Australian Welding December 2021 by Weld Australia

AUSTRALIAN

WELDING

Mental Fitness in the Festive Season Page 18

2021: A Year In Review Page 24

Q4 | December 2021 Official Journal of Weld Australia weldaustralia.com.au

Q4 | December 2021

INTRODUCING LORCH COBOT WELDING TO AUSTRALIA. MAKE YOUR TEAM STRONGER. Enhance your business with collaborative, industry 4.0 welding solutions. Quick set-up, easy to use, perfect repeatable results. Ideal solution for small to medium businesses.

Want to know more? Please contact David Wilton: LSP@lorch.eu or visit www.lorch.com.au to find your nearest LORCH COBOT partner.

4533 LorchCobot AustWeld 12.21

Australian Welding

December 2021 Contents A Message From Weld Australia’s President A Message From Weld Australia’s CEO Inside the Industry Introducing Lorch Cobot Welding to Australia and New Zealand Breaking News Health & Safety: Drugs & Alcohol at Work Business Essentials: Tips for Implementing Organisational Change Tips to Preserve Your Mental Fitness During the Festive Season Women in Welding: Jasmine Willoughby, Aus Ships Apprenticeship Eight Ways to Improve Welding Productivity Using a Weld Camera

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08 10 14 16 18 20 22

2021 Year in Review An Overview of 2021 24 Weld Australia’s Advocacy in 2021 26 A Focus on Mental Fitness in 2021 30 Workshops, Seminars & Events in 2021 32 Premier Welder Training 34 Advanced Welder Training Centres 36 Company Certifications 38 Weld Australia’s Technology Networks 42 Updates to Australian Standards 44 2021: What Weld Australia Members & Partners Have to Say 46 Fusion Welding Courses 51

Weld Australia Contacts National Office PO Box 197 Macquarie Park BC NSW 1670 02 8748 0100 office@weldaustralia.com.au

Training Guy Brooks Training Manager 0488 743 322 g.brooks@weldaustralia.com.au

Chief Executive Officer Geoff Crittenden 02 8748 0100 g.crittenden@weldaustralia.com.au

Marketing Disha Mistry Graduate Marketing Assistant 0497 497 424 d.mistry@weldaustralia.com.au

Engineering Victor Blain Engineering Team Manager 0409 823 991 v.blain@weldaustralia.com.au

Membership Eva Chun Membership Manager 0417 878 104 e.chun@weldaustralia.com.au

Qualification & Certification Arya Sharifian Qualification and Certification Team Manager 0419 414 901 a.sharifian@weldaustralia.com.au Subscription to Australian Welding is a Weld Australia member benefit included in annual membership fees. All rights reserved. No part of this publication may be reproduced or copied in any form without the written permission of Weld Australia. Weld Australia and its agents are not responsible for statements or opinions expressed by contributors in this publication, which are not necessarily those of Weld Australia. Publication of any advertisement does not constitute endorsement by Weld Australia of any product, nor warrant its suitability.

Q4 | December 2021

A Message from Weld Australia’s President: David Lake As 2021 draws to a close, I thought it pertinent to reflect on Weld Australia’s key achievements this year. At all times, the Weld Australia team focused on providing the resources and services that members needed most. Our primary goal is to ensure that the Australian welding industry remains locally and globally competitive, both now and into the future.

Advocacy In all our advocacy activities, our over-reaching vision is to facilitate the growth of a world class welding industry. With the COVID-19 pandemic continuing to cause a range of issues, Weld Australia’s advocacy agenda focused on training initiatives for the next generation of welders and fabricators, building a sustainable and productive local industry, and ensuring superior welding quality standards and public safety. This activity generated significant media coverage. Member Events and Services We launched a brand new website this year: weldaustralia.com.au. Designed specifically with members in mind, the new website is easier to use and navigate, ensuring that tasks like enrolling in training and registering for an event are quick and easy. We also launched three exciting new features in our Member Portal: a Resource Centre, Member Directory and Job Board. With face-to-face events impossible in the wake of the COVID-19 pandemic, Weld Australia held over 15 virtual events in 2021, from seminars and webinars, through to mental fitness workshops. Attended by over 500 people, these events ensured that members still had the opportunity to discuss the current climate, as well as changes and challenges to the industry. Training and Skills Development We continued to deliver superior quality training services to industry, launching three new online courses this year, including AS 2214 and AS 1796 Certificate 10. The course was extremely popular, and sold out in record time, so two additional intakes were facilitated throughout the year. Commencing in October, Weld Australia’s brand new Welding Fundamentals course provides technical personnel working with the metal and manufacturing industry an overview and understanding of welding

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Image: David Lake (President, Weld Australia).

processes, weld defects, testing and welder qualification as required by various Australian and international Standards. Weld Australia made great progress with the national Metals and Engineering online learning resources project in 2021. Weld Australia is working with TAFEs across the country through the National TAFE Consortium to create a suite of learning resources that will ensure consistent training, regardless of where in the country students undertake that training. The new resources are completely online and accessible via phone, mobile device or computer. In partnership with Workskil Australia and TAFE SA, Weld Australia delivered an innovative new training program in June 2021 for a group of longterm unemployed people. With little to no prior welding experience, the students started by using

augmented reality welding simulators to learn the skills and techniques needed to perform welds in a safe, stimulating and confidence-building environment. Students then moved onto real-world welding machines to hone their skills. As a result, nine students passed all tests required to qualify to AS/NZS ISO 9606 Qualification testing of welders — Fusion welding for MIG welding. Finally, the pilot of our Advanced Manufacturing School Outreach Program in New South Wales proved highly successful. It was rolled out across 16 schools. Augmented reality simulators were used to teach welding to students in Years 10-12 studying Manufacturing and Engineering, and Industrial Technology. This engaging, exciting learning technology provides a very safe and efficient way to teach students skills in a profession where there is high demand. Based on the success of the pilot program, the NSW Department of Education has ordered a further 20 simulators for another 10 high schools in regional areas. Qualification and Certification Our qualification and certification services proved popular in 2021, with 17 companies certified to AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials; EN 15085 Railway applications – Welding of railway vehicles; or DIN 2303 Welding and allied processes – Quality requirements to be met by production and maintenance companies for military products. In addition, 64 welders were qualified according to ISO 9606-1 Qualification testing of welders — Fusion welding. The Australian Welder Certification Register (AWCR) and WeldQ platform also continued to grow. Over 600 users registered on WeldQ this year, taking the total number of users up to 10,900. Season’s Greetings I would like to take this opportunity to thank the Weld Australia’s Directors for not only volunteering their time throughout 2021, but for their true commitment and hard work. On behalf of the entire Board, I would also like to thank Geoff Crittenden, our CEO, and his team for all their dedication and work throughout the year. Lastly, I would like to thank all of our members for their ongoing support, particularly all those members who regularly contribute to our success, such as the hard-working members of our local committees. The Weld Australia community is only as strong as its members.

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Q4 | December 2021

A Message from Weld Australia’s CEO: Geoff Crittenden As 2021 draws to a close, it is the perfect time to plan for the year ahead. As always, Weld Australia’s activities in 2022 will be guided by our vision and mission; our primary goal is to ensure that the Australian welding industry remains locally and globally competitive, both now and into the future. In 2022, Weld Australia will focus on several areas of social responsibility, including environmental sustainability, health and safety, and upskilling disadvantaged members of the community. We will also continue to implement our robust advocacy program, and deliver superior quality training, services and events to our members.

Advocacy As the peak body for welding in Australia, Weld Australia facilitates the growth of world class welding in Australia. In all our advocacy activities, our team promotes and campaigns for enhanced practices and greater opportunities for welders. In 2022, we will continue to work with all levels of government to revitalise the Australian manufacturing industry. We need a commitment from State and Federal Governments to increase levels of local content in all procurement decisions. We need the big corporates to award local contracts to local companies. The strength of the sovereign capability of Australia depends on Australians investing in Australia. It might be cheaper in the short-term to buy from Thailand, China, or South Korea, but all this does is weaken our economy. We need to invest in our economy. We need to bring home the manufacture of goods such as rail infrastructure and solar power equipment. To secure the future of Australian manufacturing and welding, we need determined action from our governments, industry leaders, and the general public to put Australia first. We need Australians to buy Australian. Environmental Sustainability A new focus area for Weld Australia in 2022 will be environmental sustainability. With COP26—the United Nations climate change conference—taking place in November, reducing emissions and limiting global warming is at the top of the agenda. To kick off our new program, Weld Australia plans to

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Image: Geoff Crittenden (CEO, Weld Australia).

conduct an industry benchmarking activity, soliciting information from members around factors such as the use of rooftop solar, carbon offsetting, electric vehicles and more. The results of our benchmarking activity will inform our planning and activities in this important area. Adapting environmentally sustainable business practices offers a range of benefits to Weld Australia members. For instance, installing solar panels and battery storage not only reduces your carbon footprint, but your energy costs—an ever-increasing overhead for any welding workshop. Health and Safety Welding is a safe occupation when proper precautions are taken. But if safety measures are ignored, welders and members of the general public face a range of hazards. In an Australian context, overall adherence to safety regulations and relevant Australian Standards is sufficient, but there are also some significant gaps in the compliance framework that have long-term safety implications. Next year, Weld Australia will undertake research and implement education and awareness programs, particularly related to fumes and electrical shocks. The Welding Safety Council has already made great progress in this area; in 2022 we will build on that progress. Upskilling Disadvantaged Members of the Community Australia is facing a lack of skilled welders. In fact, the Australian Government has projected that, to 2024, the number of job openings for structural steel and welding trades will be above average.

In some states, advertised vacancies have shown substantial increases over the last few years; Queensland has seen welding trades workers vacancies increase by 87%, Western Australia saw vacancies increase by 80%, and Victoria saw an increase of 18%. And yet, the number of welding trade workers in Australia dropped by 8% in the course of just five years; from 75,800 in 2014 to 69,600 in 2019. In addition, completion rates of welding apprenticeships, including a Certificate III in Engineering (Fabrication Trade), continue to fall by as much as 23% annually. Given this situation, innovative programs that create long-term solutions to the skills shortage are essential. In 2022, Weld Australia will continue to implement such programs, including Indigenous Welding Australia—a partnership of Weld Australia, the Indigenous Defence and Infrastructure Consortium and IPS Management Consultants. Indigenous Welding Australia was formed in 2018 to establish a national network of Indigenous Welding Academies focused on delivering welding training backed by specialist pastoral care: ‘For Indigenous people by Indigenous people’. Graduates of the program will be placed in employment with defence primes or local industry through our Indigenous partners. Our principle industry partner is BAE. Unfortunately, this program has been delayed due to the well-documented issues with defence procurement and execution. I have also been extremely disappointed with the attitude of State and Federal Governments, and their complete lack of support. Next year, we will continue to advocate for this important program. In partnership with Workskil Australia and TAFE SA, Weld Australia delivered an innovative new training program in June 2021 for a group of

long-term unemployed people. With little to no prior welding experience, the students started by using augmented reality welding simulators, and then moved onto real-world welding machines to hone their skills. If they passed the relevant tests, students qualified to AS/NZS ISO 9606 for MIG welding—a welding ticket can help individuals gain employment. In 2022, we plan to facilitate more of these types of highly successful programs. Welder Training Working in collaboration with the National TAFE Consortium, Weld Australia has made great progress with the development of nationally consistent online learning resources for the Metals and Engineering (MEM 2.0) training package. In a very important step for the entire industry, these learning resources will be launched in early 2022. This will help ensure consistent training, regardless of where in the country students undertake that training. We expect that these resources will not only be adopted by TAFEs, but by industry; we have already been in discussion with BHP regarding their use of the resources. Thank You and Warm Wishes I would like to take this opportunity to thank all those members who have contributed to Weld Australia this year. In particular, my thanks go to the hardworking members of all our local committees. I would also like to thank the Weld Australia Directors who commit a significant proportion of their free time to Board matters. I thank them for their advice throughout 2021. Finally, I would like to thank the entire Weld Australia team for their hard work, enthusiasm and dedication. I wish everyone a safe and happy festive season and a prosperous new year.

Season’s Greetings &

Happy Holidays from Weld Australia

On behalf of everyone at Weld Australia, we would like to thank our members and clients for their continued support throughout 2021, and to extend our warmest wishes for the holiday season. Our National Office will be closed over Christmas and the New Year, from Thursday 23 December 2021 to Tuesday 4 January 2022.

Q4 | December 2021

Introducing Lorch Cobot Welding to Australia and New Zealand Lorch Schweißtechnik GmbH (Lorch), is a leader in the design, development and application of advanced welding technologies. Based in Stuttgart, Germany, they are at the cutting edge of Industry 4.0, developing smarter solutions for tomorrow’s industrial challenges.

It is a well-known fact that the welding industry has a global shortage of welders. In Australia and New Zealand, we know this only too well. Top welders are in very high demand and command substantial annual salaries. Many experienced qualified welders are now over 45 and Millennials or Gen Z aren’t queueing up to enter the industry in sufficient numbers to even replace the aging welders of today. The harsh reality is that it is not going to get any better. Significant demand is building for qualified welding operators in the mining, defence and manufacturing sectors.

Australian Welding

Competition for the limited welding resources is intense and requires premium rates to be paid to attract and retain the best available talent. Small to medium manufacturing businesses can’t compete in this environment with many struggling to find and retain key welding personnel. Add to this, constant cost pressures and rapidly advancing technologies. This is a perfect storm building. Today with the advent of new Cobot (Collaborative Robot) technology the game has changed. Lorch has had a dedicated team in place developing and optimising welding with Cobots now for many years

providing cutting edge, new solutions for companies facing these issues. It’s important to note Cobot welding is not a replacement for industrial robotic welding. (Refer picture 1). Lorch Cobot welding is a new technology segment that is different from industrial robots in many areas: • Size, weight and portability: Cobots are small, light and relatively portable. They are designed to be used in the general work environment, in close proximity with people. • Safety: Cobots operate at human speed, have unique integrated safety features enabling close interaction with people with minimal or in some cases no dedicated safety guards or external protection. • Intelligent Lorch Cobotronic software: creates a simple to operate welding system that is typically programed by the welder or shop floor operator. • Lorch advanced Speed Processes: deliver perfect welding in all positions removing the need for complex and expensive jigs and fixtures. • Fast setup and simple programming: enable much smaller production quantities to be cost effectively welded. • Capital investment: Cobot systems are typically more cost effective with a quick return of investment. By comparison an industrial robot is designed for high production quantities, needs a highly trained robot technician to program, is not portable, requires extensive safety guards and barriers and typically has expensive jigs and fixtures. Lorch has developed a strong partnership

with Universal Robots (UR), the global leader in collaborative robot technology. What differentiates Lorch from any other manufacturer is their intelligent Cobotronic software and the advanced technology welding power source. Lorch takes the Cobot and creates a purpose built, fully integrated, ultrasafe, automated welding solution. Every detail is meticulously optimised specifically for multiple forms of welding. The end result is a fast, efficient and flexible, leading industry 4.0 welding solution that is ideal for small to medium businesses producing smaller production quantities. Systems are simple to use and deliver dependable productivity and consistent premium quality welding performance. Cobots are new tools, helping to address the ongoing shortage of welders, closing the skills gap and Making the Team Stronger, driving productivity, efficiencies and reducing costs. Cobot welding is growing at an exponential rate across Europe. Lorch Cobot Welding is now coming to Australia and New Zealand. Sales demonstration and application and training centres have been setup across the region with accredited Lorch Cobot Partners. Partners can be found at lorch.com. au – find a partner near you. Additionally, we have well trained Lorch certified service infrastructure already established across the region for backup and support. Further Information Want to know more? Please contact David Wilton: LSP@lorch.eu or visit lorch.com.au to find your nearest partner.

Q4 | December 2021

Breaking News Alstom to Provide X’trapolis Trains for Melbourne’s Rail Network Alstom recently signed a $986 million contract with Victoria’s Department of Transport (DoT) to locally supply 25 six-car X’trapolis trains for Melbourne’s suburban rail network. The contract follows an extensive two-year interactive design process with the DoT to design and engineer a rolling stock solution specifically compatible with Melbourne’s unique existing rail infrastructure. This new generation of X’trapolis trains will deliver a much-needed network capacity increase without the need for major, costly infrastructure and power supply upgrades. The new trains will be more accessible, reliable and energy efficient. Built in Victoria, the commitment to deliver the trains with at least 60% local content will provide a vital boost to the state’s advanced rolling stock manufacturing industry, securing the future of Alstom’s Ballarat manufacturing facility, and creating a substantial amount of welding work across Victoria. It will pave the way for new, long-term employment opportunities in the rail industry. Alstom’s Managing Director, Australia and New Zealand, Mark Coxon said, “Alstom is delighted to continue its long-term partnership with the Victorian Government and the local supply chain that will ensure we continue to build trains for Victoria, in Victoria. Following the successful delivery of Melbourne’s most reliable trains from our facility in Ballarat over the past 20 years, we look forward to working with the State and all of our local partners to deliver the next generation of X’trapolis trains, creating a new icon for railway passengers across Melbourne and the State of Victoria.”

Image: Alstom will supply 25 X’trapolis trains to Melbourne.

Australian Welding

Australian Cobotics Centre Officially Opened The Australian Cobotics Centre is officially in operation. The Centre is funded for five years as part of the Australian Research Council’s Industrial Transformation Research Program scheme and is focused on collaborative robotics in advanced manufacturing. Centre Director, Professor Jonathan Roberts, leads a multidisciplinary team of researchers from Queensland University of Technology (where the Centre is headquartered), University of Technology Sydney (UTS) and Swinburne University of Technology. These universities will work in collaboration with industry partners, including Weld Australia, B&R Enclosures, Cook Medical, InfraBuild, IR4, TU Dortmund University, and the ARM Hub. The Centre aims to improve the collaborative robotics capability within Australian manufacturing by training the next generation of manufacturing leaders, researchers, and technicians with collaborative robotics expertise. Through its research and its implementation, the Centre will support manufacturers in creating a digitallycapable workforce of the future and a safer, more efficient and globally competitive Australian manufacturing industry. According to Centre Director, Professor Jonathan Roberts, “The Centre has been established to help the manufacturing industry become more competitive globally by solving some of the problems associated with adopting collaborative robots – which we sometimes call cobots. These are robots that can work closely with people and typically in situations where they can help people avoid dangerous or repetitive actions.”

Image: The Australian Cobotics Centre is in operation.

VET Reforms Designed to Drive a Skills-Led Economic Future A fundamental overhaul of Australia’s vocational education and training (VET) system has been agreed to by the Federal, State and Territory Governments. The reforms are designed to improve the performance, efficiency, transparency and confidence in the VET sector, ensuring Australians can access high quality, relevant training and employers can access skilled workers.

Victoria Leads the Nation for Female Tradies Women in Victoria are leading the nation to get on the tools, with nearly 40,000 females employed in the building and construction industry. Master Builders Victoria analysis of ABS Labour Force figures show 39,217 Victorian women were employed in building and construction in August 2021. The next highest states were New South Wales with 38,101, and Queensland with 31,670.

The new ‘Industry Clusters’ model will replace the existing 67 Industry Reference Committees and six Skills Service Organisations. The new model is expected to be fully operational by 1 January 2023. The reforms should help ensure courses and qualifications in the sector are driven by and better meet the needs of industry, as well as students.

Nearly 1,800 women in Victoria joined the building and construction industry in the 12 months to August 2021. In Victoria, women made up 12.4% of all employees (323,791) in the building and construction industry in August 2021. However, women made up just 2.5% (2,861) of all construction trades workers in Victoria (112,957). Victoria was still higher than Queensland (1,134) and New South Wales (534) for female construction trades workers.

Training package approval processes will also change, with an independent assurance function to replace the Australian Industry and Skills Committee by 1 January 2023. The Federal Government is investing $292.5 million over the next four years to support the reforms.

With the Victorian Minister for Training and Skills, the Hon Gayle Tierney MP, recently launching the first 10 initiatives under the $5 million Women in Apprentices fund, it is hoped female participation will increase. The Women in Apprentices fund will support 615 women into traineeships and apprenticeships.

Q4 | December 2021

Breaking News Austal Australia Delivers 13th Guardian Class Patrol Boat Austal Australia recently delivered the 13th Guardian class Patrol Boat to the Australian Department of Defence. The vessel, NUSHIP Francis Agwi, was then gifted by the Australian Government to the Papua New Guinea Defence Force at a certificate signing ceremony held at Austal’s shipyard in Henderson, Western Australia. The vessel is the third of four Guardian Class Patrol Boats to be delivered to Papua New Guinea under the Pacific Patrol Boat Replacement Project (SEA3036-1), part of the Australian Government’s Pacific Maritime Security Program. Faster, with improved seakeeping, better amenities and an enhanced mission capability – including an integrated RHIB stern launch and recovery system – the Guardian class Patrol Boats provide the Papua New Guinea Defence Force with a much-improved naval asset to carry out border patrols, regional policing, search and rescue, and many other operations domestically and internationally. The Pacific Patrol Boat Replacement Project was awarded to Austal Australia in May 2016, with an additional contract option awarded in April 2018, taking the program to 21 vessels, valued at more than $335 million. The 39.5m steel monohull patrol boat – designed, constructed and sustained by Austal Australia – is based on a proven design platform that has included the 38m Bay Class, 56m Armidale Class and 58m Cape Class patrol boats that are in service with the Australian Border Force and Royal Australian Navy.

Image: The NUSHIP Francis Agwi.

Australian Welding

Bisalloy Steels Kicks Off Steel Hub II Bisalloy Steels has announced the start of a project with the University of Wollongong’s Steel Research Hub. The Project is focused on the additive manufacturing of welded overlay and will investigate and trial automated and robotic wire arc additive manufacturing to fabricate welded hard-facing overlay on quenched and tempered (Q&T) steels. Hard-facing is a process where one or multiple layers of different materials with unique properties are deposited on the base metal to significantly improve its surface performance, such as wear and corrosion resistance, or to repair the worn components. In industrial sectors, equipment is routinely subjected to extreme working conditions such as severe wear, impact, and high temperature, which requires component materials with enhanced performance. However, it is not efficient to manufacture the entire component with more costly materials. Hard-facing enables a superior priceperformance manufacturing process by depositing hard-facing consumable materials on surfaces or in critical positions of the less expensive base material. Through experimental design and trials, Project (2.1.6) will develop an optimised methodology for high hardness (wear) and toughness (impact, blast) of welded overlay which has significantly improved performance. It will then focus on the development of an automated hard-facing solution for which a robot operator can easily program and which does not require a high level of welding skill and knowledge. For steel consumers, the benefit is a product with improved performance while also having the potential to reduce maintenance, repair, and operational costs via prolonged service life.

WorldSkills Australia National Championships Crowns A Winner After not one but two postponements in both 2020 and 2021, The WorldSkills Australia National Championships were finally held at the Perth Convention Exhibition Centre in late August. Satellite events were also held virtually and in Queensland, South Australia, New South Wales and the ACT throughout August and October.

Close to 10,000 viewers watched the Nationals live, as 239 young people competed across 55 different skill categories. Despite lockdown restrictions, there were also some Victorian competitors who were able to participate in their skills virtually. Competitors were vying for the chance to join Team Australian as a Skillaroo. The Skillaroos will head to Shanghai, China in October 2022 to compete at the 46th WorldSkills International Competition.

• •

The National Championships were supported by 211 volunteers, including judges, site crew, skill managers, CIS assessment advisors and team leaders. The judges were made up of 30% past competitors with 50% from Industry and 50% from registered training organisations (RTOs) – they were impressed by each competitor’s skills and spirit, especially given the delays, additional training as part of the Training Program and lead time it took to make it to Nationals.

The virtual award ceremony took place on 27 October. Weld Australia would like to congratulate the winners of the WorldSkills Australia National Welding Championships: • Gold: Brody Stallard, Western Australia • Silver: Brody Johnston,Western Australia • Bronze: Timothy Blackwell,New South Wales

Weld Australia’s Training Manager, Guy Brooks, was the Deputy Chief Judge for the Welding Championships. Guy was joined by Chief Judge Mark Williams to oversee the NSW WorldSkills welding competition on 23 and 24 October. Over the course of two days, all welding competitors were required to: • Weld MMAW and GMAW butt and fillet welds in various positions, assessed to AS 1796 • Weld a pressure vessel using MMAW, GMAW, FCAW and GTAW

Image (L to R): Mark Williams (Chief Judge), Timothy Blackwell (Competitor), Guy Brooks (Deputy Chief Judge).

Weld aluminium and stainless steel using GTAW Produce all types of weld joints, fillets, butts and corners, in all positions with full penetration and no internal defects

All of the test pieces welded during the event in Perth were couriered over to Sydney so that Guy and Mark could judge all the competitors together for consistency and continuity.

About WorldSkills WorldSkills Australia is one of over 60 WorldSkills International member countries. Every two years, participating members converge at the world’s largest skills competition – the WorldSkills International Competition. Competitors must advance from the regional to the national level to prove their commitment and skills in their chosen field and to secure a place in the Skillaroos team; the International Competition is the ultimate test. Members of the Skillaroos team become ambassadors for their skill, local region, state and country. For more information, visit: worldskills.org.au

Image: Timothy Blackwell (Competitor).

Q4 | December 2021

Health & Safety Drugs and Alcohol at Work Welding is a safe occupation when sufficient hazard reduction is applied. However, alcohol and drugs can affect a person’s ability to work safely. Drug, alcohol and other substance misuse is everyone’s responsibility. A Workplace Drug and Alcohol Policy can assist in outlining the expectations and responsibilities of employers and employees to maintain a safe work environment for all. Health and safety is a year round responsibility across the welding and fabrication sector. However, the emergence from lockdowns and the start of the festive season offer a timely reminder of the importance of hazard reduction surrounding drug and alcohol use in the workforce. The misuse of alcohol or drugs can cause serious problems in any workspace. However, it is particularly dangerous in the presence of high powered machinery, gas flames, electric arcs, and lasers. Welding and fabrication require a strong mental acuity to ensure maximum accuracy and prevent hazardous mishaps. The presence of alcohol or drugs in the system can adversely impact an individual’s co-ordination, motor control, alertness and ability to exercise judgement. This drop in performance can lead to serious workplace consequences, including accidents, injuries or damage to equipment, reduced productivity, strain on workplace relationships and disciplinary or conduct problems. In fact, alcohol and drugs cost Australian workplaces an estimated $6 billion per year in lost productivity. It is important for organisations to employ a proactive approach to managing and reducing the risks associated with alcohol and drug use in the workplace. Workplaces are encouraged to cultivate a healthy attitude towards responsible alcohol consumption and drug use hazards that extend beyond the workplace. Employer Responsibilities Occupational health and safety is the shared duty of every member of the workplace. But at the end of the day, the ultimate responsibility for providing a safe workplace lies with the employer. According to the Occupational Health and Safety (OHS) Act, the employer has a legal duty to provide and maintain a safe and healthy work environment. It is the role

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of the employer to manage the hazards associated with drugs and alcohol in the workplace, provide education around responsible consumption, and identify and respond to potential instances of misuse. Managing the Hazards The most effective way for an employer to manage the hazards associated with workplace drug and alcohol use is to implement a company-wide drug and alcohol policy. An effective policy should apply to all members of the workforce and include prevention, education, counselling and rehabilitation procedures. It’s important to ensure the policy is developed collaboratively and is customised to your business circumstances. Involving both management and employees in the process is crucial to delivering an outcome that is consistent and fair to all employees. Some key points for employers to consider when identifying drug and alcohol hazards include: • Does your workplace culture promote a responsible approach to alcohol or drug consumption? • Do you consider responsible provision of alcohol, including food and non-alcoholic drinks at work events? • Do you broadcast safe consumption of alcohol messages and the use of support services? • Do you have support services in place for at-risk individuals experiencing personal life stressors? Identify and Respond to Signs of Misuse Hazard reduction remains a crucial step to proactive risk management, but it’s equally important to keep abreast of what may already be occurring in the workplace. Employers should take care to recognise if drug and alcohol use is occurring on site, or if workers are arriving at work under the influence. Should you detect a case of misuse, it’s your duty to eliminate or reduce any related harm as far as is practicable. A strategic approach should

be employed when communicating with a worker suspected of being under the influence. Employee Responsibilities Employees under the influence of drugs or alcohol can pose a risk to not only themselves, but those around them. Under the OHS Act, employees are required to care for their own health and safety and ensure their actions don’t adversely affect that of others. In The Workplace The first and most important responsibility an employer has is to not be under the influence of alcohol or drugs, or use alcohol or illegal drugs while at work. Each worker has a duty of care to themselves to ensure they are fit and well enough to do their job. Drug and alcohol misuse to any degree can breach this duty of care. Complying with your company’s drug and alcohol policy is the simplest way to ensure you uphold your duty to yourself and those around you. One in 10 workers report being affected by a co-worker’s use of alcohol. It may be a reduced ability to carry out their own job, taking on extra workload to compensate, or involvement in an accident or close-call. If you suspect a colleague’s performance may be impaired by the influence of drugs or alcohol, it is critical to speak up. Employees can often

feel obliged to cover unsafe work practices or avoid ‘dobbing in’ as a stance of loyalty to their workmate. However, it’s important to recognise early intervention as a key step to reducing potentially serious consequences in the future. A workplace’s drug and alcohol policy should outline a confidential reporting process for employees to report instances of misuse to management. Outside The Workplace Alcohol and other drug use, even when it occurs away from the workplace, becomes an occupational health and safety issue the moment it alters an employee’s ability to exercise judgment, coordination, motor control, concentration and alertness at work. You might not suspect a hangover would take a toll on your workplace performance, but in some cases, it can be just as dangerous as being intoxicated. The lingering presence of substances in your bloodstream runs the risk of slowing your reflexes and decreasing coordination. When paired with a high-risk environment alongside electrical equipment, it can lead to harmful or even fatal disasters. Although activities outside the workplace are a personal matter, it remains your responsibility to ensure that any drug or alcohol use outside of work hours does not hinder your ability to work safely once back on the job. For more information on workplace duty to drug and alcohol use, visit safeworkaustralia.gov.au

Prescription Medications Employees need to be aware of the side effects of any medication that they are prescribed and should discuss the risks associated with these potential side effects with their prescribing doctor and pharmacist. In addition to the obvious adverse performance affecting side effects of medication (such as drowsiness), some common medications can increase a person’s sensitivity to UV exposure—welders and people working near welding operations need to be aware of this. Technical Note 7 warns that: “Welders and those working nearby should be aware that the use of certain medications can increase the user’s sensitivity to UV exposure. Examples of common medications include (but are not limited to) antibiotics, antidepressants, acne medication, some cancer medications, diabetic medication, diuretic medication etc. Personnel exposed to arc welding taking any medication should review the end-user literature published by the manufacturer and/or discuss the potential photosensitisation effects of the medication with their doctor.”

Q4 | December 2021

Business Essentials: Tips for Implementing Organisational Change The New Year inspires change, and with it comes an opportunity to make some overdue adjustments to your organisation. Change is imperative to success; however, you don’t want to yank the rug out from beneath your team’s feet. Change needs to be managed in order to be successful. Weld Australia has outlined some key tips to successfully implement organisational change in the new year.

The business landscape is rapidly evolving. For instance, new technologies are continuously reshaping the way organisations and their customers operate and interact. These advancements provide opportunities for increased productivity, efficiency and connectivity.

Are You Making the Right Changes? It should be noted that change for the sake of change is rarely a productive goal. The direction of change you pursue should be informed by two key factors: your broader company objectives, and challenges identified in your current workflow.

Organisational change can see a business alter its culture, the underlying technologies or infrastructure it relies on, or its internal processes to produce a successful resolution. However, change can often be difficult to accept. In fact, an estimated 70% of change initiatives fail.

The majority of initiatives fail due to negative employee response. Combat this by involving your staff in the early stages of your management plan. Find out what isn’t working. Ask your staff to present areas in which they encounter challenges, and then pitch potential avenues for change.

This does not mean your ambitious plans are doomed from the outset. In most cases, failure results from negative employee attitudes towards the change and unproductive management responses. Implementing a managed approach to change is the key to seeing your organisation thrive under its new initiative.

Providing your employees with input into the process and insight into why the changes are being made allows them to realise why change is necessary. This can foster positive attitudes and support for the changes to come.

Why Implement Organisational Change? The key question is: why bother introducing a change if failure is the likely outcome?

Evidence will be your greatest ally in identifying and justifying areas that require adjustment – it’s difficult to argue with historic data and robust figures.

If the past 18 months have revealed anything, it’s that the economic landscape can shift in an instant. The COVID-19 pandemic bred a business environment in which many companies have found themselves forced to keep up or get left behind.

Whatever your change may be – an upgrade to tools and machinery, new policies and procedures for hazard reduction and risk management, or an office shake-up – ensure it’s aligned with your vision for the company. You don’t want to overhaul your business model only to discover you do not like the outcome.

Workplace processes, systems, and strategies must continuously change and evolve for an organisation to stay competitive. However, change should not merely be a reactive response. Proactive uptake of new opportunities can encourage innovation, develop employee skills, and result in greater business opportunities.

Communicating Changes Communication is one of the most crucial steps to successfully implementing organisational change. You could introduce the most groundbreaking program ever invented, but if you fail to communicate it effectively to your team, it’s unlikely to make it off the ground. The key is to formulate a

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communication strategy that coincides with the roll out of the campaign. When creating your strategy, ask yourself: • Who will be most impacted by the change? • How and when will the change be communicated to them? • Is there a channel for feedback? Even the most well-intentioned plans will be met with some resistance. Be prepared for this response. When it occurs, endeavour to understand the individual’s hesitation or motivation. Explore why the change is challenging for them and where their adverse reaction is stemming from. It could be a fear of job insecurity or perhaps insufficient training. With effective, two-way communication, many negative perceptions can be resolved. Equip Your Team to Manage the Change Once your team is aware of the impending change, follow it up with the reassurance that they will be equipped to handle it. Sufficient training is integral to the smooth uptake of change. It may take the form of online learning modules, designated training seminars, a certified course, or a blend of on-thejob coaching and mentoring. Safety is an extremely important consideration, particularly if your change introduces new hazards to the workplace. It’s the responsibility of the employer to ensure all employees receive adequate training and induction to equipment, programs and activities. Training should always be conducted before a new initiative is launched. It reduces apprehension and stress in employees and reduces friction when the change is rolled out. Depending on the scale and intricacy of your change, you might find a pilot group to be beneficial in acting as a trial run for the change.

You’ll find issues surface quickly, and it provides a contained environment in which to iron out any kinks. Remember: Change is Imperfect Change should not follow a set-and-forget methodology. Particularly in the early stages of your new initiative, feedback will shape a framework to continued improvement of your initiative. Employee focus groups and surveys are effective tools for gauging staff sentiment and identifying common roadblocks to success. Don’t be afraid to revise procedures or explore alternative products if you find your initial approach was unsuccessful. Accepting failure is fundamental to shaping a change that is practical, adaptable and effective. The underlying reason behind the organisation change is to promote business, therefore it’s imperative to check in on the business impact of the changes. Measure results pre and post-implementation to assess what results, if any, your change produced. Key questions to ask during the evaluation phase can include: • Did the change assist in achieving business goals? • What was the staff feedback? • What could have been done differently? • What have been the key hurdles to its success? And remember, the New Year isn’t the only season for change. The more dynamic your company, the better equipped it will be at tackling new challenges that arise and striving for innovation ahead of the curve. Change is inevitable and it is up to you whether your organisation chooses to embrace or combat the opportunity at its disposal.

Q4 | December 2021

Tips to Preserve Your Mental Fitness During the Festive Season The festive season is typically perceived as a time of joy and celebration, but it can also bring about certain stress and pressures. A busy social calendar, looming deadlines and various events can quickly become overwhelming. Amid the excitement of the holiday period, it’s important to take the time to care for your own mental health. Making small adjustments, setting boundaries and taking time out for yourself are simple practices that can help alleviate the burden of the holidays. We’ve put together some tips to remaining mentally fit for the festive season.

Exercise Welding is a physical and strenuous job that can demand long hours – particularly as the tools down period looms. Often the last thing on your mind at the end of a busy day is engaging in further physical activity. But when it comes to your mental fitness, a bit of movement can help kick those stress hormones to the curb.

or enclosed workspaces, taking the time to get outside can help clear your head and restore some mental balance.

Exercise and mental wellbeing are inextricably linked. In fact, just 30 minutes of joyful movement – beyond the workstation – can have lasting improvements on your mood. Daily exercise naturally stimulates chemicals that improve mood, produce stress-relieving hormones, and improve memory and mental acuity.

Set Healthy Boundaries There has never been a better time to claim the power of saying ‘no’, than during the holiday period. As the calendar flips into December, it seems like every work colleague, distant in-law, and high school friend has a Christmas BBQ in need of your attendance.

Get Outdoors If you find yourself cooped up in a confined area for the day, you may notice your mental fitness begin to slip. It’s common for overtime to arise in the mad dash to meet project deadlines ahead of the festive break. Workload increases, and the workdays become longer. Before you know it, you’re crawling into bed without having seen the light of day.

The pressure of other people’s expectations around the silly season can feel like an inescapable burden, particularly when faced with the guilt of saying ‘no’. This is likely to be further heightened this year, with much of the country having experienced extended COVID-19 lockdowns. Understand that saying no to some things is actually the kindest service you can do to both yourself and those around you. Spreading yourself too thin will quickly deplete your mental and physical wellbeing.

It may seem inconsequential, but a lack of sunlight and fresh air can pile onto your mental load. Particularly for welders who operate in factories

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Summer in Australia means longer daylight hours. Seize the opportunity to get up a fraction early and take a brief stroll, eat a meal outside, or organise some social catch-ups outdoors.

Setting personal boundaries can help filter what is,

reduce stress and induce a sense of calm and focus. Solo activities can include: • Engaging in hobbies you enjoy such as golf, sport or creative practices • Enjoying a movie or catching up on a TV show • Getting out on the bike, surfboard, or simply going for a walk • Meditation or mindful practices such as yoga or journaling • Reading a book or listening to music, free from distraction The reason alone time is so effective is that it allows your mental stores to recharge. It removes the pressures of pleasing others and social interaction. Free from distraction your brain can clear itself, focus, and think clearly. Sleep Time is not always in abundance in the festive season, which makes it all the more important to use it wisely. Sleep is one factor which should not be compromised in the lead up to the holidays. Getting less than seven hours of sleep on a regular basis can eventually take its toll on the mind and body.

or is not, acceptable in your life to inform healthy choices for yourself. It helps protect your energy and attention so that you can genuinely enjoy the moments that really count at this time of year. A few tips to setting healthy personal boundaries: • Communicate your boundaries clearly – be polite but firm • Prioritise commitments – understand what you realistically can and can’t say no to • Take stock of which events excite you and which events drain you • Don’t tear yourself down for not being able to do everything Take Time For Yourself In the lead up to the holiday period, its natural to feel as though every waking minute is dedicated to others. Between tying up loose ends at work, squeezing in the shopping and attending to a bursting agenda of social commitments – there’s barely a moment of solitude. Taking the time to pause is often the simple remedy many of us need, but fail to prioritise. Pencilling in alone time doesn’t have to consume a huge chunk of the already busy day. Experts suggest even 15 minutes can help reset the mind,

A good night’s sleep is a key ingredient to stay sharp and fighting (mentally) fit for the celebrations. Practices to achieve good sleep include: • Seven to nine hours of sleep each night • Avoid using your phone or staring at a screen in the hour before bed • Establish a consistent sleep schedule • Avoid large meals or intense exercise immediately before bed If you find you are still struggling with intense feelings of stress, anxiety or depression, it may be worthwhile seeking professional care. Despite your best efforts, sometimes it may take a doctor or mental health professional to help steer you back on course. Reach out to your GP or access further help through the following organisations: • •

Lifeline: lifeline.org.au or call 13 11 14 Beyond Blue: beyondblue.org.au or call 1300 22 4636

“In the lead up to the holiday period, its natural to feel as though every waking minute is dedicated to others. Between tying up loose ends at work, squeezing in the shopping and attending to a bursting agenda of social commitments – there’s barely a moment of solitude. Taking the time to pause is often the simple remedy many of us need, but fail to prioritise. ”

Q4 | Q1 December | March 2021

Women in Welding: Jasmine Willoughby, Aus Ships Apprenticeship Queensland’s local Super Yacht sector at Murarrie, on the Brisbane River, is recognised as one of the best repair and refit facilities in the world. It is here that Jasmine Willoughby is employed as a welder at Aus Ships. Having completed the East Coast Apprenticeships’ Launch into Work Project, with accredited welding training provided by TAFE Queensland SkillsTech, Willoughby has gone on to win several awards and is now helping to build the new City Cats designed by Aus Ships. Willoughby’s interest in trades started as a hobby, which saw her creating art and timber projects. She thoroughly enjoyed the building side of the projects, and began exploring trade careers whilst still employed in her role as a pharmacy assistant. Willoughby reached out to the Females in Trades team at East Coast Apprenticeships to discuss possible trade career pathways and opportunities. The Females in Trades team also connected Jasmine with other female apprentices and tradeswomen that she could talk to about their experiences in the trade industry.

TAFE Queensland SkillsTech General Manager, John Tucker said that Willoughby should be very proud of her achievement and the recognition she has gained from the marine industry. “We are so pleased that TAFE Queensland SkillsTech, in partnership with East Coast Apprenticeships, have been able to provide pathways for Queenslanders to be able to achieve their career goals. The need for qualified welders within Queensland’s Super Yacht, defence and naval sectors continues to grow, and TAFE Queensland will continue to support these industries by providing skilled workers,” he said.

In 2018, Willoughby enrolled in the specialist superyacht welding program through East Coast Apprenticeships. She was part of the first cohort of 14 students (including five females) to complete the federally funded Launch into Work pilot program, which was delivered at TAFE Queensland’s Acacia Ridge campus.

Willoughby took some time to answer a few questions for Australian Welding.

During the program, students completed a Certificate II in Engineering Pathways (MEM20413) followed by three-weeks of an intensive aluminium weld program and two weeks industry placement. Willoughby completed her industry placement at Aus Ships and was soon offered a boilermaking apprenticeship through East Coast Apprenticeships. “When I first started the program, I just wanted to learn welding. I had never done welding before and didn’t know if I’d be any good at it,” said Willoughby. “As the program progressed, I found myself really enjoying it. I began to look at what opportunities were available, and I was grateful when Aus Ships took me on as an apprentice after I finished my work experience.” Willoughby won the AIMEX Apprentice of the Year Award at the 2020 Australian Marine Industry Awards. The award recognises and honours young marine apprentices for their hard work, dedication and commitment to the Australian marine industry.

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Describe your job. I work at Aus Ships at Rivergate Murarrie where they do everything from new boat builds to redesign and re-fit. The new double decker City Cats were designed by Aus Ships and built at Rivergate, so I’ve been able to do various work from fabrication and welding to fit-out on all four boats. For the most part it’s all aluminium MIG welding but you’re not settled at a bench. So you’re welding in all various positions, which has been a huge learning curve from starting out at TAFE. What inspired you to choose a career in welding? More fortuitous circumstances than any inspiration on my part. I had been looking to start an apprenticeship in carpentry or cabinet-making and East Coast Apprenticeships got back to me and mentioned this welding program that they were going to run. They asked would I like to apply for that program. I had never welded before and thought even if nothing comes out of it, I could still learn something. I went through the program, did the work experience at Aus Ships, and was offered an apprenticeship. I found I enjoyed welding and just building things and, with Aus Ships, you’re not pigeon-holed into one trade so there is scope to just learn.

What do you believe is the biggest challenge for the welding industry? One of the biggest challenges is getting the skilled workers that are needed. I don’t think welding is a trade that a lot of people think of when they look for an apprenticeship. I certainly wasn’t thinking of welding until I was told about the welding program. What do you believe is the biggest opportunity for the welding industry? Working within the marine industry has shown me that there is a big opportunity for the industry to grow in Australia. The marine export and super yacht industry is growing so quickly in Australia and the quality of work in Australia is known internationally for being of a high standard. There is a great opportunity for companies to expand and enter international markets but they need the workers. Why do you think women should consider a career in welding? I think anyone who enjoys building things should consider a career in welding—there is the challenge and the opportunity to learn a valuable skill. Do you have any advice for women considering a career in welding? I’d first suggest to any woman who is considering welding to reach out to any boilermakers or welders they know—whether it be through the internet or through a magazine such as this one—just to get a handle on the safety hazards and safety equipment

they would need before they thought of even getting a machine. Stick welding is one of the easiest ways to start as you don’t have to worry about shielding gases and the machines can be compact and relatively cheap. The main thing to consider would be how you’d cope welding in the heat of summer, layered in protective gear, because welding can be uncomfortable and hot. Have you found working in a traditionally male-dominated industry difficult? I’ve been very lucky in that the guys I work with have been very welcoming and have been forthcoming in sharing their knowledge. Having the physical strength to do the work is something that I’ve had to work at and need to continue to build. What is the most interesting project you’ve worked on? All the City Cats would have to be the most interesting project I’ve worked on. There is always something different to do on each boat as I gain experience. Each one seems to have its own personality. Who has inspired you professionally? Just the level that some of the guys are welding at is incredible. I’d love to be able to grow my skill to their level. Source: https://tafeqld.edu.au/news-events/news-blogs/2020/ jasmine-willoughby-set-sail-amsterdam.html

Q4 | December 2021

Eight Ways to Improve Welding Productivity Using a Weld Camera It is essential that operators who control and adjust automatic welding processes see all the elements of the environment around a weld. These processes can present a problem for operators. An automatic welding environment is often too congested or too dangerous to have operators directly monitor the weld process while under operation (think scaffolding on the side of a pressure vessel, or small pinch points around a robotic welding station). So then, how can you, as a fabricator, have your operators properly monitor the welding process remotely?

One solution for effective remote monitoring of the welding process is the use of a welding camera that can see the very bright light source of a weld arc, as well as the neighboring dark areas of the background such as the parent material, melt pool and torch tip. There are several ways that a weld camera can help a business. Health and Safety Using a weld camera to monitor the welding process means you don’t need an operator in the direct weld area. This is a significant occupational health and safety advantage. Common on-thejob risks that can be eliminated by removing the operator from the work area include: electrical shock, welding fume inhalation, “welding eye” (direct exposure of the weld arc to the human eye), contact with weld spatter, and injuries from moving or falling objects. Adding a weld camera can mean fewer sick days, less risk of workers’ compensation claims, reduced legal liabilities and a healthier, happier operator. Reduced Set Up Time Using a weld camera can reduce the time required to set up the weld tool and materials. By looking at the weld area remotely, operators do not have

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to start and stop their welding process to inspect a weld segment for correct parameter settings during set up. Instead, they can make adjustments ‘on the fly’. Additionally, by monitoring the weld area remotely from where the welding controls are located, the operator can control and monitor the process from one place, and not have to move back and forth. Better Monitoring By adding a weld camera to the process, the operator has a clear view of the welding tip and its surrounding area. Some of the parameters that can be monitored visually with a camera are the: • Position of the weld tip relative to the seam • Position of filler wire • Height of weld tip • Size of weld arc • Condition of the melt pool Weld cameras with High Dynamic Range color imaging improve the operator’s ability to monitor the weld environment for certain weld processes, such as TIG. Color provides extra information to the user, including: • The boundary of the Heat Affected Zone • Oxidation of the melt pool and tip • Shielding gas presence

Run-Time Productivity A weld camera can increase the ‘arc on-time’ during the welding process, with less need for the operator to stop during the process to make adjustments, such as setting wire length and torch position. In traditional welding processes, the operator typically has to stop the welding process, monitor the welding wire with the arc off, and then restart the welding process, wasting valuable time. With a weld camera, this can be done in real-time. Operational Productivity Using a weld camera can reduce scrap, as well as losses that cut into profits, from weld failures in the field. Online monitoring of the weld can help detect defects as they happen, allowing the operator to make immediate adjustments to the process to help minimise defects and rework. This can vastly reduce the number of products that fail to meet quality specifications. Troubleshooting A weld camera helps an operator to identify the source of problems during the weld process, whether they are impurities in the parent material, component misalignment, improper amount of shielding gas, or improper geometry of the keyhole or weld pool. A weld camera can also help to identify what might be the most likely cause of a problem, ensuring that the solution is effective at restoring the welding process to its ideal state. Real-Time Verification A weld camera provides a direct view of the welding arc and the work environment, with enough detail for immediate adjustment. The operator can make adjustments such as: • Aligning the weld head to the seam or the filler material • Modifying wire length or shielding gas flow rates • Detecting impurities or porosity in the weld pool • Optimising the weld process by keeping the shape of the molten metal as ideal as possible Video Recording By adding a camera and capturing a live video of the welding operation, the process can be recorded, stored and reviewed offline for quality assurance monitoring, while also verifying that 100% of production was welded correctly. A recording is also essential for process verification and improvement, which means analysing offline what was working and what was not working properly during the welding process. A video recording is also ideal for training to observe an operator’s activity while playing it back for classroom review and analysis.

Xiris Weld Cameras While the use of a weld camera to monitor welding processes is not new, the development of a High Dynamic Range weld camera provides far more detail that can be monitored in a welding process than ever before. The Xiris weld camera eliminates pixel saturation that previously masked the weld process details. The result is a clear definition of the weld arc, melt pool and surrounding material. And with recent innovations such as welding process audio recording, frame triggering and video streaming over the internet, weld cameras are offering an increasingly effective and economical solution for welding productivity improvement. Weld Australia has partnered with Xiris Automation to bring their weld cameras to Australia. Xiris helps manufacturers detect, recognise, and interpret quality defects in manufactured goods. For further information, contact Michelle Bignold (Corporate Sales Manager, Weld Australia) on m.bignold@weldaustralia.com.au or 0437 106 726.

Source: Xiris Automation

Q4 | December 2021

2021 Year In Review

Welcome to Weld Australia’s 2021 Year In Review – a look at our successes, projects and programs over the last 12 months, and that of our members. This year has been exceptionally challenging for the Australian welding industry, and Weld Australia responded rapidly to the changing market conditions presented by the COVID-19 pandemic. Understanding the enormous pressure our members have been under, the Weld Australia team has remained focused on ensuring that we continue to provide the resources and services that our members need most. We are committed to using our extensive experience, combined with an innovative new approach, to achieve our core mission: promoting the interests of our members within the field of welding, not just in Australia, but across the globe. With even more exciting plans for the year ahead, it really is an exciting time to be a Weld Australia member.

10,900 Welders Registered on the Australian Welder Certification Register (AWCR)

3,468 People in the Weld Australia Community

536

People Attended Virtual Events

282

People Commenced Online Training Courses 24

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10 Member Events

Welders Qualified to ISO 9606-1

State Division Committee Meetings

Remote Audits Conducted

Technical Workshops & Webinars Q4 | December 2021

Weld Australia’s Advocacy in 2021 As the peak body for welding in Australia, our primary goal is to ensure that the Australian welding industry remains both locally and globally competitive, both now and into the future. In all our advocacy activities, our over-reaching vision is to facilitate the growth of a world class welding industry. With the COVID-19 pandemic continuing to cause a range of issues, Weld Australia’s advocacy agenda focused on training initiatives for the next generation of welders and fabricators, building a sustainable and productive local industry, and ensuring superior welding quality standards and public safety.

Onshoring, Compliance and Safety Weld Australia continued to push for state and federal governments, as well as large private companies, to onshore welding and fabrication work. This was done not only to bolster the Australian economy, but to ensure weld quality, and therefore public safety, are paramount. Manufacturing has slipped from 28% of Australia’s GDP in the mid 1960s to just 5% today. Whilst it is easy to blame the demise of Australian manufacturing on the rise of Asia as ‘the world’s factory’, there are significant structural deficiencies in our economy and in Government policy that have contributed. According to Geoff Crittenden (CEO, Weld Australia) “The importance of our local manufacturing industry cannot be underestimated when it comes to Australia’s post-COVID recovery. Australia’s jobsdriven COVID-19 recovery must be manufacturing led. Now is the time to make manufacturing a national priority. Government, at all levels, must support and invest in the manufacturing sector to aid its growth.”

For further information about Weld Australia’s Advocacy, visit our website.

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“Mandating local content in national infrastructure projects is the only way to ensure product quality and public safety, create new jobs, and strengthen Australia’s economy,” said Crittenden.

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Australia’s jobs-driven COVID-19 recovery must be manufacturing led. Now is the time to make manufacturing a national priority. Government, at all levels, must support and invest in the manufacturing sector to aid its growth.”

“We are not suggesting the government impose tariffs on all imported fabricated steel. We are calling on both sides of government to amend the necessary regulations and mandate compliance to Australian Standards whether fabricated steel is manufactured in Australia or overseas. Given a level playing field, Australian welding is internationally price competitive, and of the highest quality.”

For instance, when the jobs of 150 workers in regional south-west Victoria came under threat following the award of the wind turbine towers contract for the $360 million Ryan Corner wind farm to an overseas company, Weld Australia called on the Federal Government to mandate local content. “Weld Australia has been calling on the Federal Government for the last five years to mandate that all steelwork in Australia—both local and imported—is manufactured and erected according to Australian Standards. The Federal Government must act now to save jobs in regional areas and ensure public safety,” said Crittenden. “The importance of our local manufacturing industry and the development of robust renewable energy sources cannot be underestimated when it comes to Australia’s post-COVID recovery. The Federal Government has asserted that job creation is vital to our economic recovery. And yet, it seems unwilling to protect existing jobs.” “Australia’s jobs-driven COVID-19 recovery must be manufacturing led. Overseas, investment in advanced manufacturing is prioritised by governments. Local industry and populations support manufacturing by buying locally-made goods. As a result, manufacturing employs millions of people in overseas markets, contributing billions of dollars to their economies. Now is the time to make manufacturing a national priority. Government, at all levels, must support and invest in the manufacturing sector to aid its growth. Mandating compliance to Australian Standards is the perfect first step,” said Crittenden.

Over the past three years, the number of Australian companies certified to ISO 3834 has grown exponentially, and the number of ISO 9606 qualified welders has grown in tandem. This growth has been largely driven by private clients (such as defence primes, and roads and transport authorities) specifying certification in tender documentation. Whilst increased certification rates have substantially raised the quality of fabricated products in Australia, it has come at a substantial cost, and it needs to be paid for. It is completely unreasonable for clients to buy cheap, uncertified products from offshore, and not support local fabrication. “It appears that clients are still taking a very narrow view of project costs, allowing ‘cost to buy’ to dominate the procurement process rather than whole of life costs. If this is the case, then they are not delivering value to their shareholders or taxpayers—merely concealing the true cost of the project,” said Crittenden. Addressing the Welder Skills Shortage One of the key challenges for Weld Australia members is a shortage of labour, from Welding Supervisors and Inspectors, right through to welders. Finding competent, skilled, experienced welders is becoming more and more difficult. This shortage of welders has been exacerbated by a lack of short-term workers and immigrants, with our international borders closed due to COVID-19. Members have reported that there simply isn’t the same labour pool available to complete work. Weld Australia is calling on industry, schools and governments to work together to develop and deliver STEM programs that engage, excite and attract students. Q4 | December 2021

“We need a vibrant STEM program implemented across schools nationally so that children and parents alike understand the opportunities available—the future of employment in industries like welding is not hard, dirty work carried out in a dark workshop, it’s focused on IT and programming skills, using robots and co-bots, and implementing Industry 4.0 concepts,” said Crittenden. “STEM skills are crucial to the changing nature of work. Digital technology is now a part of our everyday lives, and is impacting the world of work in ways never experienced before.” “Our young people need to acquire complex, high order technical knowledge and skills. They need robust, deep and transferrable qualifications that provide a strong base for life-long learning and skill development.” “Kids need STEM skills. And yet, Australia is simply not keeping pace with this need,” said Crittenden. The number of school students studying STEM in later secondary (Year 11 and 12) has flat-lined at around 10% or less. In addition, the latest OECD Program for International Student Assessment (PISA) results show a long-term decline in maths and science skills for Australian students . Australia was placed 36th for Engineering and 14th for Arts; despite there being a demand for the former and a surplus of the latter. In 2003, four countries or economies significantly outperformed Australia in PISA mathematics. In 2018, that number was 23. “Australian students, their parents and their teachers simply don’t understand the importance of STEM, or STEM career opportunities, until it’s too late. One way to combat this lack of understanding around STEM career opportunities is through innovative STEM programs in high schools,” said Crittenden. This skills shortage is not a problem that can be resolved in the short term. Weld Australia is working

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on several initiatives designed to bridge this skills gap. One initiative is innovative STEM programs in high schools that expose students to the opportunities offered by a career in welding. In June 2020, the New South Wales (NSW) Department of Education and Training (DET) commenced a pilot program to teach welding to students in Years 10 to 12 studying Manufacturing and Engineering, and Industrial Technology. The program utilised cutting-edge training techniques, including the use of 32 augmented reality welding simulators and innovative teacher training delivered by Weld Australia. Based on the success of the pilot program, NSW DET ordered a further 20 simulators to be rolled out across another 10 high schools in regional NSW. To resolve the growing lack of STEM skills, Australia has adopted a ‘push’ approach by focussing on school based STEM programs like that implemented by the NSW DET. “There is no question that STEM education in schools and careers advice must be improved. But industry cannot continue to rely on Government to solve the problem. There also needs to be a ‘pull’ strategy that engages students through close collaboration between schools and the companies that will one day employ those students,” said Crittenden. “Identifying and developing skills should start in school. Students of all ages need to be excited by the opportunities available in welding, and in trades more broadly. Industry and schools need to work together to develop and deliver programs which engage, excite and attract students.” Australian welding businesses need to invest in the future of their own workforces and play an active role in the training of welding apprentices. Australia will need an additional 28,000 welders by 2030 based on the existing pipeline of work. Industry has a vital part to play in filling these roles.

Industry needs to spend more time developing apprentices—it’s no good expecting kids who have only just finished TAFE to be welding experts. Federal Budget Fails the Next Generation of Welders The 2021-2022 Federal Budget failed the next generation of welders, with a noticeable lack of funding allocated to TAFE, and vocational education more broadly. This is despite the serious skills shortage facing Australian industry, exacerbated by border closures due to the COVID-19 pandemic. According to Weld Australia’s Chief Executive Officer, Geoff Crittenden, “The welding industry is facing a looming skills crisis—the skills required to complete complex infrastructure, defence and construction projects are already in short supply. And yet, the Federal Government has repeatedly failed to invest in our TAFE system, and to implement the recommendations outlined in the Joyce Report, handed to them 18 months ago.” “In the Federal Budget, the Government claimed to be building the skills that Australia’s economy needs to thrive in a post‑COVID‑19 world. And yet, the Government demonstrated a serious lack of understanding in the way that complex skills like welding are developed.” “The Federal Government pledged $2.7 billion to extend the Boosting Apprenticeship Commencements program, without allocating any funding for the fundamental TAFE courses required to undertake an apprenticeship and become trade qualified,” said Crittenden. “An apprenticeship is only one step on the journey to becoming a qualified and competent welder. You need to complete a Certificate III in Engineering as well. If the institutions that offer this training are under-funded, a pipeline of skilled workers won’t materialise.” “This complete lack of funding for TAFE and vocational education is compounded by the Federal Government’s inaction on the 71 recommendations included in the Joyce Report—none have been implemented,” said Crittenden. Weld Australia is calling on the Federal Government to implement the ‘Early Actions’ recommendations of the Joyce Report without further delay. These include disbanding the existing infrastructure for developing training packages and qualifications and replacing it with industry led Skills Organisations; strengthening quality assurance by introducing independent student assessment to international standards; introducing vocational pathways in schools as part of the STEM program; and establishing a National Skills Commission to generate skills demand forecasts and realistic pricing models.

A Gas-Led Recovery Will Not Work “We need to get the gas from under our feet.” So said Prime Minister Scott Morrison during a speech in late January, emphasising his plans for a ‘gas-led recovery’ following the COVID-19 pandemic. Morrison has committed a whopping $6 billion to the development of gas in Australia, in an economic strategy that is entirely contrary to the interests of the country. Meanwhile, Australian manufacturing is in decline, despite the significant contribution that the industry can—and already does—make towards the economy and the national interest. Our economic recovery should be led by manufacturing. It should take advantage of, and build on, the substantial innovation, skills and technology that are readily available. Government, at all levels, must invest in the manufacturing sector to support its growth. Australia’s COVID-19 recovery cannot be resource led. It must be manufacturing led. Now is the time to rejuvenate our manufacturing industry—to make manufacturing a national priority. The Federal Government’s plan to invest in gas would expand the industry and tie our economic fortunes to the resource for decades to come. The strategy is based on the idea that manufacturing relies on gas in a way that cannot be replaced by alternative energy solutions. But as we know – and as Ai Group pointed out to the Government – manufacturing’s reliance on gas has been completely overstated. We do not need investment in gas to become a more successful industry. We need investment in manufacturing itself, including technology, equipment and education. Further, Australia’s major export markets for LNG, such as Japan and South Korea have committed to reaching net zero emissions in the next thirty years. Globally, countries are turning away from gas and coal and investing in renewables. It simply doesn’t make sense to base our economic recovery on a resource that has a clear expiry date. In fact, the gas industry has been preparing for this transition for years, cancelling major projects and laying off workers. Since 2011, Australian gas companies have lost between 50 and 70 per cent of their value. To think that this loss-making industry is going to lead Australia out of economic trouble is absurd. Our Government needs to stop pursuing industries that will be almost redundant in thirty years’ time, and begin to invest in futureproofing our local manufacturing sector.

Q4 | December 2021

A Focus on Mental Fitness in 2021

Member Directory With much of Australia experiencing extended COVID-19 lockdown restrictions this year, Weld Australia continued to help support the mental fitness of Australia’s welders. Suicide is the leading cause of death for Australians between 15 and 44 years of age, and men are three times more likely to die by suicide than women. Workers in construction and other trades— including welding—are even more at risk. Tradies are 70% more likely to die by suicide than their behind-the-desk counterparts. This means that every second day an Australian tradie takes their own life. Despite these alarming statistics, mental health definitely isn’t something that tradies talk about at smoko or after knock off. When we look statistically at mental health in Australia, 1 in 5 Australians will experience a common mental illness within a 12-month period. The 3 most common mental illnesses affecting Australians aged between 16 – 85 include Anxiety disorders 14%, Depressive and Bipolar disorders 6.2% and Substance Use disorders. Of the 1 in 5 Australians experiencing a mental health disorder, only 35% seek professional support. Like any illness, early intervention is the key to a successful treatment, and being able to recognise these more common signs can be the catalyst for positive professional intervention. As such, Weld Australia continued to work with Gotcha4Life, a not-for-profit foundation that believes in the concept of Prevention through Connection, and raises awareness of the importance of identifying a close friend in life, someone you can speak openly and honestly to when times are tough. According to Weld Australia’s Chief Executive Officer, Geoff Crittenden, Weld Australia has made

Australian Welding

supporting the mental health and wellbeing of its members and the wider welding community a priority, particularly in the wake of the COVID-19 pandemic—partnering with Gotcha4Life was a natural extension of this aim. “Weld Australia is proud to partner with Gotcha4Life. Mental fitness is a complex issue and there is no one simple solution. However, it’s clear that Australian tradies, including welders, need more support. The statistics around suicide and tradies are frightening, and we recognise how important it is for us to take a leadership role in helping to spread awareness and education in the welding community,” said Crittenden. “It’s vital that we work together, that we back one another, and that we remove the stigma associated with mental health issues. Remember: it’s OK not to be OK,” said Crittenden. Weld Australia also partnered with Man Anchor, a grassroots mental health and well-being movement that provides mental health education workshops for businesses, schools, and community. Through these two partnerships, Weld Australia was able to connect members with valuable workplace programs and provide a whole range of resources to the broader welding community.

Four Tips to Help Get Your Day Off to a Better Start In June 2021, Gus Worland (Founder, Gotcha4Life), outlined his four tips to help get your day off to a better start. According to Worland, physical fitness gets plenty of attention—for good reason. A healthy body can help prevent everything from heart disease through to diabetes. Although just as important, mental fitness doesn’t always receive the same consideration. One simple way to build mental fitness is adopting a morning routine that sets your day up for success. Morning routines are powerful. They set the pattern for the rest of the day. A stress-filled morning often spirals into an anxious afternoon. In comparison, starting the day with a focused routine can help create a sense of calm and confidence that makes the rest of the day seem more manageable. A consistent morning routine can also help to prioritise physical and mental fitness for the rest of the day.

Tips for Supporting Your Mental Health During COVID-19 In July 2021, Steven Gamble (Founder, Man Anchor) provided Weld Australia members with his tips for supporting your own mental health during COVID-19. Gamble’s tips included staying active, staying connected, limiting news feeds and keeping an eye out for changes in behaviour, thinking or mood. According to Gamble, with over 11 million Australians in lockdown due to COVID-19 at some point this year, it’s likely that you, or someone you know, has had a tough time. In these unprecedented times it is completely understandable that some people within our community will be experiencing higher levels of stress and anxiety. It is important that we address this before the stress and anxiety grows to distress or crisis.

Everyone’s ideal morning routine will be different, so the Worland’s suggestions should be considered a starting point, rather than a prescriptive step-bystep guide. These include buying an alarm clock, staying away from your phone, making your bed and simply breathing.

Interested in Running a Mental Fitness Program at Your Organisation? If you’d like further details, or are keen to run a mental fitness program at your organisation, please contact Disha Mistry (Graduate Marketing Assistant, Weld Australia) on d.mistry@weldaustralia.com.au

Free Mental Fitness Resources for Your Team Weld Australia has a range of resources available, designed to help build the mental fitness of Australia’s welders, including a range of posters that are perfect to print out and stick on the tea room noticeboard. Just some of the resources include: •

Tips for Supporting Your Mental Health During COVID-19, including free downloadable poster

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Four Tips to Help Get Your Day Off to a Better Start

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Knowing the Signs and Symptoms of a Mental Health Crisis

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Let’s Talk About Mental Health free downloadable posters (pictured opposite). Best of all, these posters are available in 12 different languages, including English, Spanish, Italian, Korean and Arabic.

Q4 | December 2021

Workshops, Seminars & Events in 2021 Each year, Weld Australia facilitates and attends a variety of member-focused events to help ensure that the Australian welding industry remains strong, competitive and up-to-date with advancements in everything from technology, through to Australian Standards. In light of the continuing restrictions around COVID-19, Weld Australia’s 2021 calendar of events was facilitated virtually, ensuring members still had the opportunity to network and connect—albeit virtually.

AS/NZS ISO 3834 Industry Workshop Queensland, February 2021 In conjunction with the Rockhampton Manufacturing Hub, Weld Australia hosted an industry workshop on AS/NZS ISO 3834 certification. The session provided attendees with an overview of the standard and its requirements for the manufacturing industry, as well as the opportunities it affords in defence and rail, as well as manufacturing. Paolo Corronca (Weld Australia’s National Manager, Engineering) explained the certification process, and how to link local Australian qualifications with the broader international network.

ISO 9606 Information Session Queensland, June 2021 In June, Weld Australia ran an information session on ISO 9606 Qualification testing of welders — Fusion welding in Toowoomba. Ross O’Bryan (Welding Engineer / Technology Trainer, Weld Australia) and Adam Coorey (Regional Training Coordinator, Weld Australia) highlighted the advantages of certification for industry, including reduced compliance and welder qualification costs. Attendees also had the opportunity to tour TAFE Queensland’s Toowoomba campus, including their state-of-the-art workshop decked out with welding simulators.

AS/NZS & ISO Standards: A Critical Update Online, March 2021 The application of Standards is growing rapidly. More and more, government bodies, as well as major contractors and primes, are specifying the use of Standards such as AS/NZS ISO 9606.1 for the qualification of welders, and AS/NZS ISO 3834 for the qualification of companies. In this hour-long online seminar, Bruce Cannon (Principal Welding Engineer, Weld Australia) focused on how various Standards are impacting the Australian welding industry, as well as the changes and revisions made over the last 12 months.

LAND FORCES 2021 Queensland, June 2021 Weld Australia’s CEO, Geoff Crittenden, attended LAND FORCES 2021 in Brisbane, where he gave a presentation on augmented reality and the powerful benefits that it has to offer training, particularly for welders. Presented in collaboration with the Australian Army, LAND FORCES is an international industry exposition to showcase equipment, technology and services for the armies of Australia and the Indo-Asia-Pacific. Over 12,000 people attended LAND FORCES over three days.

Mythbusting AS/NZS 1554.1 for Engineers and Designers Online, May 2021 The event provided everyone in attendance with an overview of the requirements of AS/NZS 1554.1 Structural steel welding - Welding of steel structures. Bruce provided practical, in-depth information to help understand, interpret and implement the Standard. The session touched on topics such as the use of non-standard steel, welding procedure and welder qualifications, inspection, lamellar tearing, and the responsibilities of engineers and designers. With more than 30 people in attendance, all the feedback received was very positive.

Australian Welding

A Revision of AS 1796: An Update for Users Online, July 2021 AS 1796 Certification of welders and welding supervisors was published in 2001. While this Standard has stood the test of time, it is being revised to align with current trends and international best practice. Facilitated by Bruce Cannon, this event provided an overview of the draft of the revised Standard focused on four key aspects: alignment of welder requirements to AS/NZS ISO 9606.1; updating the welding supervisor requirements consistent with AS/NZS 2214; adding a new qualification for Welding Inspectors; and the application of current Standards Australia policy requirements.

Zoom or Gloom? Preparing Well to Master Your Virtual Meetings Online, August 2021 Communicating virtually is here for the foreseeable future, and our ability to manage it well will bring tremendous benefits, and limit potential frustrations, for both us and our audience. We have all experienced it no matter what position you have. In this session, presenter Lisa Butler (Founder, Talea Group) focused on how to deliver an effective virtual presentation, including tips for preparation. This masterclass in effective virtual communication attracted a full capacity audience. Training for Employability and Profitability Online, August 2021 Presented by Carl Spruce (Director, Outsource Institute), this event attracted strong interest. According to Spruce, the challenge currently facing the industry is not a lack of a workforce—rather, it’s a lack of skilled and experienced people within that workforce. Spruce looked at the training landscape in Australia and delved into where businesses and individuals play a crucial role in building our skilled workforce. He also addressed employability and the relationship to training, how to know what training is available, and career pathways. Technical Resources: What, Where and Why Online, September 2021 Weld Australia provides a wide variety of technical resources that cover a range of subjects. With more and more pressure to deliver work according to high standards within tight deadlines, having access to accurate technical information is critical. Our resources can help you improve your efficiency and productivity, explain Australian Standards, and bolster the safety of your workplace. In this very popular online event, Bruce Cannon described how our resources can help you, your employees, and your business.

Ross O’Bryan presents at TAFE Queensland.

EN 15085: Railway applications - Welding of railway vehicles and components Online, October 2021 This workshop was a must attend event for railway industry personnel. It delivered insights and practical recommendations on how to implement the EN 15085 series of Standards, gain certification, and be in a position to partner with companies like Alstom and Bombardier, CAF, Siemens, Hitachi and others playing a role in the various railway projects across the country. Presented by Victor Blain (Engineering Team Manager, Weld Australia), this workshop proved very popular. A Spotlight on Augmented Reality: Peek into Welder Training Online, November 2021 Over the last few years, Weld Australia has championed the Industry 4.0 revolution, including use of the Soldamatic augmented reality welding simulator. From being used at Advanced Welding Training Centres, right through to schools and TAFEs across Australia, the Soldamatic is changing the landscape of welder training. Presented by Adam Coorey, this session covered how augmented reality is being used in schools and TAFEs, and how the technology can be used to train welders according to AS/NZS ISO 9606.1 Qualification testing of welders - Fusion welding.

For further information about Weld Australia’s upcoming events—from workshops and webinars, through to seminars—be sure to keep an eye on our Events Calendar or contact membership@weldaustralia.com.au. Q4 | December 2021

Premier Welder Training Weld Australia is Australia’s premier welder training organisation. We understand the value of ongoing professional development and are committed to upskilling the next generation of welders. This year, we launched new online courses, progressed with the MEM 2.0 Welder Learning Resources project, made a range of improvements to our online exam system, and facilitated several tailored in-house training courses. All this and more was achieved while delivering our usual high quality calendar of training courses. Weld Australia’s New Online Courses In 2021, Weld Australia launched several new online training courses. The first course was in line with AS 2214 Certification of welding supervisors Structural steel welding and AS 1796 Certification of welders and welding supervisors Certificate 10. The course proved to be extremely popular, and booked out in record time, so two additional intakes were facilitated throughout the year.

Importantly, Weld Australia’s online training includes live lectures, which have a mandatory 70% attendance rate requirement. Our combination of pre-recorded, self-paced learning and mandatory live lectures ensures that students still have the opportunity to interact with their peers and teacher in real-time. The live lectures provide the perfect opportunity for students to clarify any course materials or problems and ask questions.

The new online format makes training more accessible, particularly for people in remote and regional areas, who are unable to attend faceto-face courses. Weld Australia’s online learning platform, Moodle, stores all recordings and other content for students to access around-the-clock. This gives students the opportunity to learn at their own pace and revise the pre-recorded material several times before an examination or hurdle task. The interactive nature of Moodle assures students of what work has been completed, and any upcoming requirements.

Commencing in October, Weld Australia’s brand new Welding Fundamentals course gives technical personnel working with the metal and manufacturing industry an overview and understanding of welding processes, weld defects, testing and welder qualification as required by various Australian and international Standards. The course is suitable for technical personnel including engineers, draughtsmen, production and workshop managers, project managers and quality assurance and control officers.

Improvements to Weld Australia’s Online Exam System: WeldQ Weld Australia rolled out a range of improvements to its online exam system: WeldQ. All improvements were designed to make exams more accessible, while maintaining the rigour of a strict exam environment. To facilitate this, Weld Australia developed its own remote invigilation system. During online exams, the candidate’s screen and microphone are recorded. This means that candidates now sit examinations at home or their workplace, rather than having to travel to a central location. Candidates can attempt a trial exam to familiarise themselves with the interface. Plus, once an exam is finished, candidates can send their comments and feedback to Weld Australia.

Australian Welding

Queensland Government MicroCredentialing Pilot Program Delivers Positive Outcomes Under the Queensland Government’s MicroCredentialing Pilot Program, Weld Australia received a grant that enabled us to subsidise welder training across the state. The training focused on specific skills to support businesses and industries in adopting innovations and improving productivity. Commencing on 1 October 2020, the grant enabled approximately 25 welders from Queensland to complete Weld Australia’s training courses for just 20% of the usual fee—the Queensland Government subsidised the remaining 80% of course costs. Initially, the program was slated to run until 30 June 2022. However, the response from welders across Queensland was so positive that all funding was allocated by March 2021. Over 33% of students utilised the funding to undertake an IWE course, another 29% opted for either the AS 1796 or AS 2214 related courses, and 20% enrolled in Weld Australia’s IWT course. Weld Australia received a range of positive feedback on the program and its training. According to one student, “I [had] a salary increase and new position due to the completion of the course, immediately (thank you Weld Australia!).” Another student said, “The Queensland grant helped me to be able to study from beginning to the end. And I am more knowledgeable and confident dealing with everyday work since I obtained the certificate. I am in charge of welding jobs in our company and have increased [monthly] sales.” Business owners and development managers were equally as positive. “For our business, gaining the qualifications in IWE and IWT for our leadership team, and AS2214 for our workshop leading hands, has opened the pathway towards higher industry certifications in DIN 2303 and EN 15085. Being able to gain these certifications opens the opportunities for our business in Australian Sovereign Capability projects like the LAND400 defence program and the Brisbane Cross-River Rail project.” “Having additional supervisors and back-up welding coordination personnel has also enabled us to expand a service offering to industry in our local region for welding quality management, preparation of welding procedures, and qualification of personnel to the ISO 9606.1 standard. Our North Queensland region, and particularly Townsville, is lacking the number of qualified welding supervision and inspection personnel to support the local manufacturing space...That is why training in these micro-credentials is critical, and should continue to be supported by the State Government if they truly want to push Queensland ahead as the leading manufacturing state.”

Image: Weld Australia’s in-house training for Royal Wolf.

Tailored In-House Training Courses Weld Australia facilitated in-house training courses for a whole host of companies in 2021. Woodside Energy in Western Australia commissioned training on the topic of Welding Technology for Engineers, and both Royal Wolf and JAG Welding commissioned training on the requirements of AS/NZS ISO 9606.1 Qualification testing of welders — Fusion welding — Part 1: Steels. The IWI-B training course proved popular this year, with Weld Australia delivering in-house courses for Queensland Alumina Limited (QAL) at their Gladstone site, for TAFE Queensland at their Nambour Campus, for Monadelphous at their Gladstone site, and for MC Quality Control in Singleton. MEM 2.0 Welder Learning Resources Weld Australia made great progress with the national Metals and Engineering online learning resources project in 2021. Weld Australia is working with TAFEs across the country through the National TAFE Consortium to create excellent online resources. According to Michael Pitt, (National Manager Education and Training, Weld Australia), “We are creating a set of national resources mapped to the national MEM training package, so that learning resources for trade students are consistent across the country. This will help ensure consistent training, regardless of where in the country students undertake that training. The new resources are completely online and accessible via phone, mobile device or computer. This will allow students to access learning at the time, place and pace that suits them best. We are very excited about the project and are already seeing some great results,” said Pitt. Weld Australia recently circulated the new learning resources to members of the National TAFE Consortium. The feedback was extremely positive. Weld Australia will be working closely with the TAFEs and their students on further development of the learning resources.

For further information, contact training@weldaustralia.com.au

Q4 | December 2021

Advanced Welder Training Centres Weld Australia has worked with partners around the country to secure State and Federal Government funding for the establishment of Advanced Welder Training Centres (AWTCs). Using the state-of-the-art Soldamatic augmented reality welding simulator, the training delivered at the AWTCs quickly qualifies welders to the only industry Standard in the world that is accepted in both Europe and America: ISO 9606-1 Qualification testing of welders – Fusion welding. In 2021, we continued to support and expand existing AWTCs, and work with high schools and industry organisations to develop effective, engaging STEM skills programs.

South Metro TAFE Augmented Reality Welder Simulators Commissioned South Metropolitan TAFE in Western Australia is set to introduce augmented reality into their welding curriculum. 16 Soldamatic simulators were delivered to the TAFE this year, with Weld Australia commissioning the machines in June. We also rolled out training to their teachers in the second half of the year, in both ISO 9606 and the use of the simulators. The training was enjoyed by South Metropolitan TAFE’s teachers—they’re all looking forward to introducing their students to the Soldamatic simulators. Canberra Institute of Technology Introduces Simulators into Welder Training Canberra Institute of Technology (CIT) is the latest TAFE to introduce augmented reality simulators into the delivery of welder training. CIT offers a range of welder training programs, from entry level through to trade qualifications. The technology will be used to support student learning in customised training programs and in the delivery of the national curriculum. CIT sees the benefits of this technology for both inexperienced and very experienced learners wishing to develop their skills.

Central Queensland Manufacturing Hubs ISO 9606 Spring Fusion Events In October, Weld Australia helped facilitate the Central Queensland Manufacturing Hubs’ ISO 9606 Spring Fusion events. Working with both the Queensland Department of Regional Development, Manufacturing, and Water, and the Department of Employment, Small Business, and Training, Weld Australia ran a Spring Fusion tour covering Gladstone and Biloela. The sessions focused on how industry ensures welding quality control, safety while welding, and provided students the opportunity to practice welding using augmented reality simulators. QMI’s Women Who Weld Program Throughout the year, Weld Australia participated in the Queensland Manufacturing Institute’s (QMI) Women Who Weld Program. The program aims to increase gender diversity and participation in manufacturing careers. It provides the opportunities for female high school students in years 10, 11 and 12 to gain insight into trade skills and career pathways, including local employment opportunities. The program was facilitated at several high schools across Queensland.

Corrective Services Victoria Pilot Program Our pilot program with Corrective Services Victoria progressed this year. Under the pilot, prisoners at Langi Kal Kal Prison will use an integrated model featuring both the Soldamatic simulators and realworld welding to gain certification to ISO 9606. Weld Australia will develop the training program and roll out a ‘Train the Trainer’ course for instructors.

For further information, contact training@weldaustralia.com.au

Australian Welding

Image: QMI’s Women Who Weld Program.

Advanced Manufacturing School Outreach Program in New South Wales Last year, Weld Australia proposed an Advanced Manufacturing School Outreach Program to the New South Wales (NSW) Government. The Program received their support, with funding provided through the Department of Education’s Vocational Education and Training Program for Secondary Students. As a result, in June 2020, 32 augmented reality welding simulators were deployed in a pilot program in 16 schools across the state. The schools ranged from the Wagga Wagga, Lake Illawarra and Dapto high schools in southern New South Wales, to the Gorokan and Kurri Kurri High Schools in the Lower Hunter region. During October and November 2020, Weld Australia commissioned the machines and conducted training for teaching staff. The pilot commenced at the beginning of Term 1 in 2021. The simulators were used to teach welding to students in Years 10-12 studying Manufacturing and Engineering, and Industrial Technology. This engaging, exciting learning technology provides a very safe and efficient way to teach students skills in a profession where there is high demand. Based on the success of the pilot program, the NSW Department of Education has ordered a further 20 simulators for another 10 high schools in regional areas. The schools taking part are in the Riverina, such as Junee and Temora High Schools, and in the central northern hub, including the Broken Hill, Bourke and Cobar High Schools. The welding simulators were a hit with students and teachers in the first pilot. In June 2021, the NSW Department of Education conducted a survey of teaching staff involved in the pilot. Key benefits emphasised by the teachers were the confidence the simulators engendered in students, the safety of the program, and the gamification aspect—the welding simulators are fun to use.

Industry Program Sparks a Career in Welding for Long-Term Unemployed In partnership with Workskil Australia and TAFE SA, Weld Australia delivered an innovative new training program in June 2021 for a group of longterm unemployed people. With little to no prior welding experience, the students started by using augmented reality welding simulators to learn the skills and techniques needed to perform welds in a safe, stimulating and confidence-building environment. Students then moved onto real-world welding machines to hone their skills. As a result, nine students passed all tests required to qualify to AS/NZS ISO 9606 Qualification testing of welders — Fusion welding for MIG welding. This welding ticket can help the students gain employment. Joe Sandor (Welding Technology Trainer, Weld Australia) facilitated the training course. He was thrilled to be involved in this exciting new program that has huge potential to make a difference in the lives of long-term unemployed. “All of the students were really engaged and worked exceptionally hard throughout the training. They really put in 100%. The attendance rate was near perfect, which was fantastic—attendance can be a real challenge for these kinds of programs,” said Sandor. “All of the students were long-term unemployed. Most were in their early 20s and some have never had the opportunity to work at all. It was great to see their enthusiasm for welding and a possible new career path.” According to Weld Australia’s Chief Executive Officer, Geoff Crittenden, “With nine students qualified to ISO 9606, the program has clearly sparked an interest in welding in a whole new audience. The Workskil Australia training program is helping long-term unemployed people to get ahead, linking them to real opportunities in the workforce, and providing them with foundational welding skills on which to build a secure, successful career.” Image: Workskil Australia training program.

Image: Students at Woolgoolga High School use the simulators during the NSW Pilot Program.

Q4 | December 2021

Company Certifications

Weld Australia would like to congratulate all the companies that were awarded certification in 2021, including to AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials; EN 15085 Railway applications – Welding of railway vehicles; and DIN 2303 Welding and allied processes - Quality requirements to be met by production and maintenance companies for military products. Aerison Aerison was certified to both AS/NZS ISO 3834 and EN 15085. Founded in Perth in 1988, Aerison has grown over the years from a specialist environmental engineering company to a broad based engineering and construction company. Today, Aerison provides multi-disciplined EPC, engineering and design, construction, maintenance and mechanical installation services to the minerals and mining, oil and gas, non-process infrastructure and utilities sectors. Aerison has worked with clients such as Rio Tinto, Chevron, BHP and Roy Hill. For further information, visit: aerison.com Alstom Alstom in Dandenong (who acquired Bombardier Transportation in January 2021) was certified to AS/NZS ISO 3834 and EN 15085. Alstom has been providing sustainable infrastructure solutions in Australia for more than 100 years and currently employs approximately 1,600 people across more than 25 sites that include engineering centres,

manufacturing facilities, project delivery offices and maintenance depots and workshops.Alstom’s products range from high-speed trains, trams and e-buses to infrastructure and signalling. Alstom also maintains fleets of trams and trains across Australia. For further information, visit: alstom.com AWI Steel Established by Director Paul Mirabito in 1992, AWI Steel uses Tekla modelling software to efficiently estimate, fabricate and construct projects. Their state-of-the-art workshop is able to deliver quality outcomes with a CNC beam line, and services that extend to corrosion protection, detailed welding and custom finishing. Working with clients like Lendlease, John Holland, Transport for NSW and Brookfield Rail, AWI Steel’s projects include pedestrian bridges, overhead wiring structures, road signs, safety rail and staircases. AWI Steel was certified to AS/NZS ISO 3834. For further information, visit: awisteel.com.au

Image: Alstom in Dandenong was certified to AS/NZS ISO 3834 and EN 15085.

Australian Welding

has significant capability to undertake large scale project works. For further information, visit: cenman.com.au

Image: BRE Engineering

BRE Engineering BRE Engineering in Perth was certified to AS/NZS ISO 3834. BRE Engineering is a forward thinking engineering business that employs almost 100 staff across more than 20 disciplines. Their team of well-rounded engineers produce innovative, cost effective solutions and designs that exceed relevant standards and performance criteria. BRE is a leading provider of concept to completion mechanical and structural engineering solutions for the marine, defence, mining and industrial sectors. Their range of services extends to product development and 3D printing. For further information, visit: bre.engineering Catten Established in Melbourne in 1994 to provide a quality sheet metal fabrication service to a variety of industries, Catten is proudly owned and operated by Ian and Latinka Cubitt and their family. Catten provides a range of in-house services—from design right through to delivery—ensuring complete control over the entire manufacturing process. Their projects include everything from general jobbing, architecture, buildings and bin enclosures, through to shop fittings, signage and transport. Catten was certified to AS/NZS ISO 3834. For further information, visit: catten.com.au Century Engineering Century Engineering’s AS/NZS ISO 3834 certification was recently reconfirmed by Weld Australia. Century Engineering has been providing fabrication services to the mining, defence, water and power infrastructure sectors for over 70 years. Their growth and success has been built on providing high quality welding management fabrication solutions for critical plant and equipment for industry. Located in Edinburgh North, 25km north of Adelaide’s CBD, with a workforce of over 100 people and a 10,000m2 facility, the company

DVR Engineering DVR Engineering Melbourne was certified to both AS/NZS ISO 3834 and DIN 2303. DVR Engineering provides manufacturing solutions for a range of clients across the defence, telecommunications, rail, aerospace, mining and marine sectors. The company operates in 30,000m2 over two manufacturing facilities, with more than 95 staff operating advanced manufacturing equipment for end-to-end solutions. With over 33 years of precision metal engineering experience, DVR boasts the latest CNC machining, laser and plasma cutting and machining technology. For further information, visit: dvrengineering.com.au Global Manufacturing Group (GMG) Global Manufacturing Group (GMG) in Maryborough, Queensland was certified to both AS/NZS ISO 3834 and EN 15085 in 2021. Established in 1982, GMG is dedicated to customer service, exceptional and consistent quality, and advancements in technology, equipment and infrastructure. GMG operates from two sites—in Maryborough and Gladstone, Queensland—over a shared 7,000m2 of workshop space. GMG offers a complete turn-key operation, employing a range of skilled and highly trained personnel who operate on a rotating 24 hour roster capacity. Their services cover the entire lifecycle of metal manufacturing. For further information, visit: gmqld.com.au

Image: Prime Minister Scott Morrison visits GMG’s Maryborough facilities.

Q4 | December 2021

packaging, cutting tools, pressing and precision tools. Hofmann Engineering staff and management all pursue a single goal - a total focus on quality in every aspect of manufacture, customer service and on time delivery. For further information, visit: hofmannengineering.com

Image: RUD was certified to AS/NZS ISO 3834 in 2021.

Hard Bakka Steel Fabrication Hard Bakka is a dynamic steel fabrication company that operates from a 1,100m2 workshop in Bankstown, Sydney. The company specialises in structural steel fabrication, welding and installation for commercial, industrial, and residential projects. The company also supplies sorting machine plant structures, ore bins, rock boxes and complete wash screen units to the mining industry. Hard Bakka has gone from strength to strength in recent years, doubling its size in 2014 and tripling its size in 2018. With over 30 years of industry experience, Hard Bakka was certified to AS/NZS ISO 3834 in 2021. For further information, visit: hardbakka.com.au Hofmann Engineering Hofmann Engineering’s Bendigo facilities were certified to EN 15085 and AS/NZS ISO 3834, while their Cheltenham facilities in south-east Melbourne were certified to AS/NZS ISO 3834. Since 1969, Hofmann has provided specialist engineering services to Australia’s industry leaders. The company specialises in aerospace tooling, food

Image: The two largest mega struts supplied by NEPEAN on 8 Chifley Square weighed a massive 37 tonnes and 30 tonnes, with each strut measuring 18.5m in length.

Australian Welding

Liebherr-Australia Liebherr-Australia’s fabrication department in Adelaide recently received certification to AS/NZS ISO 3834. While the standard at the facility was already outstanding prior to certification, the team implemented some improvements to ultimately achieve the certification requirements. The upgrades included calibration of welding machines, and upskilling members of the team. Two team members, Chris Jamieson and Daryl Cornelius, completed training to become Visual Welding Inspectors through CSWIP 3.0 certification. Steve Smith, Group Leader Fabrication, was also heavily involved in Liebherr-Australia’s successful implementation of ISO 3834.2, completing International Welding Specialist (IWS) certification to fulfill the requirement of an ISO-certified Welding Coordinator at the facility. For further information, visit: liebherr.com Nepean Engineering & Innovation Established in 1974, Nepean Engineering & Innovation is now one of Australia’s largest privately owned engineering service providers. In 2021, the company was certified to AS/NZS ISO 3834. With a dedicated design and project management team that understands the diverse nature of the industry, Nepean has the capability and experience to successfully deliver the largest and most complex projects. Nepean has extensive facilities, including over 50,000m2 of workshop space, a state-ofthe-art CNC and machine shop, steel fabrication workshop, laser cutting, sheet metal, shot blasting, painting and powder coat finishing. For further information, visit: nepeanengineering.com.au

a diverse range of industries, from rail, bus and aviation, to architectural, hospital, forensics and general infrastructure works. Their services extend to design, laser cutting, CNC folding, machining, fabrication, finishing and assembly. For further information, visit: shottongroup.com.au

Image: PMG Chief Executive, Jason Elias, checks in with the team.

Precision Metal Group Established in 2000 in Western Sydney, Precision Metal Group (PMG) specialises in mechanical engineering services and welding. As the business has evolved, PMG has developed its capabilities and achieved significant certifications, including AS/NZS ISO 3834. In 2020, PMG became the first Australian company to achieve certification to the German military welding standard, DIN 2303, and in 2021, PMG was certified to EN 15085. Working across sectors such as defence, infrastructure, oil and gas, rail, mining and manufacturing, PMG is involved in high-profile projects like Rheinmetall’s Boxer Land 400 parts and seats for major rail supplier Probatec. For further information, visit: precisionmetalgroup.com RUD Weld Australia would like to congratulate RUD for their recent certification to AS/NZS ISO 3834. RUD Australia manufactures and supplies highquality round steel link chain solutions and lifting technologies. They work with clients in the defence, infrastructure, mining, quarry, power station and engineering industries plus many more. Their collaborative approach makes RUD a partner of choice for organisations who value quality. All of their products are rigorously tested and assessed against strict quality-control measures. RUD complements these high quality products with dedicated technical support and training services, delivered by in-house engineers. For further information, visit: rud.com.au Shotton Group Shotton Group was certified to both EN 15085 and AS/NZS ISO 3834. A family-owned business, Shotton Group was established in Dandenong, Melbourne in 1977. Today, the company employs a team of over 90 people at their 7,000m2 facility. With a focus on lean principles and solutionsbased engineering, Shotton Group works across

Silo Dev Based in Riverstone, New South Wales, Silo Dev has more than 20 years experience in steel fabrication and installation. The company boasts an extensive track record aligned with most tier one infrastructural construction companies in New South Wales. Silo Dev specialises in general steel and metal fabrication, and public infrastructure, such as railway stations, sports stadia, and airport terminals. The company also manufactures bridge components, silos and storage tanks. Silo Dev was certified to AS/NZS ISO 3834 by Weld Australia in 2021. Steelstruct Weld Australia would like to congratulate Steelstruct for their recent certification to AS/NZS ISO 3834. Headquartered in Henderson, Western Australia, Steelstruct was established in 1979. Steelstruct operates from their four modern, fully equipped workshops, which are strategically located at Henderson, Maddington and Yarloop in Western Australia, as well as in Rayong (Thailand) totalling 13,400m2 under roof. Steelstruct has delivered a range of services to some of Australia’s largest mining, mineral processing and equipment providers for 40 years. Their fabrication capabilities extend to platework, structural steel, pipe spooling, storage tanks, pressure vessels, conveyors, and offshore and subsea structures. For further information, visit: steelstruct.com.au

“DVR Engineering found that Weld Australia’s certification process was very good. The process helped DVR to enhance its understanding of the standards and their requirements. The process also helped DVR to gain certification within the targeted time frame.” “Weld Australia auditors were very knowledgeable and thorough, and the audit process was very comprehensive. Overall, DVR is very happy about signing with Weld Australia to gain the certifications.” “DVR Engineering highly recommends Weld Australia to other companies seeking certification to the ISO 3834 and DIN 2303 standards.” ~ Mike Nikol (Managing Director, DVR Engineering)

Q4 | December 2021

Weld Australia’s Technology Networks in 2021 Weld Australia’s Technology Networks provide a forum for technology transfer and research and development, linking members with industry and research organisations. Weld Australia works with Industry Group members to ensure they remain diverse and resilient in the everchanging and increasingly challenging global markets. Power Generation Process Safety Network Weld Australia’s Power Generation Technology Network facilitated a free online webinar on the topic Process Safety: The Start of the Journey. Several industry experts spoke during the webinar, including Lara Kayess (Manager, Asset Management, Aurecon), Ralph Villarosa (Engineering Leader, Energy Australia), Ian Rawlings (Manager Boilers, CS Energy), Ryan James (Senior Manager, Process Safety, AGL Energy) and Jon Alsop (Group Manager Engineering Services, Origin Energy). With over 65 attendees, the webinar generated a range of interesting discussions. Following on from the webinar, Ian Rawlings (Manager Boilers, CS Energy) accepted the nomination to Chair the group. A post event survey was also conducted, which resulted in recommendations for future action, including: • Development of a mechanism for the sharing of safety incidents • Production of good practice guides • Completion of baseline audits to facilitate benchmarking Since then, several meetings have been facilitated. As a result, the first two guides being produced are a Guideline for Safety Critical Elements and a Guideline for Reporting Process Safety Incidents for the Electricity Industry. These two documents have been circulated for review and revisions are currently underway. Lara Kayess (Manager, Asset Management, Aurecon) is facilitating an audit with each member of the Power Generation Technology Network to establish a baseline of Process Safety Management systems. The Group is in the process of establishing an Incident Database. The objective of the Database is to share safety events and the learnings arising from

Australian Welding

these events that have a broader industry concern. It was agreed that members of the Group will trial the Database tool for efficiency and ease of use. Power Generation Boiler Network The Power Generation Boiler Group met several times throughout the year, with attendance figures upwards of 60 people for some of the meetings. There were representatives from AGL, Alinta, ALS Global, ANSTO, Delta Electricity, Greenview Strategic Consulting, HRL, LaserBond, Quest Integrity, Stanwell, Synergy, Uniper and Weld Australia. Attendees heard from several expert industry speakers during the year, including Mehdi Soodi (LaserBond), Yun Tian (Synergy), Terry Houston (CS Energy), Wayne Hill (Delta Electricity), Russell Coade (HRL), Simon Vanderzalm (Greenview Strategic Consulting), Dave Potter (Uniper), Aron Abolis (ALS), Warwick Payten (MEC Consulting), Damien Charman (IrisNDT), Douglas Bell (IrisNDT), Stanton Puts (HRL), Mark Rooney (Loy Yang B), and Bruce Cannon (Principal Welding Engineer, Weld Australia). Welding Safety Council Weld Australia established the Welding Safety Council to advocate for strong safety requirements and risk minimisation throughout the industry. The Council provides a forum for industry and legislative safety authorities to discuss issues and work collaboratively to identify solutions. The Welding Safety Council met throughout the year, with representatives invited from Safe Work Australia, WorkSafe Victoria, WHS Qld, WorkSafe Tasmania, SafeWork NSW, SafeWork SA, WorkSafe WA, WorkSafe NZ, Australian Institute of Occupational Hygienists (AIOH),TAFE Queensland, BOC, AWS, and Weld Australia. The main topics of discussion were welding fume safety and electrical safety. As a result of the

discussions, Weld Australia will be working on an electrical safety and fume safety education program for welders and business owners. Rail Technology Network Welding is a core capability critical in the delivery of rail projects, as well as the maintenance, repair and refurbishment of existing assets. As such, Weld Australia’s Rail Technology Network will help improve welding capability, facilities and supply chains throughout the rail industry. The purpose of the Rail Technology Network is to: • Bring the welding capability of the rail industry and its supply chain to international best practice • Advocate for a national railcar and wagon fabrication facility and supply chain Australia’s rail manufacturing sector is undergoing a significant transition. It is slowly evolving from a more traditional manufacturing model of end-toend rolling stock production, to a more advanced manufacturing model, and low-volume, high-value production. The rapid advances in technology and the changing face of manufacturing generally, mean that businesses within Australia’s rail manufacturing sector are facing the immediate challenge of incorporating new technologies and processes into their operations. A world-class rail welding industry in Australia will facilitate a shift in manufacturing focus, capitalise on international opportunities, and develop the rail supply chain capabilities.

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The Benefits of Technology Network Membership • • • • • • • • • • •

A confidential forum for discussing issues with peers A unified body that advocates for change among industry clients Advantageous access to technical advice and engineering support The opportunity to benchmark against industry best practice A conduit between industry and research organisations Beneficial nationally and internationally accredited training Cost effective certification products and services Collaborative sharing of resources and services for repair options in accordance with Australian and international standards Opportunities to influence Australian Standards, contract terms and specifications Opportunity to participate in research and development projects Technology transfer and networking via industry specific forums

Contact Alistair Forbes (National Manager Corporate Businesses, Weld Australia) on a.forbes@weldaustralia.com.au for details.

Q4 | December 2021

Updates to Australian Standards Australian Standards are living documents. They reflect progress in science, technology and systems. To maintain their relevancy, all Standards are periodically reviewed, with amendments and revised editions published. The last 12 months have seen several developments, including reviews into standards related to pressure equipment, steel structures and pipelines. Weld Australia also released a range of updated technical and guidance notes.

Pressure Equipment As previously reported, the revision of AS/NZS 3992 Pressure equipment—Welding and brazing qualification was published in June 2020 as AS 3992. Users have identified a number of issues within the standard and an amendment has been prepared. The project has been approved by Standards Australia. Committee ME-001 initiated revision of AS 1796 Certification of welders and welding supervisors. A draft was prepared, public comment has been resolved, and is now being prepared for committee ballot. The revision included items from other standards including new provisions for a pressure equipment welding inspector. Committee ME-001 also published the latest revision of AS 2593 Boilers—Safety management and supervision systems. With AS 2593 published, the project proposal for the revision of AS/NZS

3788 Pressure equipment—In‑service inspection was finalised, submitted to Standards Australia, and accepted. The formal revision process has now commenced. Welding of Structures Following an initial public review, a revised draft of the revision of AS/NZS 1554.2 Structural steel welding—Part 2: Stud welding (steel studs to steel) was sent for further public comment and committee ballot in May 2021. Comments received were resolved by the drafting committee, and the standard was published on 2 December 2021. Pipelines Committee ME‑038 revised AS/NZS 2885.2 Pipelines—Gas and liquid petroleum Part 2: Welding with a modified public review draft closing for public comment and committee ballot in January 2020. The revised Standard was published in May 2020. Part 3 of AS/NZS 2885 Pipelines—

Standards Map

Earlier this year, Weld Australia released a comprehensive Map of Australian and Australian / New Zealand Standards for Fusion Welding. The Map provides an overview of various aspects of welding (including quality requirements, destructive testing, welding consumables, welding equipment, environment, health and safety, and more) along with the applicable Standard for each. This easy-to-use Map provides a fast, simple indication of the Standard you should consult before undertaking welding and associated activities. However, it should be noted that Standards do not replace education, sound judgment and good engineering practice.

Australian Welding

Download the Standards Map from the Weld Australia website

Gas and liquid petroleum Part 3: Operation and maintenance was also revised and public comment received is being resolved. Design of Steel Lattice Towers and Masts Standards Australia is currently reconstituting Technical Committee BD-073 to undertake the revision of AS 3995:1994 Design of steel lattice towers and masts. Weld Australia has a representative on this technical committee. Members are encouraged to contribute comments and relevant information about any issues with the current standard, and suggestions for its revision. Please forward comments to our representative at ashleyharris@utb.com.au. Updates will be provided as the committee’s work progresses.

Weld Australia Releases Updated Technical and Guidance Notes In 2021, Weld Australia released updated versions of three of its Technical Guidance Notes related to welder safety in Australia: • Guidance Note TGN‑SW01: Fume Minimisation Guidelines • Guidance Note TGN-SW03: Welding Electrical Safety: Electric Shock Injury and Electrocution Reporting • Guidance Note TGN-SW07: Health & Safety in Welding: Guides & Forms These Technical Guidance Notes are referenced in Technical Note 7: Health and Safety in Welding, and Technical Note 22: Welding Electrical Safety.

ISO Update ISO TC44/SC10 has commenced the revision of the ISO 3834 Quality requirements for fusion welding of metallic materials series of Standards, primarily to take cognisance of changes to ISO 9001 Quality management and the 2019 edition of ISO 14731 Welding coordination — Tasks and responsibilities. The revision is well advanced with Parts 2 to 4 inclusive of ISO 3834 published in April, and Parts 1 and 5 published in September. ISO requested that Part 6 be revised to become either an ISO Standard or a technical specification. The drafting committee has commenced work on this request and is converting Part 6 from a Technical Report to a Standard.

Technical Note 7: Health and Safety in Welding This Technical Note gives guidance on health and safety practices in welding, cutting and allied processes such as brazing, soldering, pre- and post-weld material treatments and metal spraying, for the prevention of injury, ill health and discomfort, as well as damage to property, equipment and environment by fire, and explosion. Various chapters deal with: • Basic principles of safe working • The main hazards and safety measures in welding, cutting and allied processes • Precautions required in particular working situations

TC44/SC10 also revised ISO 17660 Welding Welding of reinforcing steel to combine the two existing parts into a single document. A DIS ballot review closes in November 2021.

Technical Note 22: Welding Electrical Safety Although electric arc welding can be performed perfectly safely, there are circumstances when there is a substantial risk of electric shock. Precautions against this risk include use of properly maintained equipment, correct protective equipment and sound work practices.

Similarly, ISO TC44/SC11 has commenced the revision of ISO 9606-1 Qualification testing of welders—Fusion welding—Part 1: Steels with the intention of combining all five parts into the one standard. This will simplify the ongoing maintenance and review requirements for the standards as Parts 2 to 5 of ISO 9606-1 are in need of revision. Work has been transferred to a working group and good progress is being made on resolving comments.

With reference to industry best practice, Technical Note 22 addresses how to safeguard a person against electric shock, reviewing elements such as: equipment, the human body, the workplace Australian Standards.

Q4 | December 2021

2021: What Weld Australia Members and Partners Have to Say Weld Australia’s members and partners are made up of individual welding professionals, as well as companies of all sizes. In fact, Weld Australia members are involved in almost every facet of Australian industry and make a significant contribution to the nation’s economy. We recently spoke with a number of our members and partners, eliciting their feedback on our activities, services and membership benefits.

Jonathan Roberts (Centre Director, Australian Cobotics Centre) “From our first meeting, it was clear that Geoff Crittenden (CEO, Weld Australia) could see the benefits cobots had to offer the welding industry.” “Geoff explained to us the challenges presented by welding, one of which is encouraging young people into the profession. By using state-of-theart technology like cobots, a career in welding would become naturally more attractive to young people. Geoff understood that cobotics was one of the technologies that could enable this. We were sold on the idea. A partnership with Weld Australia seemed very logical. It’s like a match made in heaven.” “Weld Australia’s member network and industry connections have been invaluable for us. Weld Australia is able to provide market intelligence immediately. For instance, they could tell us straight away that industry doesn’t know what a collaborative robot is, let alone how they could use it in their own business.” “Sometimes, researchers make assumptions that industry understands what we’re talking about. Weld Australia helps us overcome these communication gaps.” “So many companies have very similar problems. It makes no sense at all to solve these individually, replicating the same work over and over again. Industry needs to work together in solving these common problems, and Weld Australia helps to facilitate this—everyone is a winner.”

Australian Welding

Mark Reggers (Specialist Application Engineer, 3M) “3M has been a long time corporate member of Weld Australia. We manufacture welding safety equipment, so it’s important for us to hear what is happening in industry, the changes, and the needs of industry players. Being part of Weld Australia helps ensure we have access to industry sentiment, particularly with welding fume being deemed a carcinogenic. We’re connected to the industry through Weld Australia.” “I just recently joined the Standards Australia SF010 Respiratory Protection committee as the representative for Weld Australia. It is so important to have Weld Australia’s input, and ability to act as an industry conduit, on these types of committees.” “The constant communications that Weld Australia distributes are incredibly valuable. Weld Australia delivers a consensus voice, and a consolidated source, for technical standards and best practices.” “The organisation moves issues and standards forward as a united collective, taking into account all the varied input received from the industry. Take Weld Australia out of the picture, and where would the industry be?” “In any industry, there are always things that can be improved. Weld Australia helps make these improvements, propelling the industry forward.” “Knowing that the passionate people at Weld Australia are invested in the importance of welding, the welding industry as a whole, and its place in the Australian economy, is incredibly exciting and encouraging.”

Carl Spruce (Director, Outsource Institute) “Outsource Institute became a member of Weld Australia for a number of reasons: industry currency, to remain up-to-date with the welding industry; professional development, specifically for our engineering trainers and assessors who teach welding related qualifications; access to augmented reality welding equipment; and networking opportunities.” “Weld Australia has been very supportive in 2021, offering us presentation opportunities and the ability to offer ISO 9606 training to our clients, as well as other special classes to our client and student base. They have also facilitated introductions to promote new business relationships for us.” “We’ve accessed a range of resources and services. Our engineering trainers and assessors have undertaken many webinars. We’ve also been able to on-share key information with our client network to ensure they too remain up to date with industry changes, for example AS 1796 and ISO 9606. Weld Australia has intimate knowledge of ISO 9606 and the use of augmented reality systems to train welders in the new welder qualification code.” “Weld Australia is a centralised point of contact for all things related to welding. We live in an information age, and often this can be overwhelming. Weld Australia has provided the industry with a go to location for trusted, current information pertaining to welding, which is wonderful.” “We have particularly enjoyed the collaboration we have had with Weld Australia this year. Our original agreement with Weld Australia was to

further validate our Welding Supervisors’ education, with the additional credibility of AS 1796 Welding Supervisors examinations. Our agreement spans two years duration to date.” “This has led to many mutually beneficial opportunities for both of our organisations and our respective networks. It has ultimately contributed to enhancing organisations and individuals within the Australian welding industry, enabling them to remain locally and globally competitive, both now and into the future.” Chris Jaques (Director, Flow Tech Australia) Flow Tech Australia recently achieved certification to AS/NZS ISO 3834. According to Jaques, “I think we initially underestimated what was required for this certification. However, Weld Australia was excellent to work with. Paolo Corronca (National Manager Engineering, Weld Australia) who was our main point of contact, was fantastic in giving us the direction that we needed.” Ian Bird (General Manager, HF Hand Constructors) HF Hand Constructors was also recently certified to AS/NZS ISO 3834. When asked to explain how HF Hand Constructors found the certification process, Bird said the company has always followed strict procedures, which paved the way for success. “We’ve always practiced similar standards, however never certified. As such, the audit process wasn’t a great hurdle for us. Everyone at Weld Australia was great to deal with, and the auditors were helpful – anything that we were unsure about, they were able to assist us, and guide us in the direction needed to achieve the certification.”

Q4 | December 2021

Mick Allen (Director, CQ Manufacturing Hubs, Queensland Government) Why did your company decide to partner with Weld Australia? “The CQ (Central Queensland) Manufacturing Hubs initially connected with Weld Australia through a partnership with TAFE Queensland and their access to augmented reality (AR) welding machines to deliver a Schools and Industry Technology Roadshow in Gladstone, Yeppoon, Rockhampton, and Emerald in 2019.” “In 2020 we engaged with Weld Australia on the delivery of AS/NZS ISO 9606 Fusion Welding courses in Rockhampton, Gladstone and Emerald, where numerous welders from approximately 20 CQ manufacturing businesses were successfully certified.” “In September of 2021, Weld Australia and their

Regional Training Coordinator, Adam Coorey (and four of his AR welding simulators) collaborated with the CQ Manufacturing Hubs, DESBT and ATQld to deliver the ‘Spring Fusion’ event.” “This event provided training to 24 year 10, 11 and 12 students in Gladstone, Biloela and Moura on the AR simulators. They all achieved the ‘AR Welding to Industry Standards Program’ certificate. This training gave the students the opportunity to practice welding procedures that are used to qualify welders to AS/NZS ISO 9606.1 using the AR welding simulators.” “We also had some excellent industry engagement during this event. We are planning to run similar programs around CQ in 2022.” How have you found the experience of working with Weld Australia? What sort of benefits has your company derived?

Weld Australia Membership Types • Individual Membership: Open to apprentices, tradesmen, inspectors, supervisors, technologists, engineers, academics and others with an interest in welding. • Corporate Membership: Best suited to micro, small and medium businesses. Corporate members have access to a range of exclusive and valuable resources, opportunities and events. • Premium Corporate Membership: Ideal for larger businesses, and businesses of any size wanting to take advantage of the premium offering to increase their exposure and visibility in the marketplace. • Technology Networks Membership: Technology Networks share resources for engineering innovative solutions to enhance safety, manage risk, reduce cost, and optimise operating efficiency. Technology Network members are primes and Tier One contractors, major asset owners and state authorities. • Free Student and Apprentice Membership: As part of our commitment to nurturing the next generation of skilled welders in Australia, Weld Australia is offers free membership to students and apprentices. • Free TAFE Membership: Weld Australia is proud to support, and encourage development of, Australian TAFEs and their teachers, which is why we are pleased to offer free membership to both.

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Australian Welding

“As well as partnering with Weld Australia on the Spring Fusion, Schools and Industry Tour and the ISO 9606 Fusion Welding, we have on numerous occasions worked with them to deliver information sessions to our CQ Manufacturing Hubs Defence and Rail Groups.” “In 2020 Paolo Corronca (National Manager Engineering, Weld Australai) made himself available to deliver sessions to our groups on the benefits of ISO 9606 certification, two sessions on the process of company ISO 3834 certification and in 2021 a session on EN15085 and DIN 2303 in conjunction with the release of the Rail Manufacturing Strategy for Queensland. The benefits of the events and the sessions have been: • That CQ is continually being identified as a region of progress and capability in not only the traditional resources and mining industries but also beginning to gain traction in the defence, rail and even aerospace industries. • We have been able to certify numerous welders to AS/NZS ISO 9606 across approximately 20 CQ businesses in Rockhampton, Gladstone and Emerald. • Approximately 25 CQ manufacturing businesses are now on their journey to a range of certification to improve their visibility and ability to be more successful in winning local, state and national contracts. • Approximately 700 CQ High School students from years 10, 11 and 12 have been able to interact and train on AR welding machines and understand the benefits of these machines to training and the fabrication and engineering

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industries. 24 of these students have received a certificate indicating their understanding of industry standards and the latest industry training techniques which will become a fantastic discriminator when applying for apprenticeships, traineeships, or fabrication and engineering roles in general.”

How do you see Weld Australia benefitting the Australian industry as a whole? “There are numerous benefits Weld Australia brings to Australian industry: • Being right on the pulse of new and innovative technology development in Australia. • Assisting with program development. • Building capability in regional areas. • Keeping the pressure on government to ensure the importance of training is not forgotten and is funded appropriately. • Working towards consistency in deliverables and messaging in welding, fabrication and engineering across all industry.” “From the CQ Manufacturing Hubs perspective, Weld Australia’s regional engagement and willingness to connect has been enjoyable, interesting, educational, and significant in the development of a partnership that has been and will continue to be, beneficial to CQ Manufacturing.” “A special thank you to Adam Coorey, Paolo Corronca and Ross O’Bryan.”

Q4 | December 2021 For further information, contact Disha Mistry on 02 8748 0100 or d.mistry@weldaustralia.com.au

WELD AUSTRALIA’S

MEMBER DIRECTORY Our new Member Directory provides all company members free exposure on our website. Every Corporate, Premium Corporate and Industry Group member can create a listing in the Directory with contact details, a logo, a short description of the business and their services, and industries served. The following member types are eligible to have a listing in the Member Directory: • Industry Group Members (always displays at top of results, logo listing and Industry Group badge) • Premium Corporate Members (displays above corporate member listings, logo listing and Premium Corporate Badge) • Corporate Members (standard logo listing)

HOW TO SET UP YOUR MEMBER DIRECTORY LISTING You can create your listing from within your Weld Australia profile. Just log in and select ‘My Business Listing’ from the dropdown menu under your name. Click on ‘Create’, fill in your company’s details, then hit submit. It’s as easy as that! Listings are approved by Weld Australia prior to going live, so there may be a delay between you submitting a listing and it appearing in the directory.

Visit the Member Directory 50

Australian Welding

Enrol in a Fusion Welding Course Today

Enrol in a fusion welding course at any of the Advanced Welder Training Centres listed below. ACT Canberra Institute of Technology (CIT) cit.edu.au 81 Mildura Street, Fyshwick There are two fusion welding courses that adhere to ISO 9606 Qualification test of welders on Training.gov.au. This is the authoritative source of nationally recognised training and Registered Training Organisations (RTOs). These two courses were developed in Victoria in 2018 and use augmented reality welding simulators as a key component of the training. Transition Workers To be awarded a certificate for the Course in Fusion Welding to AS/NZS ISO 9606 for Transition Workers, you must successfully complete seven units of competency (four core and three elective). Core units include: • Simulate fusion welding processes using augmented reality equipment • Identify welding processes, safe welding practices and use of hand and power tools • Interpret and apply AS/NZS ISO 9606 for fusion welding processes • Perform fusion welding procedures to meet the procedures of ISO 9606-1 (Steels – carbon steels) Experienced Welders To be awarded a Statement of Attainment for the Course in Fusion Welding to AS/NZS ISO 9606 for Experienced Welders, you must successfully complete three units of competency (one core and two electives). The core unit is: Interpret and apply AS/NZS ISO 9606 for fusion welding processes. Further Information For further information, contact: training@weldaustralia.com.au

Queensland TAFE Queensland tafeqld.edu.au • Cairns Campus: Gatton, Newton, Eureka and, Wilkinson Streets, Manunda • Townsville (Trade Centre Bohle) Campus: 763 Ingham Road, Bohle • Toowoomba Campus: 100 Bridge Street, Toowoomba City • Ashmore Campus: Benowa Road & Heeb Street, Ashmore • Nambour Campus: 91 Windsor Road, Burnside • Bundaberg Campus: 118 Walker Street, Bundaberg West South Australia TAFE SA Regency Campus tafesa.edu.au 137 Days Road, Regency Park Tasmania Tasmanian Minerals and Energy Council tasminerals.com.au 13 Wellington Street, Burnie Victoria Box Hill Institute boxhill.edu.au 465 Elgar Road, Box Hill Bendigo TAFE bendigotafe.edu.au 23 Mundy Street, Bendigo Federation University federation.edu.au Lydiard Street South, Ballarat

Q4 | December 2021

Securing the Future of

Australia’s Welding Industry

weldaustralia.com.au | office@weldaustralia.com.au | +61 2 8748 0100