processing line is remarkably high thanks to our integrated analysis– design–documentation–detailing– processing model.

Our processing line is closely linked to our Digital Engineering Team and model information can be directly imported from 3D modelling software.

This results in the consistent, reliable and accurate transfer of information between the shop drawing and fabrication process. The robot can mark out and scribe all fabricated components which reduces overall fabrication time and potential for error.

HOW DID YOU FIND THE GRANT APPLICATION PROCESS?

For an organisation of our size, the grant process afforded our executive

DINMORE & GRACEVILLE STATIONS

As part of Queensland Rail’s ongoing Station Upgrade Program, idec was contracted to detail, fabricate, protective coat and install steelwork for the upgrade of Dinmore and Graceville train stations. idec’s scope of work included: fabrication and erection of the lift shafts, fully-welded overpass sections, stairs and awnings; cladding and security screens; and high quality protective coating application.

team an opportunity to take a step back and view the company, its goals and objectives as a whole – while also focusing on the value for money of automation and overall return on investment. I recommend any manufacturer that is considering applying for the MIQ grant to begin the journey and see where it can take their business in terms of increasing their competitiveness, productivity and innovation through the adoption of new technologies – while generating high skilled jobs of the future. However, please be cognisant of the time and cost of a grant application.

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT | STEEL AUSTRALIA | WINTER 2021

LAWNTON AQUATIC CENTRE

WHERE TO NEXT FOR IDEC? WHAT DOES THE FUTURE HOLD?

We are excited about the opportunities that our robotic processing line will offer now and into the future, including the ability to upskill our existing staff particularly in the area of robotics and technology. Further to this, idec looks forward to a continual investment in automation which will see our company well-placed in the digital future while driving exceptional outcomes for our clients and their projects.

CLICK HERE TO LEARN MORE ABOUT IDEC AND THEIR DESIGN, FABRICATION AND CONSTRUCTION CAPABILITIES >>>

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CELEBRATING 30 YEARS OF CONTINUOUS CASTING AT WHYALLA STEELWORKS

LIBERTY PRIMARY STEEL IS CELEBRATING 30 YEARS OF CONTINOUS CASTING AT THEIR STEELWORKS. LOCATED AT WHYALLA, SOUTH AUSTRALIA, APPROXIMATELY 400KM NORTH-WEST OF ADELAIDE, IT IS AN INTEGRATED STEELWORKS USING MAINLY MAGNETITE IRON ORE-BASED FEED, SOURCED FROM SIMEC MINING’S IRON ORE MINES IN THE REGION. WITH A PRODUCTION CAPACITY OF 1.2 MILLION TONNES PER ANNUM, APPROXIMATELY 65% OF THE STEEL PRODUCED IS TRANSFERRED BY RAIL IN BILLET FORM TO INFRABUILD STEEL'S ROD BAR AND WIRE BUSINESS FOR FURTHER VALUEADDED PROCESSING, AND THE REMAINING STEEL IS CONVERTED TO FINISHED PRODUCTS IN THE FORM OF STRUCTURAL STEEL AND RAILS THROUGH THE WHYALLA STRUCTURAL MILL. A SERIES OF MAJOR INVESTMENTS, TECHNOLOGICAL ADVANCEMENTS, AND RESEARCH AND DEVELOPMENT PROJECTS AT THE STEELWORKS HAS RESULTED IN THE CONSISTENT MANUFACTURE OF HIGH-QUALITY STEEL PRODUCTS OVER THE LAST 30 YEARS.

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teel is a refined form of metallic iron with controlled quantities of alloying elements added. As the molten iron comes from the Blast Furnace, it contains approximately 4% carbon. During steelmaking, the percentage of carbon and other residual elements is lowered by oxidation to around 1%, depending on the type of steel being made.

The Whyalla steelworks currently produces around 90 grades of steel, which fluctuate depending on customer needs. By varying the carbon content and adding different proportions of various alloying elements, hundreds of

different grades of steel can be made.

The Basic Oxygen Steelmaking (BOS) furnace is simply a barrel-shaped steel vessel with an open top. It is lined with refractories about 700mm thick and can tilt through an arc of 360 degrees.

The Whyalla BOS has two furnaces, each of which produce 130 tonnes of steel in every 'heat' (batch). To enable a consistent supply of steel, one furnace remains in constant operation, whilst the second can be taken offline for relining with refractory bricks or repair, if required.

During charging, the furnace is tilted.

Scrap, which may comprise up to 35 tonnes of the charge, is tipped in, followed by approximately 100 tonnes of molten iron from the blast furnace.

The vessel is then returned to the upright position and a water-cooled lance is lowered to a pre-determined height above the surface of the molten iron. Oxygen of 99.5% purity is then blown through the lance at high velocity onto the molten iron whilst nitrogen is 'bubbled' through the bottom of the furnace to improve the mixing. As the oxygen is blown into the BOS vessel, a flux of burnt lime and dolomite is

The ingot route process involved the molten steel being 'teemed' (poured) into ingot moulds to produce rough blocks of steel ingots that ranged in weight from around six to 13 tonnes, depending on the final product to be produced.

In closing the ingot route, Australia joined leading steelmaking countries in the world that produce the majority of their raw steel using the continuous cast method. In addition to the Whyalla operation, there are Continuous Casters at Port Kembla in New South Wales, Laverton in Victoria, Rooty Hill in Sydney, and in Newcastle.

Continuous casting provides a significant improvement in steel yield by eliminating the need for ingot cropping to remove the shrinkage cavity, as well as negating the need for intermediate rolling products such as Blooms. In addition to the direct process yield benefits, the continuous cast product has significantly better and more consistent internal properties, which further enable higher quality yield. dropped in to control reactions and form a refining slag.

Exothermic (heat producing) chemical reactions occur as the oxygen combines with the carbon and other impurities in the molten iron, which are absorbed into the slag, or exit as gas. The oxygen blow goes on for about 20 minutes and sufficient heat is generated to melt the scrap and raise the temperature of the molten iron to above 1,600°C. At the end of the oxygen blow, the furnace is tilted, a temperature reading obtained and a sample taken for analysis. The operator then makes any necessary adjustments to the steel before tapping (emptying) the furnace.

The operator then tilts the furnace to the tapping position so that the molten steel runs through the taphole into a ladle below. The steel flows out from underneath the layer of slag.

During tapping, Ferro alloys (mainly Ferro manganese and Ferro silicon) are added to the ladle to bring the steel to the exact specification required.

After the steel has been tapped, the furnace is tilted to the opposite side to pour slag over the rim into the slag pot below. The BOS production cycle from charge to tap usually takes about 40 minutes.

CONTINUOUS SLAB AND BLOOM CASTER

The 130 tonnes of molten steel has its specifications fine-tuned after being transported out from the point where it was tapped.

Commissioned in April 1992, the $150 million Continuous Slab and Bloom (Combination or ‘Combi’) Caster represents a major addition to Whyalla Steelworks’ facilities. It provides enhanced productivity and international competitiveness for the Steelworks.

The ladle of steel is 'bubbled' with argon (much like blowing through a straw into a milkshake) to stir the steel and ensure a consistent mix of the elements. At this point, further temperature readings and samples are taken and the analysis can be fine-tuned by adding alloys.

Completed ahead of time and under budget, the Combi Caster has set high standards of productivity. It holds the Australian Slabmaking Record and Whyalla Break-Out (spillage of molten steel) Free Period of 830 days and 2,722,954 tonnes of continuously cast steel.

On completion of that process, the ladle of molten steel is picked up by a Kress Carrier, which transports the ladle to a separate building housing the Slab and Bloom and Billet Casters.

The casting process involves pouring liquid steel from a 130 tonne ladle into the 30 tonne tundish and then into water cooled copper mould. Initial solidification of steel happens in the mould and final solidification in the secondary cooling zone that is 34.5m long and where the strand is cooled by water sprays and supported by

INGOT ROUTE Prior to the opening of the Continuous Slab and Bloom Caster at Whyalla on

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT | STEEL AUSTRALIA | WINTER 2021

13 April 1992, all molten steel was poured into ingot moulds and allowed to cool. Opened in February 1965, the ingot route produced over 20 million tonnes of steel ingots before decommissioning on 30 April 1993. The former ingot route process included the Soaking Pits and Bloom Mill, which are no longer used.

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water cooled rolls.

The Slab and Bloom Caster has a maximum production capacity of more than 1.2 million tonnes per annum.

The following section sizes can be produced at the caster, single slabs (950mm to 2,070mm), twin slabs (600mm to 960mm) and triple blooms (350mm and 450 mm). Design product thickness range is 200mm to 250mm.

Current caster production is around 300,000 tonnes of cast feed per annum for structural sections and around 100,000 tonnes of cast feed per annum for rail sections—both processed through the Steelworks’ Rolling Mill complex.

BILLET CASTER Commissioned in May 1999, the Steelworks’ $83 million Billet Caster and its associated Ladle Metallurgy Facilities incorporates state-of-the-art technology and operating practices.

The Billet Caster has a capacity to produce around 750,000 tonnes of billet steel per annum and has positioned the Steelworks as the principal supplier of billet steel feed for InfraBuild Steel operations on the east coast of Australia.

The five strand Billet Caster is designed to produce Special Bar Quality (SBQ) and engineering steel grades that have high requirements for mechanical properties, surface and internal quality.

To meet quality requirements for SBQ grades the billet caster has mould

and strand electromagnetic stirrers to improve billet internal quality and to reduce harmful segregation in cast product. Convex mould technology is applied to increase mould heat transfer, which allows for a higher casting speed compared with the conventional mould design.

The following cast practices are available at the billet caster: open pour casting used for commercial steel grades, and submerged entry nozzle (SEN) casting for SBQ grades. Billet section sizes range from 127mm, 160mm to 175mm square and the maximum billet length is 12m.

Billet steel feed from Whyalla undergoes value-adding downstream processing at InfraBuild Steel's rolling mills to produce a range of products for customers in the automotive, fabrication and construction, fastener, manufacturing, mining, reinforcing, rural and wire industries.

COMBINATION CASTER UPGRADES The single strand vertical-bending Combination Caster at the at Whyalla Steelworks was designed by VoestAlpine Industrieanlagenbau (VAI) and was commissioned in April 1992. For over 27 years, the machine manufactured as-cast semis that consistently met the downstream rolling requirements for both surface and internal quality. In 2019, Liberty Primary Steel in collaboration with the Materials Processing Institute, completed a project aiming to extend the product range of

the Combination Caster to enable the machine to manufacture single width slabs for more demanding strip and plate grades without the need for costly capital expenditure.

The project identified that thermal tapering of the strand support rolls, and a static soft reduction zone could be retrofitted to the machine to improve slab internal quality. The machine was retrofitted with the new settings in November 2018, and in February 2019 the first order for single width slab was completed. This export order had a more demanding internal quality requirement than the steel plant would normally manufacture. Utilising the retrofitted thermal taper and static soft reduction settings, the order was completed with improved internal slab quality.

The machine upgrade greatly increased the capability of the Combination Caster to manufacture more demanding steel grades without the need for costly capital expenditure. The Whyalla Steelworks now supplies both single and twin width slabs to new markets that historically would not have been considered.

ADVANCED TECHNOLOGY The original Combi Caster Mould Level Control (MLC) and Break-out Prediction (BOP) systems were installed when the Steelwork's Caster was first commissioned in 1992. These systems incorporated a VAX computer system to conduct the necessary process control

Track laying has finished in one of the Sydney Metro railway tunnels under Sydney Harbour, marking a major milestone in the Metro from Chatswood, to the city, to Bankstown. The Hon. Gladys Berejiklian MP, Premier of New South Wales, and the Hon. Andrew Constance MP, Minister for Transport and Roads, recently inspected the completed tracks on the Blues Point side of the northbound tunnel, which is about 40m below the harbour’s surface.

The tracks in these tunnels connect the future Barangaroo and Victoria Cross (North Sydney) Metro Stations. Track laying in the southbound Metro harbour tunnel has reached 30% and is due for completion at the end of July.

“The 800m section of track in the northbound Metro harbour tunnel is complete, after 1,200 railway sleepers and 2,100 tonnes of concrete were installed,” Constance said. “More than 4,000 tonnes of Australian steel has been used for the 31km of tracks from Chatswood to Sydenham, including 200 tonnes under the Harbour.”

The 1,200 railway sleepers were manufactured by Liberty Primary Steel at the Whyalla Steelworks.

“Around 50,000 people will have worked on this incredible city-shaping project by the time services start in 2024, with about 800 involved in the tunnel fit out and 5,000 currently working on the project,” Berejiklian said. “It will take just three minutes to travel between the new Victoria Cross Station at North Sydney to Barangaroo Station using the tunnels, transforming the way we travel around our great city.”

Sydney Metro line-wide contractors Systems Connect, a joint venture between CPB Contractors and UGL Limited, took over the harbour tunnels in December last year to lay the tracks and fit out the tunnels. Metro trains will start running through the harbour tunnels in 2024, extending the North West Metro, into the city and beyond to Bankstown.

New stations are being delivered at Crows Nest, Victoria Cross, Barangaroo, Martin Place, Pitt Street and Waterloo, along with new underground platforms at Central Station.

functions. Over time, these platforms had become obsolete and the ongoing support of the systems was proving to be increasingly challenging. When the VAX computers were originally installed the computation required to run the systems was too high for the PLCs of the day but with modern technology the latest Rockwell Programmable Logic Controllers (PLCs) were able to handle the calculations. So, in 2018, these systems were updated to the latest Rockwell PLCs with the first cast on the new system being conducted on 23 October 2018.

The use of PLCs enabled Liberty Primary Steel to make a variety of system enhancements, including: • Clogged nozzle predictions • Start-up sequence transitions (preventing getting stuck in transition) • Adaptive gain control • Manual take-over of slidegate during start-up • Level control simulations (for training purposes) • Auto flushing At the same time, Liberty Primary Steel installed a new SCADA system to replace the old MasterView system that had become obsolete in the 1990s. Liberty changed its SCADSA philosophy to be in line with the latest world-wide Alarm System Management (ASM) standard. As part of these two upgrades, an Ethernet Network back bone was installed that can be expanded to help steelmaking at

Whyalla move into the fourth Industrial Revolution, Industry 4.0.

LOOKING AHEAD GFG Alliance has revealed further plans to transform its Whyalla steelmaking facility on the back of its South Australian mine products. The plant will transition to a direct reduced iron (DRI) facility to produce low-emission Greensteel from the company’s South Australian magnetite resources and domestic steel scrap.

The new plant will be fed by natural gas, making use of green hydrogen produced from GFG’s renewable energy projects, in alignment with the company’s ambition to be carbon neutral by 2030. It will

transition away from a blast furnace to an electric arc furnace (EAF) and new rolling mill.

In addition, the Steelworks is expected to branch out with new products into new markets, widening product quality capabilities with potential introduction of vacuum degasser along with upgrades to secondary refinement stations.

Sequence lengths will also be improved in a cost saving initiative, and 130mm billet size casting capability will be introduced. Finally, automation capabilities will be expanded to reduce the hot metalhuman interface.

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT | STEEL AUSTRALIA | WINTER 2021

SYDNEY METRO RAILWAY TRACK LAYING ON TARGET UNDER SYDNEY HARBOUR

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ACT COVID-19 SURGE CENTRE DELIVERED IN RECORD TIME WITH PRE-FAB STEEL IN THE GRIP OF THE GLOBAL COVID-19 PANDEMIC, CONSTRUCTION COMPANY MANTEENA AND PRE-FABRICATION SPECIALISTS AUSTRUSS DELIVERED A WORLD CLASS COVID-19 SURGE CENTRE IN JUST 36 DAYS. MANTEENA WAS ENGAGED BY ASPEN MEDICAL UNDER A DESIGN AND CONSTRUCT CONTRACT TO DELIVER A 17,000m2 51-BED MEDICAL FACILITY FOR THE ACT AND SURROUNDING REGION. WORKING DAY AND NIGHT SHIFTS, THE TEAM HAD UPWARDS OF 130 CONTRACTORS ON-SITE AND COMPLETED 22,000 MAN HOURS. THE FACILITY WAS BUILT USING PRE-FABRICATED WALL FRAMES AND ROOF TRUSSES MADE FROM TRUECORE® STEEL, MANUFACTURED OFF-SITE BY AUSTRUSS. THE HIGHLY COLLABORATIVE RELATIONSHIP BETWEEN MANTEENA, AUSTRUSS AND ASPEN MEDICAL WAS ESSENTIAL TO ON-TIME DELIVERY OF THE PROJECT, AS WAS THE PRE-FABRICATED, HIGHLY FLEXIBLE LIGHT GAUGE STEEL DESIGN.

O

n 9 April 2020, construction company Manteena commenced the delivery of a COVID-19 Surge Centre on Garran Oval, adjacent to Canberra Hospital.

The project team achieved practical completion after an initial design phase of seven days and a construction period of just 36 days—not only achieving the goal of a very, very tight program but delivering a facility built to Australian Standards, as well as the World Health Organisation (WHO) Sudden Acute Respiratory Infection Treatment Centre manual.

According to Damien Crough (Executive Chairman, prefabAUS), "This COVID specific project was delivered in an unprecedented timescale with the use of prefabricated frames and trusses, wall and ceiling systems, and bathroom pods."

"Australia's prefab industry is merging to mainstream, with significant projects such as the COVID-19 Surge Centre in Canberra taking full advantage of the benefits it has to offer. The focus on design for disassembly and re-use is an inherent sustainability benefit for prefabricated construction."

"Prefabrication has a crucial role to play in transforming Australia’s built environment through decreasing construction time frames and construction waste, while increasing quality, productivity and affordability."

Rod Mitton (Design Manager, Manteena) described how the project initially commenced. "I received a phone call from Mantenna CEO Simon Butt on 1 April 2020 asking if I thought we could undertake design and construction of a new medical facility within the next 40 days. Without looking at the date—which just so happened to be April Fool’s

Day 1: Site establishment.

Day 10: Wall frames.

Day 3: Installation of joists.

Day 13: Chasing trades.

Day 15: Roof sheeting installation.

Day—my answer was, ‘Yes, of course we can’."

The brief provided by the client, Aspen Medical, called for the construction of a 17,000m2 medical facility, consisting of 51 patient beds, including patient services panels, treatment areas, administration and nurse stations and staffing facilities. The structure was to be built to cyclone standards to account for the helicopter landing deck near the hospital.

"Simon also explained that the design was only at concept stage at that point. There were no working plans to start the process. The location of the building was not even confirmed," said Mitton.

"We knew that in order to get the project off the ground quickly, we’d have to develop the internal designs sufficiently so as to declare a footprint and begin manufacture of the facility structure and construction foundations immediately. We’d also need to determine construction methodology

“

The key was as many repeatable elements as possible to simplify the delivery process.”

Andrew Fowler, Founder and Managing Director, Austruss

Day 20: Wall cladding installation.

for the project. There was no tolerance for long lead times, which meant that all technology and equipment would have to be 'off the shelf', or quickly or locally assembled."

and they were all standardised. The walls were all standardised. We came up with a telescopic wall frame system to give flexibility to the whole assembly process."

"Having undertaken a number of projects with Austruss in the past, I phoned Andrew Fowler [Founder and Managing Director of Austruss] to sound him out on the project. Before the end of the day, Andrew and I had mapped out a plan on how we’d deliver the project using BlueScope’s Truecore® steel," said Mitton.

"The key was as many repeatable elements as possible to simplify the delivery process," said Fowler.

A FLEXIBLE DESIGN

SITE ESTABLISHMENT

By the time a site location was identified one week later, the project team had created a building footprint and established a flexible work-inprogress floorplan.

According to Andrew Fowler (Founder and Managing Director, Austruss), a flexible design was key. "After speaking with Rod, I worked with one of my detailers on a concept based on a sketched-up drawing that Rod had given us. This allowed us to work out how we could finalise some dimensions."

As such, site establishment was rapid and footings were in place, ready for delivery of the sub-floor structure, three days after taking possession of the site on Thursday 9 April 2020.

"The brief required that the design be flexible, allow hospital live loads, withstand high wind loads, be reusable, and be able to be packed in a shipping container at end of use. Plus, the product needed to be designed to Australian Standards and on-site within just eight days."

"The whole delivery of this project was just in time to suit what Manteena needed and so that the site wasn’t too cluttered," said Fowler.

"And we did just that," said Fowler.

"We took each section of the building and broke it into certain elements. The only way we thought we could achieve the compressed delivery timeframe was to use a simple kit of parts that were interchangeable. So we designed trusses on either side of the building

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT | STEEL AUSTRALIA | WINTER 2021

Day 16: Mechanical and electrical installation.

Austruss worked throughout the Easter period, delivering the first lot of wall frames to site on Easter Sunday.

The remaining internal design continued in parallel with manufacture of the structure. Within seven days of the initial engagement, the design team had a preliminary design for which the remaining packages of works could be constructed. In a highly flexible arrangement with the client, stakeholders, architects, engineers and suppliers such as Austruss, the design was finessed throughout the build to accommodate the client’s specific needs.

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Day 37: Handover of the ACT's COVID-19 Surge Centre.

LIGHT WEIGHT STEEL CONSTRUCTION

"There was a lot of detail packed into the very short period. Probably the most crucial decision that was made in the first few days of the project was selecting light weight steel construction," said Mitton.

Before contacting Manteena, Aspen Medical had already undertaken enquiries into some Design for Manufacturing and Assembly (DfMA) products. As the design was still evolving, most volumetric options did not provide the flexibility required of the design that was still being decided.

More importantly, advice was that other manufacturers were unable to meet the timeframes set out by the ACT Government.

"From Manteena’s perspective, Truecore®’s strength to weight ratio makes it a very viable option for this type of delivery. Its main attributes are that it doubles as a structural frame, as well as providing a substrate to directly affix cladding. It also provides flexibility for wall set out, and running services that heavy gauge structural steel doesn’t always provide. It can be produced efficiently without shop drawings if necessary. It’s quick to manufacture and easy to erect, negating the need for large in-ground foundations and cranage," said Mitton.

ASSEMBLY AND INSTALLATION

"For the assembly and installation process, our site team divided the floor plate into six stages. As foundations were drilled and concreted in first stage,

the flooring team followed immediately behind installing posts and sub-flooring elements. As soon as they finished, the frame erectors started on walls and trusses, and so on. This allowed each trade to completely finish a section without other trades restricting progress.

Night shifts were introduced to ensure that no stages fell behind," said Mitton.

"The building was spaced appropriately to allow for changes and finessing of internal design within the first two weeks of construction. As the design set out of the rooms was still being detailed, manufacturing of the frames needed to start in advance of the design if we were going to meet the tight timeframes."

"Austruss came up with the idea of making standard modular frames to meet this purpose. When erected on site, the install team was able to measure the run of the wall and then equally spread the frames to suit. No two frames were greater than 600mm apart as this was the maximum stud spacing allowed to distribute the roof load. Even as wall frames were being delivered, changes were being made to the floor. The Trucore® steel was strong enough to facilitate these changes and adapt to the different loadings on the structure," said Mitton.

Another innovation that Austruss developed was to design and construct the roof trusses to allow a full 3m gap between the trusses. This allowed significant space for plant and equipment to be installed between trusses, not underneath as would occur traditionally. This also reduced the

overall height of the building as there were no ceiling voids under the trusses.

STEEL CLADDING

According to Mitton, another important decision was the selection of the cladding to be used in the project.

"The finishes were to be clean, comfortable and thermally efficient.

We knew that traditional cladding like plasterboard and cement sheeting were not an option due to the programming constraints of fixing, setting and painting while service trades were waiting to fit out," said Mitton.

"We had to come up with a product that was thermally and acoustically sound that didn’t need painting but had a resilient finish to reduce infection control. Thermal cool room panels were the obvious choice, although consideration was given to other products like white rock."

"The thermal panels are constructed by placing an expanded polystyrene sheet between two layers of Colorbond cladding. Combining the Truecore® framing and the thermal panel meant that we still had a cavity to run the services in, without surface mounting any of the cabling or pipework. This was an important factor for infection control principles," said Mitton.

SUSTAINABILITY

While not part of the original brief, the team set a goal for the project to be able to be deconstructed and reconstructed elsewhere when no longer required.

"The best estimate is that 90% of the

"Locally sourcing materials and labour was another crucial aspect of ensuring that we were able to meet the project objectives. We were able to gain a commitment from regional and local contractors to do so. Austruss for one fabricated over Easter when most companies would have been shut down."

"There was minimal waste as a result of the build. We had very little left over on-site and what was left was deassembled and sent back to Austruss," said Mitton.

THE SPEED OF TRUST

This project was a success for both Austruss and Manteena who have worked on many projects together since Austruss opened their doors 17 years ago.

KEY BENEFITS OF TRUECORE® STEEL Design Flexibility: With the floor plan for the structure still being finalised while frame fabrication was underway, design flexibility was key to the success of this project. According to Fowler, “Even as wall frames were being delivered, changes were being made to the floor plan. And Truecore® steel was strong enough to fulfil these changes and adapt to different loadings on the structure.”

The frames made from Truecore® steel allowed for design flexibility. “The product allowed for flexibility – allowing changes to be made onsite," said Mitton. "You take out a few screws, make a few changes and then all of a sudden you’ve got an opening where you didn’t have an opening before.”

Impressive strength-to-weight ratio: "Framing made from Truecore® steel is structurally very sound, which helped to allow for large spans of ceilings," said Mitton.

Speed and efficiency: "The frames that Austruss made from Truecore® steel were produced quickly and designed in a way that they were fast to erect onsite and facilitated the running of services (water pipes, electric cabling, and so on) very easily," said Mitton.

Consistent quality: "Knowing that Truecore® steel is a consistent quality product gave Austruss confidence with what they committed to deliver," said Fowler.

Reliable supply chain: "Vital to Austruss turning around the framing so quickly was knowing that enough Truecore® steel product was readily available within such a short time frame," said Fowler.

Fowler said, “The only way this project could be undertaken was due to the trust we’d developed with Manteena.

We’ve had a longstanding relationship with Manteena. It comes down to the speed of trust. If you trust people you can get a lot done incredibly quickly.”

The unique circumstances of this project just further cemented their working relationship. “It just adds a new level of trust between both parties,” said Fowler.

Mitton praised Fowler and the Austruss team. "I want to acknowledge the relationship between Manteena and Austruss and the collaborative nature in which Austruss worked with us. This collaboration enabled the decision making process to proceed unimpeded, with the main objective being to open the facility as quickly as possible."

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT | STEEL AUSTRALIA | WINTER 2021

materials used in the construction of the building can be reclaimed and nearly all of the building can be flat packed and re-established in a different location, either locally or internationally. This meant that no component could be no longer than what could fit into a 20 foot container.

That goal was set for designers and suppliers," said Mitton.

Hospital triage..

Resuscitation bays.

“Andrew’s very inventive and if you have an idea or a need, he will come up with a solution. We knew that if Andrew committed to the project, then he would deliver,” said Mitton.

ASI would like to thank prefabAUS for providing access to their recent webcast on the COVID-19 Surge Centre case study, which provided much of the content for this article. For further information about prefabAUS, visit: https://www.prefabaus.org.au.

Main corridor.

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STEEL RESEARCH HUB: CREATING A GLOBALLY COMPETITIVE, SUSTAINABLE AND RESILIENT STEEL INDUSTRY THE ARC RESEARCH HUB FOR AUSTRALIAN STEEL INNOVATION (STEEL RESEARCH HUB) IS A FIVE YEAR (20212025), $28 MILLION RESEARCH PROGRAM DESIGNED TO SUPPORT THE TRANSITION OF AUSTRALIA’S STEEL MANUFACTURING INDUSTRY TO A MORE SUSTAINABLE, COMPETITIVE AND RESILIENT POSITION BASED ON THE CREATION OF NEW, HIGHER VALUE-ADDED PRODUCTS AND MORE ADVANCED MANUFACTURING PROCESSES. A GLOBALLY COMPETITIVE DOMESTIC STEEL MANUFACTURING INDUSTRY IS A STRATEGIC ASSET FOR AUSTRALIA’S NATION-BUILDING, ECONOMIC GROWTH AND EMPLOYMENT.

The first Steel Research Hub began operating in 2014 with the vision of bringing together teams of internationally recognised research and industry talent to deliver innovative solutions and breakthrough technologies in manufacturing and product development.

These collaborative teams focused their attention on strategic outcomes that were not otherwise realisable.

Led by the University of Wollongong, the new Steel Research Hub brings together nine universities (RMIT University, Australian National University, Swinburne University of Technology, University of Newcastle, Deakin, University of Sydney, University of New South Wales, and Monash University) and eight industry partners (BlueScope, InfraBuild, Liberty Primary Steel, ArcelorMittal, Australian Steel Institute, Weld Australia and Australian Industry Group) to deliver innovative research designed to enable a significant technological shift in the steel supply chain.

To accomplish this goal, a new Steel Research Hub, which began in June

2020, brings together a network of preeminent academics, talented researchers and experienced leaders from across the steel manufacturing supply chain. Across four integrated research programs, the Hub is creating a multi-disciplinary team of 20 PostDoctoral Research Fellows and 31 PhD candidates, and numerous steel plant engineers and scientists, creating a more skillful and diverse workforce that will be critical in achieving this transformation.

Areas of research focus include integrating advanced enabling technologies in large and small businesses, developing step-change performance in anti-corrosion treatments and coating lines, generating more functional and durable products, and improving material resource intensities.

A STRATEGIC ASSET FOR AUSTRALIA’S NATION-BUILDING The Hub Director, Dr Paul Zulli is looking forward to the Steel Research Hub strengthening its collaboration with the Australian steel industry, through

(L to R): Hub Director Dr Paul Zulli, Chief Investigator Professor Lip Teh, Lecturer Dr Aziz Ahmed, Dr Refat Ahmed, and Lab Manager Cameron Neilson. Picture: Paul Jones.

delivering both new innovative research outcomes and training of a new generation of capable and influential researchers and technologists.

“A globally competitive domestic steel manufacturing industry is a strategic asset for Australia’s nation-building, economic growth and employment,” Dr Zulli said.

“The domestic industry must continue to provide a secure, flexible and high-quality local source of steel and products for infrastructure and construction, manufacturing, mining and agriculture. The research outcomes delivered over the coming five years will benefit the competitiveness and future growth of large and small steel-related businesses in Australia."

“In turn, these should positively affect key societal challenges, such as providing affordable housing and quality infrastructure, developing longer-lasting materials, recycling of resources, and training a more capable and diverse workforce,” said Dr Zulli

THE NEW STEEL RESEARCH HUB PROGRAMS Process Integration and Sustainability

New specific manufacturing processes and methodologies that significantly improve resource intensity and utilisation, and energy efficiency, while maintaining productivity, quality, and asset life objectives, including: • Integrated and efficient steel manufacturing • By-product utilisation and sustainability

HIGHLIGHTS FROM THE FIRST STEEL RESEARCH HUB Improved Abrasion Resistant Quench and Tempered Plate Steels

In collaboration with BlueScope and Bisalloy Steels, this project aimed to improve the performance of abrasion resistant quench and tempered (Q&T) plate steels for various applications including in the minerals and defence industries. It offered enhanced wear resistance over conventional metallurgical approaches but without the traditional useability trade-offs including reduced weldability, formability and toughness. In comparison, the conventional approach to increasing wear resistance in Q&T plate products is via raising the hardness of the martensitic phase by increasing the carbon content of the steel.

Liquid Metal Processing and Coating Quality

Continuous high-speed deposition of metallic alloy coatings, thinner than a human hair, on steel substrates is a challenging industrial process. This project generated new knowledge on the properties of liquid Al-Zn metallic alloy, providing a better understanding of how these properties vary with processing conditions, alloy composition and atmospheric exposure. New data helped identify a change to processing conditions that may improve the coating surface stability. Another highlight was the use of micro X-Ray fluorescence at the Australian Synchrotron, which helped elucidate the potentially important role of trace elements on the coating process and properties.

Development of Antimicrobial Coatings for Steel Surfaces

The aim of this project was to develop coating technologies that contribute to the defence of a coating against fungal attack, helping reduce the build-up of microbial organisms that may impact the product appearance, increasing

maintenance and replacement costs. The team was able to develop a family of surface-modified nanoparticles, that provided added biofouling resistant functionality to the material.

Trace Element Modelling and Optimisation of Byproduct Use in an Integrated Steelworks

This project aimed to deliver a reusefocused optimisation model that would allow BlueScope to assess its use of by-products, and reduce both the cost of raw materials, and further accumulation of by-products at its Port Kembla Steelworks. The model was fine-tuned based on plant trials, was flexible enough to be extended to various by-product reuse scenarios, and incorporated the key trace elements that limit reuse.

Effects of Retained BOS Slag on Refractory Wear

While there has been much work carried out on the effects of BOS slag composition on carbon-bonded magnesia refractories, there has been little that has dealt with the specifics of retained BOS slag practice on refractory wear. This project was aimed at providing a fundamental understanding of the effects of retained slag practice on furnace refractory wear. This was to inform the most effective strategy for BOS vessel operation with respect to balancing flux and slag composition targets with refractory wear and maintenance.

The importance of the work was in extending the life span of the BOS refractories, leading to a decrease in the cost per tonne of steel and a decrease in the amount of waste, thereby improving the economic and environmental sustainability of the steelmaking process.

Product Innovation and Technology

Novel approaches to nextgeneration product solutions incorporating improved functionality such as higher strength, ductility, durability, and material resilience, including: • Product durability and functionalisation • Structural steel and Cold Formed Steel (CFS) optimisation Advanced Corrosion Performance and Operational Efficiency

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT | STEEL AUSTRALIA | WINTER 2021

One of the projects undertaken during the first Steel Research Hub investigated the effects of retained BOS slag on refractory wear.

Step-change performance in anti-corrosion treatments, together with new processing capability and more productive coating manufacturing lines, including: • Corrosion performance and prediction • Coatings process effectiveness Steel Supply Chain Transformation

New applications of enabling technologies and advanced manufacturing to achieve a generational shift in capability across the entire Australian supply chain, including: • Enabling technologies integration • SME engagement and innovation

CLICK HERE FOR FURTHER INFORMATION ABOUT THE STEEL RESEARCH HUB AND ITS PROJECTS >>>

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PROTECTING & IMPROVING STEEL NEW GALVANIZERS DESIGN MANUAL THE GALVANIZERS ASSOCIATION OF AUSTRALIA (GAA) IS SET TO LAUNCH A NEW AND IMPROVED EDITION OF THE GALVANIZERS DESIGN MANUAL. FIRST PRODUCED IN 1965 AND AVAILABLE ON CD SINCE 2008, THE DESIGN MANUAL HAS UNDERGONE A MAJOR REVISION PROCESS TO BRING ITS CONTENTS IN LINE WITH TECHNICAL AND TECHNOLOGICAL INNOVATIONS, AS WELL AS CHANGES IN AUSTRALIAN STANDARDS. FOR INSTANCE, THE SECTIONS DEDICATED TO BOLTED STEEL STRUCTURES, PAINTING, SUSTAINABILITY AND DURABILITY HAVE ALL BEEN COMPLETELY OVERHAULED. IN ADDITION, THE MANUAL WILL BE AN ENTIRELY ONLINE, HIGHLY INTERACTIVE REFERENCE TOOL COMPLETE WITH ASSETS SUCH AS 3D MODELS AND EMBEDDED REFERENCES. THE TRADITIONAL DOWNLOADABLE PDF FORMAT WILL STILL BE AVAILABLE, COMPLETELY FREE OF CHARGE. GAA'S GALVANIZERS DESIGN MANUAL IS DESIGNED TO ASSIST DESIGNERS, SPECIFIERS, MATERIALS ENGINEERS, CONSULTANTS, AND FABRICATORS TO PROTECT AND IMPROVE THEIR STEEL PRODUCTS. ALL IMPORTANT ASPECTS OF THE GALVANIZING PROCESS AND THE PROPERTIES AND APPLICATIONS OF GALVANIZED COATINGS ARE COVERED. SECTIONS DETAIL THE DESIGN AND SPECIFICATION OF GALVANIZED PRODUCTS, FABRICATION METHODS INCLUDING BOLTING AND WELDING, GALVANIZED REBAR, AND THE PAINTING OF GALVANIZED STEEL SURFACES.

SUSTAINABILITY

One of zinc’s most exceptional qualities is its ability to protect steel from corrosion. Galvanizing protects steel by providing a physical barrier, as well as cathodic protection for the underlying steel, allowing the steel’s service life to be significantly extended.

GAA's updated Design Manual includes a new section dedicated to sustainability.

It provides information on the Environmental Product Declaration (EPD) for Galvanizers Association of Australia: Hot dip galvanizing in Australia, including how and why to use the EPD. According to Peter Golding (Chief Executive Officer, GAA), “Our EPD provides an independently verified representation of the environmental impact of the hot dip galvanized product going into your project. EPD data can be used to aid environmental assessment of building design and infrastructure projects, and to help obtain credits for Green Star and Infrastructure Sustainability rated projects across Australasia.”

“Attention to the durability of steel structures and components has important environmental, economic and social consequences. Some of these are less obvious than others. The overall economic cost of corrosion has been studied in several countries and is commonly estimated at around 4% of gross domestic product."

"By protecting steel from corrosion, galvanizing performs an invaluable service. It helps to save natural resources by significantly prolonging the life of steel and capital investments. The long-term durability provided by galvanizing is achieved at a relatively low environmental burden in terms of energy and other globally relevant impacts," said Golding.

DURABILITY

Three key Standards provide considerable information on the corrosion rate of steel and zinc under various conditions of atmospheric service: AS/NZS 2312.2 Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings Hot dip galvanizing; AS 4312 Atmospheric corrosivity zones in Australia; and SNZ TS 3404 Durability

requirements for steel structures and components.

Over the last few decades, the CSIRO, HERA and other industry organisations have carried out extensive mapping to establish the corrosivity of the Australian and New Zealand climate. Following on from this mapping, AS/NZS 2312.2 was updated in 2014 and is now the best source for the durability of galvanized coatings in Australian and New Zealand conditions. Likewise, AS 4312 is the best source of Australian data for corrosivity of steel in the local environment. The Design Manual now reflects both of these Australian Standards.

BOLTED STEEL STRUCTURES

The Galvanizers Design Manual provides an overview of the Australian Standards and industry best practice for bolted steel structures, structural fasteners and bolting techniques, design details, tightening procedures, inspection of fasteners and covers a range of selection of zinc coatings for bolts. It also provides additional notes about the influence of hot dip galvanized coating on design, particularly for slip factors, fatigue behaviour, bolt relaxation and torque and induced tension in tightening.

In recent years, there have been major revisions to the Australian Standards that cover bolted steel structures; AS/NZS 1252 High-strength steel fastener assemblies for structural engineering was revised in 2016. As a result, there have been follow-on updates to other related Standards such as AS/NZS 1214 Hot dip galvanized coatings on threaded fasteners to ensure consistency. The new version of the Design Manual takes all these Standard updates in account.

The Manual also includes a review of the recent European research on slip factors, showing the methods required to obtain an increased slip factor for galvanized steel structures.

Dr Peter Key (National Technical Development Manager, Australian Steel Institute) has led the development of updates to Standards before, most notably around AS/NZS 5131 for structural steelwork fabrication.

“From time to time, we revise national Standards, as we uncover new information, data or circumstances that

“In the case of AS/NZS 1252 High Strength Steel Bolts with associated nuts and washers for structural engineering, revision was necessary because most of the bolts are no longer made in Australia.

As companies are still demanding that quality needs to be shown as a forethought across various building sites, it was necessary to better define product conformance and how to assess it in the Standard,” added Key.

ABOUT THE GALVANIZERS ASSOCIATION OF AUSTRALIA

The Galvanizers Association of Australia (GAA) comprises the leading galvanizing companies throughout Australia, New Zealand and parts of Asia. An industry association established in 1963, GAA represents galvanizing companies and provides technical consulting services on a not-for-profit basis.

GAA’s objectives are to provide the highest standards in design and quality of galvanized products, and to assist consumers achieve the economics inherent in the correct design and application of galvanized products. GAA provides free technical publications and practical assistance on all aspects of design, application, process, bolting, welding and painting of galvanized steel.

CLICK HERE FOR FURTHER INFORMATION AND TO ACCESS THE GAA'S GALVANIZERS DESIGN MANUAL >>>

PAINTING OR DUPLEX COATING

The painting of hot dip galvanized steel is an orthodox and well-proven practice in outdoor environments, both in Australia and internationally. The practice is commonly called ‘duplex coating’.

"The section dedicated to painting in the Design Manual has been completely revamped," said Golding. "It is now quite expansive and covers the standard paint systems from every major paint supplier in Australia and New Zealand," said Golding.

"There are examples of early failures of duplex coatings due to incorrect specifications and poor practice.

The Design Manual aims to avoid such failures by directing specifiers and applicators to the paint systems, surface preparation and application practices that will provide a durable duplex coating in a broad range of service conditions."

FEATURE: TECHNOLOGY, RESEARCH & DEVELOPMENT | STEEL AUSTRALIA | WINTER 2021

require changes to the standard. It’s important to stay up-to-date and, with changes to a number of the Australian Standards that involve bolting, a guide like this one from Galvanizers Association can help keep you across the critical components,” said Key.

The louvered facade of the $66 million Arts West Redevelopment Project at the University of Melbourne involved ground-breaking use of steel and galvanizing. Image Credit: John Gollings.

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NEW ASI MEMBERS THE AUSTRALIAN STEEL INSTITUTE (ASI) WOULD LIKE TO WELCOME SEVERAL NEW MEMBERS WHO JOINED OVER THE LAST QUARTER. TO BECOME A MEMBER, SIMPLY VISIT: STEEL.ORG.AU/ABOUT-US/ MEMBERSHIP

ASSOCIATE MEMBERS JK Concrete Co T: 0447 238 833 E: admin@jkconcreteco.com.au W: jkconcreteco.com.au A: PO Box 875, Elanora Queensland Ron Mack Machinery T: 08 9445 0700 W: ronmack.com.au A: 8 Hector Street (west), Osborne Park Western Australia MANUFACTURER MEMBERS Reids Mechweld T: 08 9574 4420 E: steve.reid@reidsmechweld.com.au W: reidsmechweld.com.au A: Lot 111 Clarkson Street, Toodyay Western Australia

Fraser Lever T: 0432 223 937 E: info@fraser-lever.com.au W: fraserlever.com.au A: 973 Fairfield Road, Brisbane Queensland Graeme Moulston & Associates Engineering T: 07 5530 6214 E: info@gcma.com.au A: 2 Bimberi Row, Pacific Pines Queensland ICM (Integrated Construction Modelling) T: 08 8353 5321 E: gtanner@integratedcm.com.au W: integratedcm.com.au A: Unit 19, 22 Ware Street, Thebarton South Australia MWC Building T: 0427 492 000 E: admin@mwcbuilding.com.au W: facebook.com/MWCbuilding A: 20 Pelican Crescent, Nambucca Heads, New South Wales TGL Engineering Group T: 03 9774 2067 W: tigerli@tglengineering.com.au A: 58 Broadway, Bonbeach, Victoria Trident Detailing T: 0412 824 503 E: enquiry@tridentdetailing.com.au W: linkedin.com/company/tridentdetailing A: Level 2, 141-149 Ifould Street, Adelaide, South Australia

FABRICATOR MEMBERS Allcore Engineering T: 0436 400 598 W: allcoreengineering.com A: 5 Bellchambers Road, Edinburgh North, South Australia Bhullar Group T: 02 9647 2949 E: info@bhullargroup.com.au W: bhullargroup.com.au A: 5 Junction Street, Auburn New South Wales Clare Metal Fabricators T: 08 8842 2699 E: sales@claremetal.com.au W: claremetalfabrication.com.au A: 4 Archer Place, Clare, South Australia HVAC Australia T: 07 3280 8400 E: info@hvac.com.au W: hvac.com.au A: 50 River Road, Redbank Queensland Icon Metal T: 02 9637 2102 E: admin@iconmetal.com W: iconmetal.com A: 81 Egerton Street, Silverwater New South Wales Universal Welding Services T: 07 3208 8034 E: paul@universalwelding.com.au W: universalwelding.com.au A: 13 Rowland Street, Slacks Creek Queensland

PROFESSIONAL MEMBERS DEFAUS T: 0477 700 246 E: info@defaus.com.au W: defaus.com.au A: Level 1, 57 Berwick Street, Fortitude Valley, Queensland Design and Analysis T: 08 6118 4550 E: info@design-analysis.com.au W: design-analysis.com.au A: Level 2, 5 Ord Street, West Perth Western Australia DVT Consulting Engineers T: 0427 445 804 A: 13 Roundhouse Parade, Jindalee Western Australia

ARE YOU TAKING ADVANTAGE OF YOUR ASI 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 our Convention 3. Regular industry news, as well as steel Australia magazine and Steel Construction journal 4. For corporate members, promotion in the online ASI Directory and use of the ASI logo 5. Member discounts on ASI publications and eLearning courses 6. Superior technical advisory services, delivered by 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 like-minded companies and people CLICK HERE TO LEARN MORE ABOUT THE BENEFITS OF ASI MEMBERSHIP AND JOIN THE ASI TODAY >>>

Motoring Package THE AUSTRALIAN STEEL INSTITUTE IS PROUD TO ANNOUNCE ITS BRAND NEW EXCLUSIVE MEMBER OFFERS PROGRAM. TO KICK OFF THE LAUNCH OF THE PROGRAM, WE HAVE CREATED A 'MOTORING PACKAGE'. WHETHER YOU'RE LOOKING TO PURCHASE A LUXURY LEXUS, FILL UP YOUR TANK OR BOOK IN A SERVICE THROUGH MOTORPASS, OR HIRE A EUROPCAR VEHICLE, THE ASI's 'MOTORING PACKAGE' HAS GOT YOUR COVERED. WE'RE LOOKING FORWARD TO ANNOUNCING THE EXPANSION OF THE EXCLUSIVE MEMBER OFFERS PROGRAM OVER THE COMING MONTHS.

INSIDE THE ASI | STEEL AUSTRALIA | WINTER 2021

Exclusive ASI Member Offers

THE LEXUS CORPORATE PROGRAMME The Lexus culture is based on one simple phrase, 'Experience Amazing'. This is a promise that extends far beyond the experience of driving a superior vehicle—it’s encapsulated in every element of ownership.

The Lexus Corporate Programme delivers on this promise, offering luxury and performance combined with unique privileges, experiences and membership rewards. Eligible members can receive great benefits, including preferential corporate pricing.

WEX MOTORPASS Whether you’re a sole trader, small business or multinational organisation, WEX Motorpass offers exceptional benefits. One of the most widely accepted company fuel cards on the market, WEX Motorpass can be used for fuel, vehicle-related services, roadside assist, and a host of discounts with industry partners.

A convenient, cashless solution for fuel and vehicle management, WEX Motorpass offers benefits both on and off the road, anywhere you are.

EUROPCAR PRIVILEGE CLUB Europcar's Privilege Club is recognised in over 140 countries worldwide. With four levels of membership, the key benefits include: priority service (skip the queue), precompleted rental agreements, dedicated pickup points at airports with reduced waiting time, and complimentary vehicle upgrades (conditions apply).

You can also enjoy coupons and rewards from Europcar's partners, and add your Velocity Frequent Flyer Number to earn extra points.

For further information, or to join the ASI, email membership@steel.org.au or visit www.steel.org.au

51

SUPERIOR MACHINERY STRATEGIES

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The Compact Steel Beam Assembly Machine is suited to volumes from 1500 ton/year to 7000 ton/year fully fabricated and 21,000 ton/year for assembly only. Within its range of operations, the SBA creates an opportunity to reduce man-hours per ton from your workshop. The added confidence of flexibility and availability reduces the cost of sale and increases productivity.

Receive our FREE time studies, brochures and software demonstration by signing up to the link provided below: LEARN MORE ABOUT ZEMAN COMPACT

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The KF series is constructed for full processing of specific steel and system construction components such as top plates, base plates, gusset plates, ribs, and flanges to name a few.

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REDUCE YOUR RUNNING COSTS TO HALF WITH HAEUSLER'S NEW TECHNOLOGY: EVO PLATE BENDING MACHINE The future of bending begins now. The EVO is the only 4-roll plate bender with VSA technology - allowing bending of thicker plates and smaller diameters. For our clients, it means that they are now in a position to get a machine with up to 85% more bending moment compared to conventional bending machines.

All EVO machines are already extremely well equipped as standard. Even in their basic configuration, they are far superior to all other machines on the market.

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INCREASE YOUR PRODUCTIVITY & SAVE 30% TO 40% OF YOUR WORKING TIME WITH STIERLI-BIEGER'S BEAM ROTATORS The Stierli rotator was developed to turn heavy and large loads like beams and welded structures quickly and safely without a crane. This allows you to

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The turning device is not only used for beam welding but other sections can also be turned with it, e.g. the use as a pipe turning device. Loading is impressively simple with the overhead crane or by pushing the rotator to the sides.

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CONTACT SPECIALIST MACHINERY SALES TODAY TO DISCUSS A SUPERIOR MACHINERY STRATEGY FOR YOUR BUSINESS. 1300 262 123 / +61 8 6500 6880

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