Australian Welding March 2019 (Q1)

AUSTRALIAN 1

WELDING Industry Calls for Review of

Unfair Contract Terms Page 14

Women, Welding & the

Workforce Dynamic Page 24

AS/NZS 9606-1 & the AWCR:

Helping Welders Win More Work Page 32

Q1 | March 2019 Official Journal of Weld Australia www.weldaustralia.com.au

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Australian Welding: March 2019

Weld Australia’s Value Proposition

Weld Australia is the peak industry body, representing the welding profession in Australia.

Our members include individuals and companies in almost every facet of Australian industry, making a significant contribution to the economy.

Weld Australia is the Australian representative member of the International Institute of Welding (IIW).

Our mission is to represent the interests of our members and safeguard the public.

We do this by ensuring the integrity of in-service welds, and promoting the use of best practice technology and quality systems.

HowWeld WeldAustralia AustraliaDelivers DeliversValues Value to How to Members Members Network

Learning

We provide a network for the exchange of ideas and the sharing of resources.

Technology Transfer

We facilitate technology transfer from research institutions and overseas markets.

We deliver pathways for learning.

Technical Solutions

We offer specialist technical solutions on all welding and materials related issues.

Voice

We are the voice of industry to promote awareness of welding to decision makers.

Certification We are an internationally accredited certification body.

Weld Australia Contacts National Office

Qualification & Certification

Editorial Submissions

Building 3, Level 3, Suite 5 20 Bridge Street Pymble, NSW 2073 (PO Box 197 Macquarie Park BC NSW 1670) T: +61 (0)2 8748 0100 E: info@weldaustralia.com.au

Paolo Corronca T: +61 (0)438 012 099 E: p.corronca@weldaustralia.com.au

Sally Wood T: +61 (0)434 442 687 E: sally@wordly.com.au

Chief Executive Officer

Marketing & Advertising

Geoff Crittenden T: +61 (0)2 8748 0100 E: g.crittenden@weldaustralia.com.au

Donna South T: +61 (0)2 8748 0130 E: d.south@weldaustralia.com.au

Training Paul James T: +61 (0)2 8748 0150 E: p.james@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 the 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 the Weld Australia. Publication of any advertisement does not constitute endorsement by the Weld Australia of any product, nor warrant its suitability.

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Contents: March 2019

Contents 14

Business Essentials: Industry Calls for Review of Unfair Contract Terms & Payments

A Message from Weld Australia’s President

5

A Message From Weld Australia’s CEO

6

Inside the Industry Breaking News Business Essentials Health & Safety Australian Standards

8 14 18 20

Feature & Technical Articles

24

Women, Welding & Workforce Dynamics

30

Member Profile: CPT Engineering

The New Frontier for Welding: Editorial Opinion by the Hon Gayle Tierney MP Women, Welding & the Workforce Dynamic National Manufacturing Summit Member Profile: CPT Engineering AS/NZS ISO 9606-1 & the AWCR: Helping Welders Win More Work Welding Supervisors, RWCs & AS/NZS ISO 3834 National Manufacturing Week

22 24 29 30 32 34 38

Inside Weld Australia

34

Welding Supervisors, RWCs & AS/NZS ISO 3834

Meet the Weld Australia Board of Directors Meet the Weld Australia Team Advanced Welder Training Centres Hotline Update Training Calendar Member Directory Upcoming Events

40 42 46 48 50 52 55

About Weld Australia A membership-based organisation, Weld Australia represents Australia’s welding profession. Our primary goal is to ensure that the Australian welding industry remains locally and globally competitive, now and into the future. Weld Australia is the Australian representative of the International Institute of Welding.

Visit: www.weldaustralia.com.au.

Australian Welding: March 2019

NATIONAL 4

MANUFACTURING

SUMMIT 2019 SAVE THE DATE 21 TO 22 AUGUST 2019, MELBOURNE, AUSTRALIA The National Manufacturing Summit gathers leading representatives from all the major stakeholders in Australia’s manufacturing sector—business, unions, universities, the financial sector, suppliers, and government—to discuss the sector’s prospects, and identify promising, pragmatic policy measures designed to support an industrial turnaround. The aim of the Summit is to leverage the opportunities currently available in the manufacturing sector, and translate these into action.

Register your interest: https://manufacturingsummit.com.au

https://manufacturingsummit.com.au | 02 8748 0130 | events@weldaustralia.com.au

A Message From Weld Australia’s President

5

A Message From Weld Australia’s President The key objective of the Weld Australia Board of Directors is to facilitate the growth of a world class welding industry in Australia.

To ensure that we are in the best position possible to deliver on this objective, the Weld Australia Board has actively reviewed its composition and operations over the last 12 months. We are ensuring that your Board has the necessary skills and knowledge to support Weld Australia members and its executive team in achieving their goals, whilst also maintaining sound corporate governance principles.

Moving forward, we will continue to create opportunities for all our members and advocate for welding policies and practices that protect the Australian public.

(To meet the Weld Australia Board of Directors, see the article on page 40.)

The Current Landscape Australia’s resources sector (which was once where much of Australia’s welding work was concentrated) is predominantly in an operation and maintenance phase. This is generating much of the income needed by government to support the massive investments that are occurring throughout Australia in sectors such as infrastructure and defence.

However, we have identified that there is a significant shortage of appropriately skilled welders and fabricators in Australia. Without action, a significant proportion of upcoming welding work could be sent offshore.

Weld Australia wholeheartedly believes that Australia must maintain its own world class welders, fabricators and manufactures to

remain competitive on the global stage. As such, action is needed.

Weld Australia’s Response Weld Australia has embarked upon a significant program of change. We are currently working with federal and state governments, as well as various TAFEs across the nation, to train new welders and facilitate the upskilling of existing welders.

To their credit, the federal and state governments have pledged financial support to this initiative, funding the establishment of several worldclass, state-of-the art Advanced Welder Training Centres (AWTC).

The AWTCs employ augmented reality welding simulators to train and upskill welders, and are supported by the Weld Australia team. (For further details about the progress of the AWTCs, please see page 42).

Augmented reality training enables welders and students to practice a welding procedure as many times as they need to feel competent, before testing their skills on real world test pieces. Not only does this encourage more apprentices into the industry— making the training process more hands-on and exciting—it also offers significant safety and cost benefits for training providers.

All welders trained at an AWTC can then be certified to ISO 9606 Qualification testing of welders - Fusion welding and register on the Australian Welder Certification Register (AWCR). Employers can then search for suitably certified welders via the AWCR who are able to support their upcoming project needs.In addition to individual welder certification, Weld Australia is also assisting many companies with the development of welding

David Lake President, Weld Australia quality systems to ISO AS/NZS 3834 - Quality requirements for fusion welding of metallic materials.

These quality systems can then be audited, leading to IIW certification and, therefore, increased likelihood of global supply chain opportunities and repeat business.

AS/NZS ISO 3834 is the minimum benchmark for welding quality globally. As more companies become certified to the standard, those without it will find it harder to win work from local and international suppliers alike, particularly in sectors such as defence and aerospace.

The Weld Australia executive and operations teams are comprised of a range of experts with superior quality skills in: advocacy across all levels of government and industry; specialist training subjects and systems; certification of personal and fabrication businesses; and a huge array of technical topics.

Our team is comprised of a significant number of highly qualified IIW International Welding Engineers (IWE) who are capable of supporting members and industry in general. I encourage all members to utilise the expert skills and knowledge of the Weld Australia team.

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Australian Welding: March 2019

A Message From Weld Australia’s CEO “

The lack of regulation covering steel manufacturing, fabrication, and erection is a national disgrace that has reduced our industry to the lowest common denominator: cost.”

Geoff Crittenden Chief Executive Officer, Weld Australia

The lack of regulation covering steel manufacturing, fabrication, and erection is a national disgrace that has reduced our industry to the lowest common denominator: cost.

In a misguided commercial experiment, Australia eradicated the regulations that mandated compliance to Australian Standards.

The aim of this experiment was to cut through the regulatory red-tape imposed on Australian industry, in a bid to give our homegrown manufacturers more of an opportunity to compete within an increasingly global marketplace.

In reality, the abolition of these regulations has handed a substantial portion of our local industry—and therefore local jobs—to our overseas competitors.

More importantly though, this complete lack of regulation has put Australian lives at risk. There is no compulsion for either a client or a fabricator to comply with Australian Standards. The problem is that, if structures and components are not fabricated in accordance to

Australian Standards, there is simply no way to guarantee that they will not fail.

The entire lifecycle of the welding process—from design right through to inspection—must consider all aspects that could affect weld quality, and therefore public safety.

This type of approach is essential because it is impossible to undertake verification of a completed welded joint, particularly if it has been painted over and galvanized.

Unfortunately, inspection after completion does not guarantee weld serviceability. As such, quality must be built into the welding process, right from the very beginning.

Just look at some of the recent examples reported across Australian news outlets. On 8 January 2019, a sign over the Tullamarine Freeway in Melbourne fell on a car, narrowly avoiding killing the driver.

Preliminary findings indicate that the road sign may have failed due to a missing stiffener plate in the gantry that held the sign. However,

investigations into the cause of this accident were still underway at the time of writing. If the collapse of this sign is proven to be due to welding or fabrication failure, it could spell disaster for freeways across Australia—thousands of road signs may require remediation, costing taxpayers millions of dollars.

Similarly, the new Opal apartment tower in Sydney had to be evacuated because of structural cracking that occurred on Christmas Eve. The large cracks are believed to have been caused by ‘factors of safety lower than required by standards’.

The lack of fatalities to date is pure luck; it simply will not last with the current level of regulation.

The International Perspective In Europe, it is mandatory for all companies involved in welding to be certified to the appropriate International Standards by an independent, accredited, third-party authority. All products and structures must be CE marked (an abbreviation of French phrase ‘Conformité

7

A Message From Weld Australia’s CEO

Européene’, which literally means ‘European Conformity’).

Similar regulations apply in Japan, where products and structures are JIS (Japanese Industrial Standards) marked. In Canada, a mandatory system was implemented in 1947 that ensures the safety of all publicly funded welded structural steel. A system that has now been adopted by many of Canada’s large companies. While the United States does not mandate compliance, it has a legislative framework that delivers the same result.

Our close neighbours, suppliers and competitors, China, Thailand, Indonesia, Malaysia and Vietnam do not have welding compliance regulations or systems in place.

Instead, welders and fabricators in these countries tailor production to customer specifications. As a result, most imported fabricated steel is of inferior quality and does not meet Australian Standards.

Weld Australia estimates that over 30% of fabricated steel structures and products in use in Australia are imported. Whilst Australian companies normally specify Australian or International Standards, the cost of ensuring compliance is so high it rarely happens. There is no requirement for imported steel to be tested and inspected prior to installation. Weld Australia estimates there could be as much as 1.5 billion tonnes of non-compliant welded structural steel in Australia.

Australian welders and fabricators

have the opportunity to join the likes of Europe, Japan, Canada and the United States. By substantially raising the quality of the welded components and structures produced in Australia, we bolster the competitiveness of the local manufacturing industry, helping reverse the decline in local manufacturing jobs and provide a safer environment.

The Way Forward The Federal Government must show leadership and amend the necessary regulations to mandate compliance to Australian Standards, or wear the consequential loss of life.

It is critical that all: • Fabrication completed in Australia is compliant with AS/NZS 1554 Structural steel welding • Welders are qualified to ISO 9606 Qualification testing of welders • Welding and fabrication companies are certified to AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials • Workplace Health and Safety legislation holds the importer responsible for ensuring mandatory compliance to relevant Australian or International standards governing welding production and fabrication Clearly, these regulations are necessary, as evidenced by the specifications developed by Roads and Maritime Services (RMS) in New

“

The only way to guarantee public safety is to implement and enforce regulations that mandate compliance to Australian Standards for the manufacture, fabrication, and erection of steel within Australia, and the inspection of imported structural and fabricated steel.”

South Wales. RMS has already rolled out a highly successful welding safety control system under which companies must be certified to AS/NZS ISO 3834 in order to undertake work on gantries and bridges. The other states have yet to implement similar systems.

There is absolutely no question, lives are at risk. The fundamental issue is a lack of adequate regulation across Australia. The only way to guarantee public safety is to implement and enforce regulations that mandate compliance to Australian Standards for the manufacture, fabrication, and erection of steel within Australia, and the inspection of imported structural and fabricated steel.

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Australian Welding: March 2019

Breaking News LaserBond Breaks into US Export Market Surface engineering and coating business, LaserBond has broken into the US market, delivering its first order of composite carbide steel mill rolls to an American steel producer.

LaserBond’s steel mill rolls have been in use in the Australian market for over a decade, and typically last five to 15 times longer than competitors. Sydney-based LaserBond said that this was the first of many orders it expected for its new range of composite carbide steel mill rolls.

LaserBond CEO, Wayne Hooper, said pressure to increase productivity and reduce maintenance costs meant customers were searching for better performance from wearing components.“The products division directly exported $2.6 million in FY18 and we intend to grow that strongly,” Hooper said. “These early international orders for a new product range form part of a strategy that will deliver tremendous growth.”

“Constant pressure to improve productivity and reduce maintenance costs requires companies all over the world to search for improved performance from the wearing components that form a large slice of their operation costs. LaserBond’s composite carbide enhanced rolls well and truly deliver in this regard.”

According to Liberty House Group, one of LaserBond’s domestic steel customers, and the operator of the Whyalla blast furnace and a number of electric arc steel mills, LaserBond’s products are integral to its supply chain.

Images: LaserBond’s composite carbide steel mill rolls have been in use in the Australian market for 18 months and typically last five to 15 times longer than competitors.

“Within a time period of less than six months, LaserBond has become an integral supply chain partner with our procurement and maintenance teams.”

“In every case, the composite carbide components that are manufactured and supplied to us by LaserBond have far exceeded our expectations in terms of the service life we are now achieving.”

LaserBond utilises advanced surface-engineering techniques to reduce the wear rates, maintenance and operating costs of production-vital components of industrial customers.

LaserBond’s composite carbide steel mill rolls offer: • Surface texture finished to individual customer requirements from ‘as laser clad’ with a roughness similar to coarse emery paper, to a superfinished Ra 0.2-0.5 micron • Coarser finish offers excellent ‘pulling’ through where necessary • Superfinish offers mirror finish, with no scratches visible on the end product • Roll Shell manufactured to replace OEM shaft • No retrofitting or modifications required • Manufactured to customer specifications • The product coming off rolling mill generally defaults to one side of every run-out roll, which greatly increases the wear factor • Outstanding resistance to frictional wear and operating pressure • A single quoted price covering door-to-door delivery, in sturdy fumigated wooden crates designed for forklift use

9

Inside the Industry: Breaking News

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Australian Welding: March 2019

Breaking News Lincoln Electric® Elevates the Welding Training Experience with New VRTEX® Models Lincoln Electric® has launched new VRTEX® virtual reality welding training simulators to provide a powerful, cutting-edge solution for training welders faster and more efficiently, while driving down material costs.

With superior graphics and accurate sounds, the VRAW™ (Virtual Reality Arc Welding) experience offered

by VRTEX simulators transfers seamlessly into realworld, hands-on welding training.

The next generation of VRTEX welding systems feature an extremely detailed and realistic GTAW (TIG) welding experience. The weld puddle, including weld discontinuities, is exceptionally accurate and visually and audibly responsive to operator behaviour. The operator uses an adaptive current foot control and can perform welds with and without filler metal, on a variety of materials.

The new VRTEX 360+ allows schools or training centres to train two welders at the same time from one machine, each independently performing welds using different processes, coupons, joints and Welding Procedure Specifications (WPS).

Additional VRTEX simulator features include a Weldometer™ ROI calculator that records material savings for each practice weld performed. A virtual bend test provides results instantly to reveal what causes a weld to pass or fail. ‘Demo’ and ‘Replay’ modes can be used by instructors to display optimal welding techniques and review actual student behaviour.

VRTEX virtual reality simulator benefits include: • Reduced training costs • 23% faster training • 42% increase in certification rates • Improved safety, with no sparks, heat, gas or fumes • Immediate performance evaluation and enhanced student engagement Baker & Provan Increase Workshop Capabilities Baker & Provan recently acquired a Hwacheon Mega 130 lathe. As a result, Baker & Provan now has an additional CNC turning capability of up to 1,300mm diameter swing over the bed, 920mm cross slide and 6,500mm between centres. Used in combination with their existing capacity, Baker & Provan can now handle lengths up to 20.9 metres and 1,388mm in diameter.

Image: Lincoln Electric® has launched new VRTEX® virtual reality welding training simulators to provide a powerful, cutting-edge solution for training welders faster and more efficiently while driving down material costs.

Inside the Industry: Breaking News

Thales Welcomes OneSKY Milestones Thales Australia recently welcomed the announcement

by Airservices Australia that two key milestones in the delivery of the world-leading OneSKY program have been reached. Thales worked with Airservices Australia, the Australian Defence Force, and industrial partner Frequentis to introduce the new Civil Military ATM (CMATS) voice communication system at the Sydney, Melbourne and Perth ATM facilities. Thales and Airservices have also reached another key milestone with the finalisation of the system definition review for the integration of Australia’s civil and military air traffic control systems.

Thales Australia CEO Chris Jenkins said that this represents a major milestone in this historic program to deliver the world’s most advanced and integrated civil and military air traffic management system. “We have brought together the best team and the best expertise in the world to deliver OneSKY, and this includes a substantial amount of new talent, creating the next generation of STEM careers and intellectual capability.”

“Following a $12 million refurbishment, Thales also recently reopened our state of the art systems engineering facility to develop the highly secure digital systems at the heart of OneSKY and continuing to create the ATM systems of the future. This is a large, complex and nationally significant project that requires the highest levels of technical excellence. With the completion of the system definition review we will move into the detailed design phase,” said Jenkins.

OneSKY will use the latest cutting-edge technology to improve flight co-ordination, safely increase the use of airspace, optimise air traffic flow and improve the way planes approach the runway. OneSKY will manage all civilian and military air movements across 11% of the earth’s airspace, covering the vast continent of Australia and extending west into the Indian Ocean and east to New Zealand.

Exclusive BOC Offer for Weld Australia Members Weld Australia is pleased to announce that all new and existing members now have access to discounted pricing on BOC equipment purchases, as well as discounts on gas and cylinder rental charges. Weld Australia is committed to representing the interests of its members and promoting the use of best practice technology and quality systems.

BOC is one of Australia’s leading gas and welding equipment specialists, offering gases, welders and welding supplies, PPE, workplace safety and industrial equipment. For details, visit: www.weldaustralia.com.au

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Liberty to Transform Whyalla Operations Liberty has announced significant steps towards the transformation of its iconic Liberty Primary Steel operations at Whyalla. Liberty recently signed contracts worth more than $600 million, representing a significant portion of the overall transformation cost. In a major move forward, two contracts have been signed for the design of equipment and construction, with partners: • Danieli, for a new, world-leading, state-of-the-art rail and structural heavy section mill • CISDI Engineering Co, for a Pulverised Coal Injection (PCI) Plant GFG Alliance Executive Chairman Sanjeev Gupta said these components would play a key role in securing Whyalla’s long-term future. “This transformation will vastly improve the operational, financial and environmental performance of the operations, paving the way for Whyalla to become an enticing, global hub for innovative industry,” Gupta said.

City of Whyalla Mayor, Clare McLaughlin, said this was yet another fantastic announcement for the community.

“Most importantly for Whyalla, this project will create thousands of additional construction jobs and several hundred ongoing, with GFG committing to prioritising local skills,” McLaughlin said.

Following the announcement on progressing the Whyalla Transformation Program, Mr Gupta shared plans for a visionary ‘Next-Gen’ mega steel plant for Whyalla, signing an engineering contract with CISDI for the ambitious project.

“Our cutting-edge transformation plans for the existing steel plant are just the beginning of what GFG Alliance has in store for the region,” said Gupta.

“Utilising almost perfect local conditions – our own infrastructure including a deep-sea port; rich local resources; and unrivalled community passion – we now plan to build a new steel plant, one of the world’s largest, right here in Whyalla. Liberty Next-Gen Steel will be the largest in the Western world, capable of producing 10 million tonnes per year, with the ability and infrastructure to double capacity in time.”

The project will be based on state-of-the-art technologies and best-in-class environmental measures. It will focus on production of semi-finished steel – slabs, blooms and billets – exported to downstream operations in key strategic and growing markets around the world.

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Australian Welding: March 2019

Breaking News Naval Group Signs Submarine Design Contract for Australia’s Attack Class Submarines Naval Group has achieved another milestone in the Future Submarine Program with the signing of the first phase of the Submarine Design Contract. The occasion was marked by the Hon Christopher Pyne MP, Minister for Defence and representatives from Naval Group and the Commonwealth of Australia (CoA) at a ceremony in Canberra.

Osborne shipyard in South Australia, including ongoing support to Australian Naval Infrastructure (ANI) for the design and build of the Submarine Construction Yard and the ICT systems that will be employed in there.

The Submarine Design Contract is the first contract to be fully executed under the Strategic Partnering Agreement. The scope for this phase of work includes the ongoing maturation of the Attack Class design as it progresses into the next design phase known as the Definition phase. This will include the source selection of over 100 critical and main equipment that will contribute to the submarine design solution. This will mark significant opportunity for Australian industry, which together with ongoing Australian workforce skills development, will play an important part in the growth of the sovereign submarine capability in Australia.

“The signing of the Submarine Design Contract is another significant milestone in the journey of the Future Submarine Program. Through the execution of this Program, the Naval Group teams in both Australia and France will deliver a sovereign, regionally superior submarine capability to Australia.”

The Submarine Design Contract also includes ongoing preparations for the build of the Attack Class in the

“There is tremendous continuation and progress being made with the Future Submarine Program,” said Jean-Michel Billig (Executive Vice President Future Submarine Program, Naval Group).

“In doing so, we will also help build a stronger Australian industrial capability, which will be supported by a skilled and experienced Australian workforce, providing jobs and other economic benefits for decades to come.”

The first phase of the Submarine Design Contract is worth $605 million and will extend through to 2021.

Defence Industry Skilling and STEM Strategy Minister for Defence Industry, the Hon Steven Ciobo MP, released the first Defence Industry Skilling and STEM Strategy at the 2019 Avalon International Airshow in early March. The Strategy outlines how the Liberal National Government will help Australian defence industry meet its workforce skills requirements with an initial investment of $32 million over the next three years.

“The strategy is part of the Government’s plan to grow a robust, resilient and internationally competitive Australian defence industrial base that is better able to help meet defence capability requirements,” said Minister Ciobo. Australia’s defence industry is about to enter a new era of growth, thanks to our record $200 billion investment in defence capability, with opportunities in trades, advanced manufacturing, engineering, ICT, cyber security and other fields across Australia. There is a long-lead time to developing many of the skills needed by defence industry which is why we’ve developed this strategy.”

Highlights of the Defence Industry Skilling and STEM Strategy include: • $4 million for a new model of skilling support grants, administered through the Centre for Defence Industry Capability, that will help reduce

Image courtesy of BAE Systems.

• •

•

the financial barriers SMEs face when up-skilling their workforce $2.6 million for the 2019-20 continuation of the Schools Pathways Program; An additional 20 places in the Defence Industry Internship Program. There will now be 50 internship opportunities in defence industry SMEs to facilitate pathways into the sector.

Defence will establish the National Defence Industry Skills Office to improve collaboration and coordination between industry stakeholders. The Office will help facilitate information sharing, put defence industry’s skills concerns in a national context and leverage opportunities for collective action to meet the sector’s workforce needs.

Pipeline Repair, Hot Tapping & In-Service Welding Course Expressions of Interest Now Open Perth, Australia Expressions of Interest are now open for the proposed Pipeline Repair, Hot Tapping & In-Service Welding course to be held in Perth, in mid-2019.

Presented by international expert Bill Bruce, this course provides an in-depth overview of the various aspects of pipeline modification and repair (full encirclement sleeves, hot taps, and so on) and addresses common concerns around welding in-service pipelines.

The course is designed to help avoid pipeline shutdowns and interruptions of service, bolstering both economic and environmental benefits for operators and welders alike.

Plus, repairs can be undertaken efficiently, effectively and with full confidence.

Register your interest: https://weldaustralia.com.au

https://weldaustralia.com.au

|

02 8748 0130

|

events@weldaustralia.com.au

14

Australian Welding: March 2019

Industry Calls for Review of Unfair Contract Terms, Payment Times & Practices Australia needs competitive businesses to grow its economy, future prosperity, and ability to compete on a global stage. For small-to-medium Australian businesses particularly, the key to competitiveness is prompt, on-time payment, coupled with fair allocation of risk and proportionate liability. The reliable cash flow (ensured by prompt, on-time payment) enhances a business’s ability to grow, create jobs, and plan for the future. However, Australia’s payment times are currently the worst in the world, with invoices paid on average 26.4 days late. It is little wonder that industry is calling for review and the introduction of measures such as legislative reform.

Ombudsman Payment Times and Practices Inquiry In early 2017, the Australian Small Business and Family Enterprise Ombudsman (ASBFEO), together with the Council of Small Business Australia, the Australian Institute of Credit Management, and the Small Business Commissioners in New South Wales, Victoria, South Australia and Western Australia, conducted a self-initiated Inquiry to examine payment times and practices in Australia.

The Inquiry came as a result of feedback from small business and family enterprise in 2016, which stated

that late and extended payments is their number one problem. Input was sought from state and territory governments and authorities, relevant stakeholder groups, and large and small businesses.

ASBFEO’s Inquiry found that Australian corporations paid invoices on average 26.4 days late - the worst in the world. More recent research conducted by ASBFEO, involving 1,600 businesses, identified the biggest cause of dispute remains payments (44%); either the full amount not being paid (26%) or not being paid on time (18%).

According to ASBEFO’s report, “Late

payments affect the cash flow of the business owed the outstanding debt, forcing them to find ways to finance the short fall in their working capital instead of being paid on time and using the cash flow to grow their business. Furthermore, in Australia, a lack of cash flow is the leading cause of business insolvency. This underscores the importance of the issue of late payments, which can easily put many businesses out of operation.”

“Against the backdrop of late payments, there has been a growing trend in payment practices, particularly amongst large Australian and multinational businesses, to

15

Inside the Industry: Business Essentials

“

The Inquiry by the Australian Small Business and Family Enterprise Ombudsman (ASBFEO) found that Australian corporations paid invoices on average 26.4 days late - the worst in the world.”

extend payment times. The growth in extended payment times is partly linked to the practices of multinational businesses who apply global policies to improve their working capital efficiency. Extending payment times for suppliers effectively uses the businesses in the supply chain as a cheap form of finance.”

“The growing trend for extended payment times impacts the economy in two ways. Firstly, it slows down the flow of cash through supply chains which limits the growth of businesses as they have more capital tied up in financing their operations, and secondly it raises costs for businesses which are financing longer trade credit to their customers. When a business experiencing extended payment times also experiences late payments, it will stress the business further with significant ramifications for the solvency of the business. Aside from these business challenges, there are a range of personal effects which spill-over, including mental health issues.”

Unfair Payment Terms According to Doug Hawkes (Principal Structural Engineer and Managing Director of Structural Integrity Engineering, and Weld Australia’s Deputy President), “There are two to three major issues that exist in contracts, particularly when smallto-medium sized businesses are contracting with large corporations.

These corporations attempt to offload as much risk as possible onto

suppliers. This risk takes the form of extremely onerous indemnity and insurance requirements and unfair payment terms.”

“In undertaking business with large resources companies, actual payment terms are frequently longer than 30 days. Whilst engaged via contract, many terms set by large corporations are governed at the executive level and a request for altered terms at an operational level is seen as a hindrance and is unlikely to be promoted further (as there is generally no fundamental advantage to an employee of a large company to advocate for a supplier). This effectively results in a ‘take it or leave it’ scenario.”

“Our experiences suggest that the ability for small businesses to achieve altered payment terms (from the prescribed ‘standard’) with large businesses is limited, once a ‘standard’ payment term has been set by the corporate level of the organisation,” said Hawkes.

According to Hawkes, the ability to achieve change is stifled by: • Operational personnel lacking authority or will to change payment terms • The additional work and effort required by operational personnel to obtain approvals to change from standard payment terms • The potential and likely damage to reputation or standing

•

caused by a small enterprise simply asking to have payment terms altered (i.e. perceived to be different and/or difficult, compared to those who accept the standard terms without challenge) Many employees of large companies do not understand, or relate to, the effects of extended payment terms

“Whilst many large businesses are good corporate citizens and provide significant benefits to the wider economy, some (either intentionally or inadvertently) exploit the vulnerabilities of small businesses created by the imbalance in bargaining power. In some circumstances this could be construed as an abuse of power,” said Hawkes.

“Large businesses sometimes seek supposed ‘assistance’ from suppliers to ‘share our burden’ during tough economic times, yet our experience suggests none come running through the door to ‘share the spoils’ of the better economic times. The recent observations of large company claims that extending their payment terms ‘improves’ their working capital is nothing more than using someone else’s capital at a reduced (or no) cost. With a ‘take it or leave it’ power imbalance, this effectively imposes an involuntary ‘transfer’ of working capital.”

“The apparent ‘competition’ with

16

Australian Welding: March 2019

“

The government doesn’t want to upset large corporates but, in the meantime, small business is not coping—large corporates are effectively using small business as their own personal bank.”

ASX-listed entities to show the market that their working capital management is better than a competitor is potentially destroying value in other market sectors. This form of ‘competition’ logically leads to the question – when will the widening of payment terms stop?” asked Hawkes.

practices on the cash flow of small businesses and family enterprises in Australia. This followed a written request by the Minister for Small and Family Business, Skills and Vocational Education, Michaelia Cash, for advice on the effect these payment practices are having on small and family businesses.

“Considering the modern technologies available, it must be pondered why payment terms are not reducing, on the basis that electronic submission, approval and payment systems should be accelerating what were previously manual, paper based processes.”

“In our 2017 Payment Times and Practices Inquiry, we found Australian payment times were the worst in the world, with invoices paid on average 26.4 days late,” said Carnell. “We identified a growing trend for large Australian and multinational companies to delay and extend payments from 30 days to 45, 60, 90 or 120 days.”

“This comparison of ‘mechanics’ versus ‘financial strategy’ suggests that decisions on extending payment terms by large businesses are for their own interests only and are contrary to overall capital efficiency in the wider economy.”

“The entire situation is exacerbated by the fact that government is dragging its feet on this issue. The government doesn’t want to upset large corporates but, in the meantime, small business is not coping—large corporates are effectively using small business as their own personal bank,” said Hawkes.

The Need for Review, Reform and Legislative Change In November 2018, the ASBFEO, Kate Carnell, announced a review of payment times, to measure the effects of late or extended payment

“Partial and late payments, seeking discounts to pay in 30 days, offering loans to cover extended terms, all place stress on the cash flow of small businesses. It forces the business to find ways to finance the short fall in their working capital.

We have also written to large corporations requesting a copy of their payment terms and conditions to suppliers. Extended payment times for suppliers effectively uses the businesses in the supply chain as a cheap form of finance. Too many small and family businesses are being crippled by slow payments and the national economy suffers as a result,” said Carnell.

The Federal Government’s Payment Time Plans A week after the ASBFEO, Kate

Carnell, announced this name-andshame review of payment times, Prime Minister Scott Morrison unveiled a payment time plan designed to assist small businesses.

In a speech at a Business Council of Australia event, Prime Minister Scott Morrison announced that the Government will require 3,000 of the nation’s largest businesses, defined as those with turnover greater than $100 million, to publish information on how they pay small businesses.

While the Federal Government is currently committed to paying invoices within 30 days, Morrison said the Government would cut this to 20 days for invoices under $1 million by July 2019. In addition, the Federal Government has set a new target of 35% of smaller government contracts to be fulfilled by small businesses.

While acknowledging that New South Wales had already made similar moves, Morrison encouraged state governments to match the payment policies.

According to Morrison, “We’re committed to levelling the playing field and [providing] more transparency for small business and we’ll also, I announce tonight, be developing an annual reporting framework requiring large businesses over $100 million in turnover to publish their payment information.”

“It will cover 3,000 of the largest businesses in Australia, including

Inside the Industry: Business Essentials

foreign companies and government entities. Small business will have more transparency, allowing them to do business with better payers.

Large businesses will get the benefit of their suppliers and their customers knowing that they play fair and they pay on time.”

“We are committed to using every available lever to support businesses by pursuing these processes across the supply chain and so we’ll also deliver a new government procurement connected policy, which will require those large businesses seeking to tender to have satisfactory payment times in line with the Government’s pay on time policy of 20 days. So if you want to do government work, you’ve got to pay your suppliers and you’ve got to pay your contractors on time within 20 days,” said Morrison.

Labor To Make Unfair Contract Terms Illegal In January 2019, the Australian Labor party announced that, under a Labor Government, large firms would face penalties and deterrents for unfair contract terms. Their suite of competition and small business measures will be strengthened. A Shorten Labor Government will make unfair contract terms illegal, introduce penalties of up to $10 million for contracts that contain unfair contract terms, and increase the number of small businesses eligible for protection from such contract terms.

According to Hawkes, “These issues are significant and important, but it is recognised that reform is likely to be difficult as it is likely to encroach upon the freedom to contract principles. It is important that any proposed reform is effective and not token. For example, if legislation or codes of practice were introduced that permitted ‘contracting out’ of maximum payment term periods, or onerous disclosure of supplier financial information to prove a supplier was a ‘small business’, the reform would likely be ineffective in practice (for example take civil liability state legislation where contracting out of proportionate

liability is permitted in some States),” said Hawkes.

The ASBFEO Kate Carnell welcomed the Labor party’s commitment to three key changes to unfair contract terms legislation. “The changes to unfair contract terms announced by Labor is in line with our submission to the review currently being undertaken

by Treasury,” said Carnell.

“Making unfair contract terms illegal would be a major improvement in protecting small businesses.

17

Currently where a standard form contract contains an unfair contract term, the only way for a small business to take action is through the court system. And even if the term is proven to be unfair, there is no penalty to the big business.”

“By making unfair contract terms illegal, the Australian Competition and Consumer Commission (ACCC) would be able to penalise big businesses up to $10 million and issue infringement notices,” said Carnell.

How Payment Times and Practices Can Be Improved: Recommendations from the Australian Small Business and Family Enterprise Ombudsman’s Payment Times and Practices Inquiry Final Report Recommendation 1: The Australian Government to adopt a 15 business day payment time. All levels of government to consider adopting.

Recommendation 2: The Australian Government to require its head contractors to adopt the payment times and practices of the procurement through its supply chain. All levels of government to consider adopting.

Recommendation 3: The Australian Government to extend its payment policies to all its agencies and entities. All levels of government to consider adopting.

Recommendation 4: The Australian Government to publish its payment times and policies, and for all its agencies and entities, with performance against best practice benchmarks. All levels of government to consider adopting.

Recommendation 5: The Australian Government to mandate the use of Project Bank Accounts in public works and construction projects. All levels of government to consider adopting.

Recommendation 6: The Australian Government to procure from businesses which have supply chain payment times and practices equal to or better than its practices. All levels of government to consider adopting.

Recommendation 7: Industry codes which regulate business to business transactions to include best payment practices including set payment times.

Recommendation 8: The Australian Government to introduce legislation for larger businesses to publicly disclose all of their payment times and practices and performance against those terms. Larger businesses being the top 100 listed on the ASX and multinationals.

Recommendation 9: The Australian Government to introduce legislation which sets a maximum payment time for business to business transactions. Certain industries may need terms greater than the maximum which can be agreed providing they are not grossly unfair to one party. Where a longer term is called into dispute it will be considered an unfair contract term.

Recommendation 10: Governments should encourage the adoption of technology solutions, such as e-invoicing, to assist business to streamline administrative tasks and facilitate payment practices.

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Australian Welding: March 2019

Managing the Risk of Asbestos when Welding During construction and maintenance, welders can be exposed to asbestos. Workers can be exposed when disturbing asbestos themselves, or simply by being present in the general work area.

There are specific regulations that specify how work must be done if asbestos may be present.

These regulations are designed to keep personnel safe from asbestos hazards.

What is Asbestos?

Asbestos is the name for a group of fibrous minerals that were used to manufacture more than 3,000 different products, including a wide range of construction materials. Just some of its uses in the construction industry include: • Thermal systems insulation on ducts, pipes, tanks, boilers, furnaces, and so on • Refractory, such as fireproof brick, mortar and cement • Roofing and siding, including shingles, boards, coatings, cements and paints • Floor coverings and levelling compounds • Wall and ceiling finishes, such as plaster, tiles, spray-on, sheetrock • Fire protection systems, gaskets and dampers These construction materials were used in Australian buildings until the mid-late 1980s because of their superior heat and chemical resistance.

There are two types of asbestos: friable and non-friable. Friable asbestos is a material containing asbestos that when dry, is in powder form or may be crushed or pulverised into powder form using your hand. This material poses a higher risk of exposing people to airborne asbestos fibres. Friable asbestos was commonly used in industrial applications rather than the home, although loose-fill asbestos has been found in homes in NSW and the ACT, where it was sold as ceiling and wall insulation. Nonfriable or bonded asbestos products

are solid and cannot be crumbled in your hand—the asbestos has been mixed with a bonding compound such as cement. If non-friable asbestos is damaged or degraded it may become friable and will then pose a higher risk of fibre release.

Health Risks Asbestos fibres can be long enough to make into cloth or paper, but most are too small to see with the naked eye. These very small asbestos fibres become a health risk when released into the air and inhaled. Breathing in asbestos fibres can cause asbestosis, lung cancer and mesothelioma.

The risk of contracting these diseases increases with the number of fibres inhaled. The risk of lung cancer from inhaling asbestos fibres is greater if you smoke. Those who get health problems from inhaling asbestos have usually been exposed to high levels of asbestos for a long time. Symptoms do not usually appear until 20 to 30 years after initial exposure.

The Asbestos Ban The use of asbestos is banned in Australia. It is illegal to import, manufacture, supply, sell, use or reuse asbestos or products that contain asbestos. The asbestos ban came into force on 31 December 2003. However, some materials containing asbestos may inadvertently be imported.

Every Australian state has a Code of Practice that outlines asbestos management requirements, including

duties related to identifying asbestos in workplaces, labelling it, keeping an asbestos register and controlling risks to health associated with asbestos. For instance, SafeWork NSW outlines these requirements in the How to Manage and Control Asbestos in Workplace Code of Practice, as well as the How to Safely Remove Asbestos Code of Practice.

Managing the Risks Associated with Asbestos According to Safe Work Australia, managing the risks associated with asbestos involves: • Identifying asbestos and asbestos containing material at the workplace and recording this in an asbestos register • Assessing the risk of exposure to airborne asbestos • Eliminating or minimising the risks associated with asbestos by implementing control measures • Reviewing control measures to make sure they are effective Asbestos Register If you manage or control a workplace, it is your responsibility to ensure an asbestos register is prepared, maintained and kept at the workplace. An asbestos register is a document that lists all identified—or assumed—asbestos in a workplace.

An asbestos register must: • Record any asbestos that has been identified or is assumed to be present at the workplace • Record the date when the asbestos was identified

Inside the Industry: Health & Safety

• • •

Record the location, type and condition of the asbestos Be maintained and up-to-date Be given to the employer or business (or other PCBU) when there is a change of management or controller of the workplace

Where possible, asbestos must be labelled. For example, a label can be placed in an electrical meter box indicating that the building contains asbestos and the location of the register. Photographs or drawings are useful for showing the location of asbestos in the workplace.

Asbestos Management Plan A person who has management or control of the workplace must ensure that an asbestos management plan is prepared if asbestos has been identified. The asbestos management plan must: • Identify the location of asbestos • Include decisions—and reasons for them—about the management of asbestos at the workplace, for example safe work procedures and control measures • Outline procedures for incidents and emergencies involving asbestos, including who is responsible for what • Be maintained with up-to-date information • Be reviewed at least every five

•

•

years or when requested by a health and safety representative, or when asbestos is removed, disturbed, sealed or enclosed, or when changes to a control measure are made or when the plan is no longer adequate Be accessible to any worker or the PCBU who has carried out or intends to carry out work at the workplace and any health and safety representatives who represent workers at the workplace Provide information, consultation and training responsibilities to workers carrying out work involving asbestos

Choosing the Best Control Measure When choosing the most appropriate control measure, you should consider: • Eliminating the risk, for example removing the asbestos • Substituting or isolating the risk or applying engineering controls, for example enclosing, encapsulating, sealing or using certain tools, using administrative controls, for example safe work practices • Using PPE What Not To Do When you are working with or near asbestos, you must not use

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high-pressure water sprays or compressed air, brooms or anything else that might release asbestos into the air. You also need to control the use of power tools.

Removing Asbestos Unless you are removing less than 10 square metres of non-friable asbestos, you must be licensed. If you are removing less than 10 square metres of non-friable asbestos it is still recommended that you engage a licensed removalist and undertake asbestos awareness training.

Health Monitoring of Workers Businesses must provide and pay for health monitoring for all those working with, or exposed to, asbestos. Before removing asbestos, you must arrange and pay for health monitoring by a medical practitioner for all asbestos removal workers or workers who may be exposed to asbestos during the removal process. The monitoring should identify any changes in a person’s health because of exposure to asbestos. All health records must be kept for 40 years and the worker must receive a copy of the report.

References https://www.safeworkaustralia.gov.au https://www.safework.nsw.gov.au https://www.worksafe.vic.gov.au https://www.aws.org

“

Very small asbestos fibres become a health risk when released into the air and inhaled. Breathing in asbestos fibres can cause asbestosis, lung cancer and mesothelioma.”

20

Australian Welding: March 2019

The Changing Face of Australian Standards Australian Standards are living documents. They reflect progresses in science, technology and systems. To maintain their relevancy, all Standards are periodically reviewed, with amendments and revised editions published. The last few months have seen several developments, including ongoing reviews into Standards related to pressure equipment and steel structures.

Aged Standards Following a period of public review, committee WD‑003 has completed the balloting process for the updated adoption of two parts of the AS/NZS ISO 3834 series (Quality requirements for fusion welding of metallic materials), specifically to update Part 5 of AS/NZS ISO 3834 and adopt ISO/TR 3834-6.

The ballots for these Standards were successful and publication is due in early March. Committee WD-003 also submitted two projects to update the aged testing standards on the Nick-break (AS 2205.4.1) and Fillet break (AS 2205.4.2) tests, and the Macro test (AS 2205.5.1). Following a period of public review and balloting, these Standards will be updated via the adoption of the relevant ISO Standard. The ISO adoptions will be published as part of the existing AS 2205 series of weld tests ensuring continuity of designation for users.

Users of the fracture test will be able to continue to utilise the current test methods as well as utilise alternative forms of notch profiles. The change in standard for the macro test will also include, for the first time, an option for micro examination of test samples as well as the traditional macro examination. Publication of these Standards is due in early March.

Pressure Equipment Work on the revision of AS/NZS 3992 Pressure equipment—Welding and brazing qualification continued with the drafting committee completing the preparation of a public review draft in December 2018. A number of

errors and anomalies were corrected, additional guidance on the repair of in‑service pressure equipment included, and cognisance was taken of recent changes within the relevant ISO Standards. The draft is currently being prepared for release for public review by Standards Australia.

A working group continued their work in the revision of AS 3788 Pressure equipment—In‑service inspection.

Work on the draft is progressing, with submission of the draft to Standards Australia currently scheduled for the third quarter of 2019.

Steel Structures The public review of the draft revision of AS 2214 Certification of welding supervisors - Structural steel welding was completed in February. The drafting committee is now assessing the comments received. The committee also submitted a project to Standards Australia to correct an error within AS/NZS 2980 Qualification of welders for fusion welding of steels— Additional requirements for Australia and New Zealand. The project was approved and a public review draft will be prepared in the second quarter of 2019.

Sub‑committee WD-003-02 also successfully submitted a project to revise AS/NZS 1554.2 Structural steel welding—Part 2: Stud welding (steel studs to steel). Work on the final preparation of a public review draft is scheduled to commence in the second quarter of 2019. It should be noted that the prepared draft has taken cognisance of the relevant ISO Standards and now includes

provisions for the use of stainless steel studs and studs for wear applications.

With the successful adoption of ISO 9606‑1 Qualification testing of welders—Fusion welding—Part 1: Steels in Australia and New Zealand as AS/NZS ISO 9606‑1, Committee WD-003 has moved to facilitate its use by adopting key referenced ISO Standards as AS ISO or AS/NZS ISO Standards. In addition to updating some of the AS 2205 weld testing Standards as noted above, it was agreed to adopt ISO 5817 Welding— Fusion‑welded joints in steel, nickel, titanium and their alloys (beam welding excluded)—Quality levels for imperfections. AS/NZS ISO 5817 is scheduled to be published in March following public review and ballot.

As previously reported, Committee BD-001 completed the preparation of public review drafts for the revision of two of its Standards, AS/NZS 5131 Structural steelwork - Fabrication and erection, and AS 4100 Steel structures. Preparation of the drafts for public review were unfortunately delayed. However, they are now due for release in the coming months.

International Standards ISO 14731 Welding coordination— Tasks and responsibilities has been under revision by ISO. This Standard is a core Standard referenced by the AS/NZS ISO 3834 Standard series, and is now being referenced in some other Australian Standards. The revision process and final FDIS ballot has been completed and it is likely that the 2019 edition of ISO 14731 will be published prior to May.

PROUDLY PRESENTED BY:

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CROWN PROMENADE MELBOURNE, AUSTRALIA 24–27 NOVEMBER 2019

FIRST ANNOUNCEMENT AND CALL FOR PAPERS Corrosion & Prevention 2019 will be a three day gathering of leading experts with premium networking opportunities and a source for the latest information concerning corrosion and its mitigation. Hosted by the Victorian Branch of the ACA, Corrosion & Prevention 2019 will comprise a detailed program of presentations under a range of industry streams, technical forums with the opportunity to openly discuss the latest industry advances and issues, social functions as well as an exhibition showcasing the latest products and services.

The ACA expects over 500 delegates and visitors from a diverse range of industries to attend either the full three day conference.

Technical Streams Corrosion and Prevention 2019 invites technical papers on all subjects related to corrosion. The conference will bring together leading researchers and industry practitioners who combat corrosion daily. Diverse technical streams will showcase the latest developments in corrosion, ranging from fundamental corrosion science to hands-on application.

Submissions may include research papers, review papers and case studies related to the industry sectors and technical streams listed below: • Concrete • Steel Corrosion • Water Infrastructure • Oil & Gas

Sponsorship and Exhibition Sponsorship will enable your company to make a significant contribution towards the success of Corrosion & Prevention 2019. In return, the conference offers strong branding and exposure in a focussed and professional environment.

Call for Papers Submissions are now welcome on all aspects of corrosion and it’s control for Corrosion & Prevention 2019. Papers are subject to peer review and if accepted will be published in the Conference Proceedings. Critical dates for acceptance of abstracts and papers are: Close of Abstracts:

25 March 2019

Acceptance of Abstracts: 15 April 2019 Receipt of Papers:

3 June 2019

Submit an Abstract Please refer to conference.corrosion.com.au for further information about the submission process

Your Hosts The Australasian Corrosion Association Incorporated (ACA) is a not-for-profit, membership association, that disseminates information on corrosion and its prevention through the provision of training courses, seminars, conferences, publications and other activities.

The vision of the ACA is that corrosion is managed sustainably and cost effectively to ensure the health and safety of the community and protection of the environment.

• High temperature corrosion • Non-ferrous metal corrosion • Asset Management • Microbiologically Influenced Corrosion

conference.corrosion.com.au

22 22

Australian Welding: Welding: March March 2019 2019 Australian

The New Frontier for Welding An Editorial Opinion Piece

By The Hon Gayle Tierney MP Minister for Training and Skills and Minister for Higher Education

Welders play an essential role in our economy and their work is vital to our way of life. Welding can be found in the medical devices that keep us healthy, the ships, aircraft and rail transport that keeps us moving, and the electronics that power our cities, towns and homes.

In supporting Victoria’s future infrastructure needs, skilled welders will play an increasingly important role in priority sectors such as defence and advanced manufacturing industries, as well as major rail and infrastructure projects.

Welding is a skill, trade, engineering discipline, science and art rolled into one – presenting a challenge for how we train the next generation of welders. That’s why the Andrews Labor Government is proud to

have invested $1 million to help get Australia’s first advanced welding training centre off the ground at Box Hill Institute.

The Advanced Welder Training Centre (AWTC) opened in 2018 and is already training welders to the international welding standards required for working on complex jobs in the defence, aerospace and other high-value manufacturing sectors.

The Centre is at the frontier for vocational, technical and industrial training. It’s fusing innovative augmented reality technology with traditional training to ensure Victoria’s next generation of welders are some of the best in the world.

Developed as a partnership between Weld Australia, Box Hill Institute,

the Victorian Skills Commissioner and industry, the new Centre is helping welders practice their skills using augmented reality technology with real 3D objects, using virtual computer images.

This training method significantly reduces the cost of training welders, while also eliminating fume emissions and the risk of injury to students as they safely master complex welding skills.

Augmented reality training uses computer-simulation techniques with artificial vision technology to create a life-like welding environment.

The base material software allows trainers to manage and monitor students from a central computer, providing real-time data on student progress and level of competency in

Left: The opening of the Advanced Augmented Welding Training Centre (AAWTC) at the Box Hill Institute in 2018.

(L to R): Jennifer Oliver (Acting CEO, Box Hill Institute), the Hon Gayle Tierney MP, Geoff Crittenden (CEO, Weld Australia) and Neil Coulson (Victorian Skills Commissioner).

Inside the Industry: The New Frontier for Welding

the simulated environment prior to using real-life welding tools.

The AWTC is taking enrolments for students in two courses - Fusion Welding for Transition Workers, and Fusion Welding for Experienced Workers.

Fusion Welding for Transition Workers targets those with no welding experience and provides them with the essential skills they need to find a job while Fusion Welding for Experienced Welders is designed to help upskill those already in the workforce, and provides them with requirements of the international standard: ISO 9606. To qualify for this standard, the emphasis is on the welder’s ability to manipulate the electrode, welding torch or welding blowpipe, thereby producing a weld of acceptable quality.

By employing welders with this recognised standard, employers can bid for international contracts and major projects, making them competitive on the world-stage.

The courses also give students the opportunity to engage in aspects of the theory before undertaking practical activities in a hands-on environment.

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The Centre is a great resource for young people wanting to enter the construction industry, or people looking to reskill or upskill, and it will deliver benefits to organisations undertaking major projects by providing highly skilled welders.

Upon completing the course, welders will have the skills to get some of the most sought after welding jobs in the world, including here in Victoria. Take the defence sector for example.

from which the manufacturing and construction sectors will draw.

World-class training centres like these are a must at a time when construction is booming.

The Centre was funded under the Regional and Specialist Training Fund, part of the Andrews Labor Government’s Skills First initiative, which is delivering training to respond to industry-led demand for specific skills in regions and specialist areas that are not being adequately met in the current training market.

Just last year, we invested $304 million to meet industry demand for trained graduates that are critical to Victoria’s economic prosperity.

This investment is funding our TAFEs, Learn Locals and private training providers to deliver an additional 30,000 training places.

Defence pumps $8 billion into the Victorian economy every year and it pulls into its orbit about 20,000 workers and more than 400 businesses. But there remains a shortage of welders, trained to a level to handle the highly complex work required to build military hardware. This Centre will address that shortfall, and not only to the benefit of the defence sector. It will create a pool of welding talent

The AWTC is another great example of TAFEs working closely with industry to respond to their changing needs while helping Victorians into training - to make them not only competent, but the very best in the world.

To make it easier to access training, we’re also investing $172 million to make 30 priority TAFE courses and 20 pre-apprenticeship courses tuition free in areas that are most in demand from Victorian employers and lead to jobs.

The Andrews Labor Government is taking the lead to deliver a high quality, accessible training system that gives Victorians the skills they need to get the real jobs that are building our state and growing our economy.

About The Hon Gayle Tierney MP, Minister for Training and Skills and Minister for Higher Education Gayle has a strong connection with rural and regional communities, having completed primary and secondary education at rural schools. Apart from being an advocate for regional infrastructure and employment, Gayle is also a strong supporter of environmental sustainability, gender representation, social inclusion and community development. Gayle studied politics and Asian studies at Flinders University.

Gayle was the first woman to become a State Secretary of the Vehicle Division of the traditionally male-dominated Australian Manufacturing Workers Union, serving in this role from 1993 to 2006, and also as the Federal President from 2000 to 2006. Gayle also served on the Executive of the Australian Council of Trade Unions (ACTU) from 2000 to 2006.

In 2006, Gayle was elected to represent Western Victoria in the Legislative Council. Gayle was appointed as Minister for Training and Skills, and Minister for Corrections in November 2016.

Following the 2018 Victorian State Election, Gayle was appointed as Minister for Training and Skills, and Minister for Higher Education.

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Australian Welding: March 2019

Women, Welding & the Workforce Dynamic Gender equity and diversity in the construction and manufacturing industry workforce is a persistent problem that exacerbates skills shortages, reduces economic productivity, and constrains innovation. Whilst there are signs that Australian employers and both state and federal governments, are taking action, there is still a considerable way to go. This is not an issue isolated to Australia; other western nations echo a similar gender profile in construction.

According to the Australian Bureau of Statistics, the construction and manufacturing industries are two of Australia’s largest employing sectors, accounting for 9.4% and 7.1% (respectively) of Australia’s entire workforce. They are also two of Australia’s most maledominated sectors. According to the Australian Government’s Workplace Gender Equality Agency, in 2018, women made up just 17% of the construction workforce, and 26% of the manufacturing workforce.

At 29.4%, the construction industry saw a 2.0pp increase in the gender pay gap in 2018—men are taking home approximately $40,000 more per annum than their female counterparts. This makes construction the industry with the second-highest gender pay gap, behind only the finance industry.

In the manufacturing industry, the gender pay gap was 13.8% in 2018—equivalent to approximately $14,000 per annum.

“

Women account for less than 1% of Australia’s welding and fabricating workforce. Greater participation of women will not only benefit the industrial sectors, it will boost Australia’s economy.”

For women construction professionals, poor participation rates are compounded by poor retention rates; early enthusiasm for the sector declines with increased exposure. Women leave construction 38% faster than their male colleagues, and rarely reach management. In fact, the construction industry has the lowest rate of representation of women in management of all Australian sectors—just 12% of management roles are occupied by women. The manufacturing industry fares better, with 23.5% of management roles occupied by women.

Women In Welding Given these industry-wide statistics, it is not surprising that there are few female welders in Australia. In fact, according to Weld Australia CEO Geoff Crittenden,“Women account for less than 1% of Australia’s welding and fabricating workforce.

Greater participation of women will

not only benefit the industrial sectors, it will boost Australia’s economy.”

Encouraging the participation of women in male-oriented industries such as construction, manufacturing and welding is long overdue in ending the cycle of employment disparity, gender pay gap, and representation of women in management positions.

“There are many advantages waiting for women who opt for a career in welding. There are significant economic benefits for women in non-traditional trades, from increased choice and availability of jobs, through to improved job security,” said Crittenden.

The welding industry is fast evolving.

The advent of automation and other progressive welding technologies are paving the way for the manufacturing of high-tech equipment for the aerospace and defence industries, among others.

Inside the Industry: Women, Welding & the Workforce Dynamic

Welding itself is no longer precarious, dirty work in dark workshops, but the precise work of the technically minded in bright, open workspaces.

“More and more, welding is becoming a high-tech trade. The modern welder must be skilled in robotics, computer programming and engineering. They must have an affinity for maths and science, as well as artistic and spatial skills that enable them to quickly and easily conceptualise ideas,” said Crittenden.

“Plus, they must have the patience and temperament for precise, exacting work. Given all these specialist skills, welders have access to extremely well-paid jobs that offer the flexibility and mobility that modern women—particularly working mothers—need.”

Moving Forward Clearly, women still face

Austal Sets Women-Only Apprentice Target Australia’s biggest defence exporter is loading its ranks with women to overcome a skills shortage in the shipbuilding industry as it competes for workers against a resurgent mining industry and government-funded infrastructure projects.

Austal has introduced a womenonly apprentice initiative after becoming concerned that its recruiting pool was too limited and male-dominated to meet orders for defence vessels and commercial high-speed ferries.

considerable barriers within sectors such as construction and manufacturing. However, according to the Australian Government’s Workplace Gender Equality Agency, there has been solid growth in the number of employers analysing their payroll data for gender pay gaps. The number of organisations implementing formal policies or strategies on remuneration with specific pay equity objectives is also increasing.

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now have an overall gender equality strategy or policy (up 2.8pp to 74.3% in 2018). There have also been large gains in the number of employers with targeted policies to support gender equality in succession planning, talent identification, retention and promotion.

According to the Australian Government’s Workplace Gender Equality Agency, in 2018 61.6% of organisations reported that they had a formal policy or strategy on remuneration, an increase of 3.2% in the past year. Of these organisations, 40% now have pay equity objectives in their remuneration policy or strategy.

Along with state governments, the Federal Government has prioritised initiatives that focus on tradeswomen. For instance, in New South Wales, the Government plans to introduce gender targets for tradeswomen working on state infrastructure projects. Their aim is to double the number of tradeswomen from 1% to 2%. With the Federal Government committing $75 billion to transport infrastructure projects in the next 10 years, it an influential construction industry client, and could help foster change.

In addition, nearly 75% of organisations reporting to the Agency

Sources • https://www.abc.net.au/news/2018-10-17/women-inconstruction-goverment-can-do-more • https://www.wgea.gov.au

apprentice intake that is designed not just to get more females into the company, but to make it easier for them to assimilate into the company by being part of a larger group.”

Singleton said the gender target was justified because women were under-represented in the trades they require and the gender imbalance points to their being disadvantaged in job-seeking there.

The second part of Austal’s recruiting plan involves luring mature-aged women from the retail sector and home duties into shipbuilding.

It is taking 45 female apprentices and no males on board at its Australian shipyards this year.

Last year it employed 95 male apprentices and just one woman.

It is working with West Australian authorities on women-only preemployment courses and will alter its rostering to offer more familyfriendly shifts suited to job sharing.

Singleton said Austal had realised it was tapping into only 50% of the workforce and wanted to get to a tipping point where it was recognised as an employer of women and a good place for women to work.

“And therein lies the problem.

One woman among 95 guys,” said Austal Chief Executive David Singleton. “For the first time this year we have an all-female

The women-only initiative was not set in stone; if an outstanding male candidate ‘was knocking down the door’, Austral would be open to giving him an apprenticeship. Mr

“We recognised a while back that if we don’t break through a critical mass of females in the organisation, we’ll never get there,” he said. “The first step is the apprentices. The second step was to say, ‘well what about mature women who are at home who perhaps ordinarily would get attracted to retail jobs or things like that they can do during the day’ and attracting some of those into the organisation as well.”

Austal is having trouble filling about 200 jobs to augment its 1,200-strong workforce at its Henderson and Naval Base shipbuilding yards south of Perth, with spots for fabricators, welders, engineers, boilermakers and others going begging.

Originally published on https://www.afr.com

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Women In Welding Profile: Emma Claridge, Quality Assurance Advisor, UGL With over 10 years industry experience, Emma specialises in the coordination of welding quality assurance and quality control across the structural, mechanical, piping and civil sectors. She is adept at creating, implementing, auditing and verifying quality systems and processes, as well as inspecting all aspects of fabrication to ensure the appropriate Standards and specifications are met, and the finished product is fit for purpose.

A boilermaker by trade, Emma holds an AS1796 Welding Supervisor Certificate 10, and is an International Welding Specialist (IWS), having completed both qualifications through Weld Australia.

Emma commenced her career at UGL in Mackay as a class one AS1210 pressure welder and boilermaker. Initially, Emma undertook welding of nickel, stainless steels, and mild steels using GMAW, GTAW, MMAW, and submerged arc welding. Her welding experience was gained on onshore and offshore projects, coal mines, sugar mills, and coal shipping terminals, at heights and in confined spaces. Since then, Emma has held various welding inspector and quality assurance roles, including: as Laing O’Rourke’s representative on the

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I think more women should consider a career in welding because it pays well and it’s interesting.

Plus, I am a firm believer that women have a keen eye and attention to detail—skills that are essential in welding and fabrication.”

Australian Welding: March 2019

Ichthys LNG Project Accommodation Village; as ConocoPhillips’ representative for the Bayu-Undan offshore facilities; for the Dalrymple Bay Coal Terminal; and as UGL’s representative for the Olympic Dam Shutdown.

Until recently, Emma was a Quality Assurance and Quality Control Inspector at HiVue in Brisbane, having just taken on a Fly-In, FlyOut (FIFO) quality role with UGL at Olympic Dam (the fourth largest copper deposit and the largest known deposit of uranium in the world).

Describe your job.

I am currently a quality assurance advisor for UGL. Throughout my career, I have worked on everything from oil rigs, chemical plants, coal terminals, and gold, copper and uranium mines, right through to providing quality assurance for the local fabrication workshop.

My main tasks have included weld inspection, weld supervision and SMP inspection.

What I love most about my job is that it covers a vast array of quality topics and processes, from inspection and supervision, to document creation and control. Each of these topics plays a vital role in weld quality. At the moment, in my current role, I have the opportunity to be a part of each of these processes, which definitely keeps me on my toes.

What inspired you to choose a career in welding?

A career in welding is not something I planned during school. I did consider a career in engineering after school, but could not afford to study full time. So, instead, I thought a trade would be a round-about way to end up working in the same field.

Once I started my apprentice as a boilermaker, I realised just how interested I was in how the whole welding process fitted together, from fabrication to installation. There’s a lot more to welding than most people realise, particularly once you start to learn about all the variables, such as metal thicknesses, grades,

types and fillers. This alone is an extremely interesting topic.

Why do you think women should consider a career in welding?

I think more women should consider a career in welding because it pays well and it’s interesting. Plus, I am a firm believer that women have a keen eye and attention to detail—skills that are essential in welding and fabrication.

Do you have any advice for women considering a career in welding?

If you’re thinking about a career in welding, and you’re being put off, thinking that it’s too hot and heavy, and too hard physically, don’t let this stop you. There are workplace health and safety rules that limit factors like the amount of weight you can lift.

I completed my apprenticeship with UGL and they were great. If you can find a job with a larger company, like UGL, then you’re more likely to find a better ratio of men to women in the workplace. This way, your workplace may not be quite so male dominated.

Have you found working in a traditionally male-dominated industry difficult? If so, how have you overcome any challenges?

At first, I was on a mission to prove a point to myself—and everyone else around me—that I could do the job.

This was mainly because there were so many people around who believed that a boilermaker shop was for men only. I quickly found that I had a passion for learning about metal. But I needed the practical application in the boilermaker shop to understand the theory, and I wasn’t going to let anyone deter me from my end goal.

I knew early on in my career that I wanted to focus on the quality side of things. I knew that being on the tools was only a stepping stone for me.

In the end, I don’t think being a woman in a male dominated industry has impacted me or my career negatively. If I couldn’t practice what I preach, I definitely wouldn’t be where I am today.

Inside the Industry: Women, Welding & the Workforce Dynamic

What is the most interesting project you’ve worked on?

I would have to say the Olympic Dam Shutdown in 2017 was very interesting for me. It was the first project on which I had worked that wasn’t a part of a process, and the mine was huge. I was lucky enough to be the BHP Billiton representative (contracted through UGL) for the project. I ensured all turnaround work activities complied with the relevant specification and Standards through inspection and verification of the structural, mechanical and piping scope of works. It was quite an experience.

Who has inspired you professionally?

I have been very fortunate along my journey to have certain people take me under their wing. I am always one of the youngest inspectors and am always pushing to learn more.

When I was an apprentice, my very first welding supervisor was in his 70s. I had to work hard to prove myself to him. He was the first person to make me realise that I have a passion for understanding the process of welding exotic materials. Until recently, I worked alongside Andrew Gray, the Managing Director of HiVue. Andrew has helped me understand how to put together all the pieces of the puzzle to create a Welding Procedure Specification.

There is always something new to learn and I am so grateful to everyone that has had time for me over the years.

What do you believe is the biggest challenge for the welding industry at the moment?

One of the biggest challenges for the welding industry is changing people’s mindsets around why we need quality control in the first place. There is a lot involved in the quality control process, and a lot of confusion around why we need to record and do the things we do in the first place. Some people don’t understand why they now need to be qualified to weld certain things when they have been welding them their whole lives. It’s not usually until something goes wrong that the welding process is reviewed.

If we help people understand the need for quality control, we can create a better product and a more consistent product.

What do you believe is the biggest opportunity for the welding industry at the moment?

Welding is not going away. If you can weld, you can create. There’s always room for new and improved ideas.

Top: Emma Claridge, Quality Assurance Advisor, UGL. Middle: Emma Claridge performs an inspection on a pipe according to ASME B31.3 Process Piping.

Bottom: Emma Claridge performs an inspection on a pipe according to ASME B31.3 Process Piping.

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Australian Welding: March 2019

Describe your job.

As a third year apprentice, I have worked on a wide range of projects from small workshop tasks to the pad weld of the 100-section hull cut. This was a major welding task, involving up to 15 welders working in three shifts around the clock using advanced equipment.

Evyenia Kontakos (Third Year Welding Apprentice at ASC).

Women In Welding Profile: Evyenia Kontakos, Welding Apprentice, ASC ASC third-year welding apprentice Evyenia Kontakos admits it was competitive to win a place in ASC’s apprenticeship program but now knows why.

“We are given time to learn and all the facilities and tradespeople to learn from,” said the 23-year-old.

“As soon as I started, we spent time in the welding school and were then trusted to go out and work with tradespeople on the boats (submarines).”

Following school, Evyenia tried a few different jobs including working in a fish processing factory. She jumped at the chance to compete for an adult apprenticeship at ASC, earning a place in the welding program.

ASC welding is among the most demanding and quality tested in the country. Every weld on an Australian submarine must be of a very high quality, to ensure the safety of the submarine and crew in service.

In 2018, Evyenia was part of the team that re-furbished the MGR Hull Stiffening support jig on HMAS Collins – a steel structure that ensures the submarine retains its shape to support the hull as a large roof section is removed as part of deep maintenance.

“All the butt weld tests for the Collins stiffening jig came back showing no defects – so it was a great result for us,” says Evyenia. “As for working within this trade area, I’m not the only woman in the fabrication team and there are no disadvantages working at ASC towards women at all.”

According to ASC, Evyenia is highly skilled and reliable and was recently trained to weld the high tensile steel of submarine hulls. She passed with flying colours and will be putting those skills into practice later this year on a real submarine in deep maintenance.

Evyenia is one of 54 apprentices employed by ASC, with 34 based at their facilities in South Australia, and another 20 based in Western Australia.

What inspired you to choose a career in welding?

What attracted me to this career is that I like hands-on work where there is a high level of skill required. It is also a versatile job and work opportunities are high in Australia and overseas.

Why do you think women should consider a career in welding?

Women with an interest in a hands-on trade should consider this career path, as it is a challenging and rewarding career.

Do you have any advice for women considering a career in welding?

Concentrate on learning the trade as well as you can.

Have you found working in a traditionally male-dominated industry difficult?

As a woman in an industry with a high representation of males, I have experienced little or no difficulties in fitting in or working in a team.

What is the most interesting project you’ve worked on?

The most interesting project I have worked on was the simulated hull sections, which were fabricated and welded. All aspects of this project were new, and I learned a variety of skills in boilermaking and fabricating.

Who has inspired you professionally?

During my first stages of study at Noarlunga TAFE SA, my two lecturers were my biggest inspiration to continue this career path. My lecturers have worked all over the world, in so many different and extreme work places all related to fabrication and welding, but they were very committed to the success of their students and passing down their knowledge.

What do you believe is the biggest challenge for the welding industry at the moment?

The biggest challenge for the welding industry in South Australia is growing the number of skilled tradespeople to meet the needs of several exciting shipbuilding projects in the years to come.

What do you believe is the biggest opportunity for the welding industry at the moment?

The biggest opportunity as a welder or boilermaker is the sheer volume of upcoming naval work in South Australia.

National Manufacturing Summit

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National Manufacturing Summit to Tackle Key Issues Weld Australia is pleased to announce that it will once again host the National Manufacturing Summit. The 2019 National Manufacturing Summit will see a diverse group of industry stakeholders assemble in Melbourne to tackle key issues facing the Australian manufacturing industry. The Summit will be held on Wednesday 21 and Thursday 22 August, so be sure to save the dates.

The National Manufacturing Summit gathers leading representatives from all the major stakeholders in Australia’s manufacturing sector— business, unions, universities, the financial sector, suppliers, and government—to discuss the sector’s prospects, and identify promising, pragmatic policy measures designed to support an industrial turnaround.

The aim of the Summit is to leverage the opportunities currently available in the manufacturing sector, and translate these into action.

Background 2019 marks the third National Manufacturing Summit; the event was held in both 2018 and 2017 at Australian Parliament House in

Canberra. Hosted by the Centre for Future Work, the 2017 Summit was themed ‘Converting Opportunity into Action’. The 2018 Summit theme was ‘Solutions to Critical Issues: Energy and Technical Training’.

Speakers and panel participants have included leading spokespersons from across industry, as well as the political spectrum.

In 2018, just some of the keynote speakers included Professor Ross Garnaut (President, SIMEC ZEN Energy), Dr Jim Stanford (Economist and Director, Centre for Future Work), Neil Coulson (Victoria Skills Commissioner), Dr Jens Goennemann (Managing Director, Advanced Manufacturing Growth Centre), the Hon Mark Butler

Sponsor the National Manufacturing Summit Sponsor the 2019 National Manufacturing Summit to give your company unparalleled exposure to an interested, engaged audience. Your involvement in the Summit will demonstrate your organisation’s commitment to innovation and excellence.

Sponsoring the Summit will give you the opportunity to: • • • • • •

Maintain and build on professional relationships Connect with a highly targeted audience Showcase your new products and services Gain instant market feedback Increase and strengthen brand awareness Stay at the forefront of industry developments and innovations

Keep in mind that we’re more than happy to tailor a sponsorship package to suit your needs and budget.

Please contact Weld Australia on +61 (2) 8748 0130 or events@weldaustralia.com.au for further details.

(Shadow Minister for Climate Change and Energy), the Hon Karen Andrews MP (then Assistant Minister for Vocational Education and Skills), and the Hon Doug Cameron (Shadow Minister for Skills, TAFE and Apprenticeships). This year’s speakers and panellists are set to be equally as exciting and engaging.

Attended each year by over 100 delegates, the Summit program is designed to open new ground in the policy dialogue over how to sustain and nurture manufacturing: a vital segment of Australia’s economy.

Register your interest now: https://manufacturingsummit. com.au/register-your-interest

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Australian Welding: March 2019

Member Profile: CPT Engineering CPT Engineering has grown from a one-man manufacturing business based in Scottsdale, Tasmania into a specialist steel fabrication operation with a presence not only in Tasmania, but Australia-wide.

Whether it’s a powder-coated architectural sign, an industrial shed, furnace stand, or a thousand small machined parts, CPT Engineering delivers custom-made orders in a highly efficient time frame, cost-effectively. CPT Engineering does this by investing in the latest technology, creating new, efficient and exciting opportunities for their clients.

A family business, CPT Engineering is owned by directors Geoff and Sally Watson. The company began in 1982 as Watson Engineering, a one-man concern in Scottsdale, Tasmania. Operated by Geoff, the company manufactured and supplied products to rural, mining, agricultural and timber industries in north-east Tasmania. As these industries grew, so did Watson Engineering.

Comalco (now Rio Tinto). Three years later, in 2006, Geoff and Sally Watson amalgamated the two operational arms of the business, relocated Watson Engineering to George Town, and changed the company name to CPT Engineering.

Keen to expand the capabilities the company could offer clients— particularly with an increase in contracts with mainland Australian companies—Geoff and Sally purchased the Centre for Precision Technology (CPT) in Glenorchy.

Since that time, CPT Engineering has maintained a strong presence in the area, investing in technology and a team of over 80 highly trained, enthusiastic staff. It is estimated that in over 30 years of operation, the company has employed more than 300 Tasmanians, and has trained more than 40 apprentices, many of whom have stayed with the company well beyond the completion of their apprenticeship.

By 2003, Geoff and Sally had decided to relocate CPT closer to Watson Engineering. A sizeable premises was purchased in George Town to offer economical and timeefficient service to multinational companies such as Alcoa and

According to Nick Watson (Manager, CPT Engineering), “CPT Engineering is a general engineering company.

We provide a diverse range of engineering solutions in fabrication, tube bending, machining and, more recently, 3D laser cutting.”

“We also do a lot of prototyping because of the diverse range of capabilities we have in-house.

We can take care of the entire prototyping process, from designing and building a part, to painting and testing it. Just some of the industries we work with include mining, utilities, whitegoods, transport, construction, architectural, electrical, and forestry.

It really is quite a diverse mix.”

“Some of our recent projects include a contract for the supply of components for 100 public transport buses in Tasmania, a significant prototype job for an aluminium smelter in Tasmania, and a new batch of kiln trolley and bricks for a timber mill. We also processed a lot of heavy tube for the front façade of a new museum in Victoria,” said Watson.

“We are heavily focused on being at the forefront of technology. We utilise a range of cutting-edge technology to provide the best possible

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Member Profile: CPT Engineering

outcome for our clients: fast, efficient turnaround, repeatability, and superior quality, regardless of whether it is a small one-off job or a large-scale project.”

The Secret to Success It is CPT Engineering’s customer service and in-house diversity that really sets the company apart.

“We really work hard on building relationships with our customers. As opposed to being a supplier, we want to be a partner—a partner that adds value. We’re really flexible, and where there are tight turnarounds, we try to help wherever we can. We have an ‘open door’ policy. We encourage all our customers to drop into our workshops at any time to see their jobs being completed,” said Watson.

“We also pride ourselves on our in-house diversity. Our workforce is comprised of people with hugely diverse experience, from the types of machines and technology in which they’re skilled, through to the industries they’ve worked in, and the type of welding they’re experts in. This translates into value for our customers.”

3D Laser Cutter In 2018, CPT Engineering installed a 3D laser cutter in its Victorian workshop. With the installation complete, CPT now offers fast, accurate processing of any shape material up to 12m long that fits within a 406mm diameter area. The 4kw laser can load and unload up to 12m and process beams, columns, angles, SHS and RHS, tube and pipe, channels or odd profiles.

According to Watson, “Since we installed the laser cutter, it has opened up a lot of new doors. We initially invested in the technology for existing fabrication work and other contracts we regularly undertake.

However, we’re finding that the technology is opening up a lot of new doors due to its extensive capabilities. The more that people find out about the laser cutter, the more interest there is.”

“With fabrication project work, all of

the material first goes through the laser. The result is that everything is millimetre perfect. It all fits together well and fabrication is really easy.

It is much simpler, more efficient and more cost-effective when compared to the traditional ways of processing the material. These time and cost savings are passed onto our suppliers and customers who are really seeing the value in their fabricated parts. Everything is a lot more accurate and repeatable. It saves a lot of time.”

Development of In-House Skills CPT Engineering first discovered Weld Australia when looking for technical advice on a specific welding process.

“We were having a bit of trouble with some specialised brazing. We looked around for some expertise in the area and found Weld Australia.

Their technical experts visited our workshop and gave us some good suggestions,” said Watson.

“In dealing with this brazing issue, we became interested in the further training and accreditation that Weld Australia can assist with, particularly as this training and accreditation will become more important with the roll out of upcoming defence industry work. This year, we are set

Left: The 3D laser cutting machine at CPT Engineering’s Victorian workshop.

Above (Left): The 3D laser cutting machine in action at CPT Engineering’s Victorian workshop.

Above (Right): Completed fabricated components.

to focus on the training of our staff, rather than capital investment. We’re looking to develop our in-house skills—at both a management and technical level—even further.”

“The development of in-house skills is important with growing opportunities in heavy commercial fabrication, particularly as we’re starting to see a bit of a swing back to local input, as opposed to international supply. More and more, Australian companies are seeing value in a local supplier—in being able to visit their workshop, confirm quality control mechanisms, and have access to fast turnaround times.”

“Supporting this is the defence work that the Government is behind for the next 20, 30, 50 years. The amount of money being spent in the defence industry is a real incentive for welders to develop workforce skills and improve in-house capabilities,” said Watson.

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Australian Welding: March 2019

AS/NZS ISO 9606-1 & the AWCR: Helping Welders Win More Work In 2016, the Victorian Government ordered 65 nextgeneration high capacity trains for the metropolitan network. The $2.3 billion investment is the largest single order of new trains in Victoria’s history and is being delivered through a Public Private Partnership with Evolution Rail, a consortium consisting of Downer, CRRC and Plenary.

The Victorian Government’s investment includes the design, manufacture and delivery of 65 next-generation high capacity metro trains which are expected to service the Cranbourne and Pakenham lines from mid-2019. The project team will also deliver a state-ofthe-art depot including train maintenance facility and stabling yard for 30 trains, a light service facility and two driver simulators.

The train fleet will be built with at least 60% local content – trains are being assembled in Newport in Melbourne’s west using locally made systems and components. The HCMT Project will result in 1,100 jobs, including 175 jobs at the Newport manufacturing facility, hundreds of jobs for local suppliers throughout Victoria, including regional areas, 450 jobs at the peak of construction for the new depot in Pakenham East, and 100 long-term rail maintenance jobs.

The Evolution Rail consortium required welding assistance with the project. Weld Australia was in a unique position to provide the project with a complete end-to-end reliable welding solution to help ensure the safety of future rail passengers.

According to Victor Blain (Senior Welding Engineer, Weld Australia), “Weld Australia is in a unique position; we are able to provide a complete one-stop-weldingshop for organisations. We can provide the welding consumables, the welding equipment, and even the welder or fabricator.”

Weld Australia can assist with the development of Welding Procedure Specifications for a project, and then provide welding supervision and inspection services to ensure that all welding is completed in compliance with the Specifications, as well as all relevant Australian Standards and International Standards.

Weld Australia can also help ensure that the welder is certified to all appropriate Standards. If they are not certified, Weld Australia can work with the welder or company to ensure they gain the relevant certifications, including AS/NZS ISO 9606-1 Qualification test of welders — Fusion welding —Part 1: Steels, AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials, and EN 15085 Certification for Welding of Railway Vehicles and Components.

“For this project, Weld Australia sourced a contractor on behalf of the Evolution Rail consortium, who was able to supply both a welder certified according to AS/NZS ISO 9606-1 and the equipment. This contractor was DJM Fabrications,” said Blain.

Australian Welder Certification Register Weld Australia was engaged to source and supply a welding contractor to deliver safe and reliable welding solutions for Melbourne’s newest train fleet. “We were able to search the Australian Welder Certification Register (AWCR) for someone already certified to AS/NZS ISO 9606-1,” said Blain.

“It really is essential that all welders in Australia are registered on the AWCR. The benefits are immense—in this instance, DJM Fabrication won a major contract simply because their welders were registered.”

Chris Marshall (General Manager, DJM Fabrications) wholeheartedly agreed with this, “I definitely recommend that welders and fabricators register themselves on the Australian Welder Certification Register. There are huge possibilities to win more work by doing so.”

This project came along at the perfect time for DJM Fabrications. According to Blain, “DJM was looking to expand their business into on-site welding services and the maintenance of railway vehicles.

So, this project was perfect for them. They were very enthusiastic to be a part of the project, and the skills of DJM’s welders were exceptional. Weld Australia and the HCMT project team were very pleased to work alongside DJM’s extremely professional team.”

Inside the Industry: AS/NZS ISO 9606-1 & the AWCR

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Left & Below: The High Capacity Metro Trains. Image courtesy of the Victoria State Government Department of Transport. The Victorian Government has ordered 65 next-generation High Capacity Metro Trains capable of carrying 1,100 passengers - 20% more than any other train on the network.

Melbourne’s bigger, better trains will be approximately 160m long, have seven carriages and deliver a smoother, quieter and more comfortable ride with improved seating and standing areas. In addition, the trains will feature improved real-time information through dynamic route maps and passenger information displays, as well as improved passenger safety, with full CCTV surveillance. The trains will initially run on the Cranbourne and Pakenham lines and will eventually run through the Metro Tunnel to Sunbury.

AS/NZS ISO 9606-1 Certification Gaining certification to AS/NZS ISO 9606-1 is as equally as important as registering on the AWCR. AS/NZS ISO 9606-1 provides for a standardised method of testing a welder’s skill utilising welding processes, materials, consumables and procedures likely to be encountered during the fabrication of steelwork. Unlike other welder qualification standards, AS/NZS ISO 9606-1 is not specifically limited or linked to any specific industry sector. As such, it provides for a broad range of application without complexity or compromising quality. This affords fabricators and welders alike, the opportunity to work across industry sectors without the costs associated with requalifying welders welding on similar joints and materials.

According to Marshall, “The process of obtaining certification to AS/NZS ISO 9606-1 is not cheap. It is a big investment for any company or welder. But, what we found, is that you don’t really understand how far-reaching the benefits are until you’ve done it. The process of being certified is extremely thorough—our welders learnt so much that they are able to apply to their work every single day. The certification has actually improved the way in which we operate. This certification is something that DJM Fabrications will be doing more and more for our welders, particularly as we want to stay ahead of the curve, ahead of our competitors,” said Marshall.

ISO 9606-1 is gaining importance throughout the world, and within Australasia as AS/NZS ISO 9606-1. With major government spending now underway on defence and transport projects and with the major contractors being European based and utilising ISO welding standards, certification to this Standard will only grow in importance. Already, defence industry groups are referencing AS/NZS ISO 9606-1 as the basis for welder qualifications for their industry, as are the pressure equipment industry and transport bodies.

Benefits of AS/NZS ISO 9606-1 Qualifying welders to AS/NZS ISO 9606-1 presents a number of benefits associated with reduced compliance and welder qualification costs: • Welder qualifications are not specific to any one industry (or application standard) • Welder qualifications valid for two or three years are transportable across worksites and employers, avoiding the need to requalify welders where there is evidence of maintenance of qualification • Options available for welders to simultaneously qualify for both butt welds and fillet welds • Welder qualifications utilises a six monthly confirmation process to ensure maintenance of welder skills without the need for additional testing • Multiple test assessment methods available to suit project budgets and mitigate risks ranging from ultrasonic radiographic examination to simple destructive tests • Option available for alternative assessment criteria • Test system is based on welding to qualified weld procedures (option available to qualify welder and procedure at the same time)

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Australian Welding: March 2019

Welding Supervisors, Responsible Welding Coordinators & AS/NZS ISO 3834 While the roles of Welding Supervisor and Welding Coordinator may seem similar, there are some very specific—and very significant—differences between the two. The levels of knowledge, competence and qualification required to act as a Welding Supervisor are much less strict than those required for a Welding Coordinator. In addition, one of the most significant features of AS/NZS ISO 3834 is the requirement that a fabricator must have at least one Welding Coordinator.

Welding Supervisor The role of the Welding Supervisor is probably one of the most well known in the Australian welding industry.

It is referred to in several Australian application Standards, including: AS/NZS 1554 series Structural steel welding; AS/NZS 1665 Welding of aluminum structures; AS/NZS 3992 Pressure equipment – welding and brazing qualification; and AS/NZS 2885 Pipelines – Gas and liquid petroleum.

Welding Supervisors combine supervision skills, with knowledge of welding processes and production NDT to plan, staff, monitor and safely deliver welding projects.

These responsibilities place Welding Supervisors in a unique position, to ensure product quality in every industry that uses welding as a core process in the manufacture of their products.

It is a mandated requirement that all welding activities are carried out under the supervision of a Welding Supervisor. As defined in Clause 4.12.1 of AS/NZS 1554.1, the Welding Supervisor’s function is to ensure that the weld process is appropriately managed before, during and after the welding. The Welding Supervisor would normally be an employee of the fabricator, but in some cases may be contracted to the fabricator to perform such functions.

As welding supervision is one of

the four key pillars of weld process control in Australian application standards, the expectation is that the Welding Supervisor will have a full working knowledge of: • Relevant application Standard(s), • Knowledge of the relevant welding technology, • At least basic metallurgy, and • General fabrication requirements.

Specific areas that the supervisor is trained in are detailed in the Australian standard AS 2214 (and similarly, in AS 1796). It is important to note that the syllabus items and competencies required are somewhat consistent with the tasks specified within ISO 14731 Responsible Welding Coordinator – tasks and responsibilities.

Depending on the application standard and specific task, minimum knowledge requirements for supervisors can vary. Regardless of which other alternative qualification or level of experience the welding supervisor qualifies under, evidence is still required of their technical capability. The role of the supervisor starts by identifying the key tasks that the supervisor has to perform within the scope of work, materials and welding processes used by the fabricator.

In situations where the fabricator needs to undertake more technically challenging work, an alternative available to the fabricator is to

contract in a person with higher level skills and qualifications for the duration of the work to provide specific engineering and technical advice as required to the fabricator’s staff.

There are several qualifications that can be held by a Welding Supervisor.

These include National and International qualification, such as: • AS 1796 Certification of welders and welding supervisors Certificate 10 Welding Supervisor • AS 2214 Certification of welding supervisors – Structural steel welding • IIW International Welding coordinator (International Welding Specialist, Technologist, or Engineer) With further training, knowledge or experience (or a combination of these), a Welding Supervisor can go on to become a Welding Coordinator.

Welding Coordinator Unlike the mentioned application standard, AS/NZS 5131 (product Standard) and AS/NZS ISO 3834 (process Standard) refer to welding coordination in addition to welding supervision.

Welding coordination is more of a management task, and less of an operative task.

A Welding Coordinator is someone who can competently apply best practice in the welding activities

Inside the Industry: Welding Supervisors, Responsible Welding Coordinators & ISO 3834

carried out by the fabricator.

As such, they must be suitably competent, experienced and qualified for the type of welding activities carried out by the fabricator.

Welding Coordinators may be required to perform a variety of tasks, one of which is welding supervision, particularly in smaller fabrication companies. In larger companies, welding coordination tasks may be undertaken by a number of people. However, the Welding Coordinator retains responsibility for the overall process.

The Welding Coordinator is required to have greater technical knowledge and experience to competently undertake the tasks at hand. The minimum recommended technical knowledge requirements for welding coordination personnel is defined in ISO 14731.

It is recommended that Welding Coordinators undertaking welding supervision tasks in accordance with the Australian application standards should at least have a recognised welding supervisor or welding specialist qualification plus relevant experience, unless more extensive technical knowledge is required in accordance with the contract (such Premier Welding Training Weld Australia delivers a comprehensive range of training and certification services, designed to help Australian welders and fabrication companies achieve and maintain a competitive advantage. As the premier welding certification body in Australia, an International Institute of Welding (IIW) Authorised Nominated Body (ANB) and an Authorised Training Body (ATB), Weld Australia offers a range of individual certifications: • Welding Inspector • Welding Specialist • Welding Technologist • Welding Engineer • AS1796 Welding Supervisor Certificate 10 • AS2214 Welding Supervisor

as welding technologist or welding engineer). Such requirements though remain a matter for resolution between the fabricator and principal.

Different Welding Coordinators can be appointed by a fabricator to look after different products or aspects of the fabrication process.

In this case, we have the ‘welding coordination team’ where there is a clear allocation of roles and responsibilities, so that: • Responsibility is clearly defined for each team member, and • The individuals are knowledgeable and qualified for each specific welding coordination task The Welding Coordinator makes decisions on behalf of the fabricator. As they assume the ultimate responsibility for all welding activities, the knowledge and competency of the Welding Coordinator is of paramount importance.

The requirement of a Welding Coordinator under AS/NZS ISO 3834 is crucial—it is included to ensure that a manufacturer understands the problems which can arise while manufacturing an welded product, and how they can be avoided.

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With further training, knowledge or experience (or a combination of these), a Welding Supervisor can go on to become a Welding Coordinator.”

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There are several different qualifications that can be held by a Welding Coordinator. These include, with increasing level of knowledge: International Welding Specialist (IWS); International Welding Technologist (IWT); and International Welding Engineer (IWE).

Welding Coordination According to ISO 14731 AS/NZS ISO 3834 is to be used

Australian Welding: March 2019

in conjunction with ISO 14731 Welding coordination – Tasks and responsibilities. Welding Coordination is described in ISO 14731 as including: • Welding engineering • Welding supervision • Material selection • NDE Control and management • Quality control management • Review and analysis of contract requirements

Differences Taking into consideration AS/NZS 1554.1 and ISO 14731, a comparison of the various roles, responsibilities and requirements is given below, to identify the main differences, in specific areas of knowledge, required to perform the two job function. The table, however, is not exhaustive of the depth of knowledge difference between a welding supervisor and coordinator.

Table 1: Comparison of ISO 14731 and AS/NZS 1554.1 Job Functions

ISO 14731

AS/NZS 1554.1

Requirements and technical review including • Standards and supplementary requirements • Capability of the manufacturer • Materials and welded joint specifications • Quality and acceptance criteria

Section 1, Appendix D Matters for resolution

Sub-contracting

Not specified

Welding personnel • Welders • Welding coordination personnel

Clause 4.12

Inspection and testing personnel • Includes NDT personnel

Section 6, Clause 7.4

Equipment • Production equipment and ancillaries • Capacity identified • Maintenance records

Not specified

Welding activities • Production plan • Weld procedures • Work instructions

Sections 4 and 5

Storage and handling of welding consumables

Clauses 2.3, 4.6, 5.4

Storage of parent materials

Clauses 2.1, 2.2, 5.1, 5.4

Post weld heat treatment

Not specified – refer to AS 4458

Inspection and testing

Sections 6 and 7

Non-conformance and corrective actions

Clauses 4.10, 6.7, 6.8, Appendix D

Calibration

Not specified

Identification and traceability

Not specified

Quality records

Clauses 4.10, 6.8, Appendix D

Notes: 1. Specific production planning requirements are usually a contractual matter upon which AS/NZS 1554 is intentionally silent. Requirements are typically specified contractually in larger or higher risk fabrication.

2. Further detail of requirements can be found in Annex B of ISO 14731.

References: https://www.aws.org

Inside the Industry: Welding Supervisors, Responsible Welding Coordinators & ISO 3834

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Figure 1: Welding coordination overview. The activities listed are typical of those managed by welding coordination personnel (see ISO 14731)

Welding Coordinator or Equivalent Coordinates Requirements for Welding AS/NZS 1554 Part 1 Clause 1.7.1 Quality Management Fabricators shall ensure that all welding and related activities prescribed within Clause 1.7.2 and this Standard are managed under a suitable quality management system. Such a system should generally comply with the requirements of AS/NZS ISO 3834 and its parts, particularly where fabrication activities require the approval of the principal or inspecting authority, or where the fabrication of large, complex or critical structures is being undertaken.

Estimator

Needs to understand production capability for tendering purposes.

Purchasing

Needs to purchase correct steel/ welding consumables to procedures.

Consumables need to be stored effectively and traceable.

Manages subcontracted services, such as NDT, PWHT, fabrication, inspection, etc.

Manages: • Systems associated with welding , such as production, planning, weld identification, testing and traceability of all records, steel and consumables; • Equipment maintenance and calibration, etc.

Training

Welding Supervisor

Needs to have all welding procedures documented, available for welders.

Reviewed per project for welding requirements.

Supervisor needs to have authority to enforce procedures.

Manages inspection and testing during and after welding.

Staff need to be trained and competent.

Trade and subcontracted welders need to be tested for competence and approved to that welding type.

Looks to work conditions, environment, allocation of qualified personnel, and safety.

• • •

Qualified welders Trade welders Subcontract welders

Further Information For further information about becoming a Welding Supervisor or a Responsible Welding Coordinator, or to enrol in a Weld Australia training course, please contact: W: www.weldaustralia.com.au E: training@weldaustralia.com.au T: +61 2 8748 0100

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Australian Welding: March 2019

Industrial Evolution the Focus for NMW 2019 Australia’s largest manufacturing exhibition and conference returns in 2019, with the 20th edition of National Manufacturing Week to be held from 14 to 17 May at the Melbourne Convention & Exhibition Centre. After the successful Melbourne event in 2017 with over 10,000 attendees, National Manufacturing Week 2019 will be about driving continuing innovation in local manufacturing and the evolution to advanced technology solutions, sharing insights to stay ahead of the game and celebrating the Australian manufacturing sector’s success that has been generated in recent times.

“National Manufacturing Week 2019 arrives on the industry’s calendar at a truly exciting time of growth in Australian manufacturing. This year’s event is focused on supporting manufacturing’s continuing evolution to a high-tech, highly integrated and innovative industry, while providing the latest expert insights, industry research and technology to generate even greater momentum,” said Robby Clark (Exhibition Director, National Manufacturing Week).

As the focal point for the manufacturing community to come together, interact, connect, and be inspired, Industrial Evolution will be the theme for National Manufacturing Week in 2019 across the conference program and exhibition’s four days.

“Automation, collaborative robots, the Internet of Things and high-level engineering, will be of prime focus at this year’s event, offering industry professionals and decision-makers with an unmissable opportunity to acquire new insights and source innovative solutions for ongoing operational success,” said Clark.

Strategic partners and industry associations supporting National Manufacturing Week in 2019 include the Advanced Manufacturing Growth Centre (AMGC), Innovative Manufacturing CRC (IMCRC), Engineers Australia and Weld Australia. These partners strengthen National Manufacturing Week’s industry relevance and cement the event’s status as the hub for the manufacturing community to share

insights to support continued growth in the industry.

National Manufacturing Week will also again be co-located with Austech, the only metalworking, machine tools and ancillary market focused event in Australia. With Austech’s organiser, AMTIL, explaining the co-location will see the long-held relationship provide further benefits for attendees in 2019.

“AMTIL is delighted to further cement the long-term relationship between Austech and National Manufacturing Week with our joint conference program at our event this May. We are excited to collaborate on what promises to be a highcalibre program which involves cutting edge concepts in the Industry 4.0 space,” said Kim Banks (Events Manager, AMTIL).

This increased collaboration between the AMGC, Austech and National Manufacturing Week, will see the 2019 conference program feature an impressive line-up of more than 70 expert speakers, who will share their exclusive insights about industry challenges and recommendations for operational success.

Divided into the Industry 4.0 Theatre and Connected Manufacturing Theatre, these two theatres will focus on the impact of the Internet of Things to business, and improving efficiency, safety and operational management. “This year’s conference program for National Manufacturing Week will be our most

extensive and in-depth to date, with attendees offered unprecedented access to industry leaders who will share their expertise and knowledge,” said Clark.

Industry 4.0 Theatre Program The Industry 4.0 Theatre program will offer attendees the latest opinions, developments and research about the impact of Industry 4.0 on businesses and operations.

This stream within the conference program will begin with a keynote delivered by Australia’s Chief Scientist, Dr Alan Finkel, followed by an innovation and collaboration stories series run by the AMGC. Following this session will be a panel discussion run by Peter Roberts, a leading journalist, editor and founder of the 4,200-member Australian Manufacturing Forum.

Day two will feature a second panel run by the Australian Manufacturing Forum focused on the benefits of onshoring. This will be followed by a presentation on driving innovation through advanced materials, and case study examples about how the adoption of smart technologies in factories can lead to success.

Days three and four of the conference will cover topics such as artificial intelligence in advanced manufacturing, Industry 4.0 digital shipbuilding in global supply chain, the outlook of the defence market, and the evolution of robotic manufacturing in Australia. Speakers featuring in Industry 4.0 sessions include: Dr Nico Adams (Director of

Inside the Industry: National Manufacturing Weeks 2019

Factory of the Future, Swinburne University), Dr Elliot Duff (Principal Research Consultant, CSIRO Data61), David Chuter, (CEO, Innovative Manufacturing CRC), Christopher Vains (Head of Digital Enterprise, Siemens) and Dr Jens Goennemann (Managing Director, AMGC).

Connected Manufacturing Theatre Program The Connected Manufacturing Theatre conference program is targeted at offering business owners, managers, WHS professionals and designers with expert advice about business management, design and industrial safety challenges.

Conference sessions within this stream will focus on industry topics, including: environment and energy policies, process improvement and optimisation, safety innovation, safety policies, safety management and culture, mental health and wellbeing, marketing and sales, additive manufacturing and design, and government grants and tariffs.

Speakers featuring in the Connected Manufacturing sessions include: Peter Ticker (Digital Innovation and Advisory Lead Energy Solutions, ERM Power), Philip Smith (Director of Business Development, Victoria and Tasmania, Efic), Brooke Donnelly (CEO, Australian Packaging Covenant Organisation), Toni Kennington (HR Systems Owner,

Fonterra Cooperative Group), Dr Arash Niavarani (Director, CBIS), Alex Kingsbury (Managing Director, Additive Economics) and James Woolcock (Founder and Engineering Director, Bastion Cycles), Gareth Berry (CEO, Unleashed Software) and Kate Whitehead (Managing Director, Avant Group).

The Exhibition Visitors to National Manufacturing Week 2019 will be able to take advantage of six designated product zones on the exhibition floor. The six product zones for 2019 are Automation and Robotics, Engineering, Industrial Internet of Things, Safety, Welding Technology, and Manufacturing Solutions.

As a strategic partner of this year’s event, Weld Australia will also have a presence on the exhibition floor, offering visitors an interactive experience and deeper insight into the latest in welding skills training and development. “Weld Australia will have an Advanced Welder Training Hub on the exhibition floor which will showcase the augmented and virtual reality technology that is revolutionising welder training here in Australia, and around the world.

Attendees will have the chance to see and try a range of different welding simulators, which are making welder training and upskilling safer, more cost-efficient and

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engaging for new and experienced welders,” said Donna South (Marketing and Communications Manager, Weld Australia).

This year’s exhibition floor will feature over 200 leading industrial suppliers of game-changing solutions, new technology, advanced manufacturing products and operational services.

Exhibiting suppliers include: WAGO, 3M Australia, Central Innovation, Universal Robots, Profifeed Technologies and Kobot Systems.

A wide array of specialised welding technology exhibitors are also joining this year’s event, such as Lorch South Pacific, Lincoln Electric, BOC, Supagas, Kemppi Australia, Air Liquide Australia and Gullco International.

National Manufacturing Week 2019 will include several networking and celebration functions, including the 20th Anniversary networking function, the 2019 Victorian Manufacturing Hall of Fame Awards and the Endeavour Awards.

Free registration is now open for the 20th National Manufacturing Week, which will be held in Melbourne from 14 to 17 May 2019. Register at: nationalmanufacturing week.com.au

Top Right: Mehdi Tajfar (Welding Engineer, Weld Australia) demonstrates the Soldamatic demonstrates the Soldamatic welding simulator at Weld Australia’s stand at NMW. Bottom Right: The exhibition floor at National Manufacturing Week 2017 in Melbourne.

Bottom Left: A keynote presentation at National Manufacturing Week 2017.

www.nationalmanufacturingweek.com.au

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Australian Welding: March 2019

Meet the Weld Australia Board of Directors Weld Australia is governed by a Council (Board of Directors) elected from its members. Our Councillors are experienced industry professionals, whose primary responsibilities are to monitor the performance of the Institute and the implementation of Council approved strategies and policies. Weld Australia Councillors act with independence and in the best interests of members in all decisions to ensure that the Australian welding industry remains locally and globally competitive, both now and into the future.

David Lake, President, Consultant With over 40 years’ industry experience, David Lake is Weld Australia’s President. For the past ten years, David was the Managing Director of ATTAR (Advanced Technology Testing and Research). Prior to this, he was in Victorian Senior Operations Management roles for Austral Bricks, Fletcher Insulation, Olex Cables, and an engineer at companies such as BHP Steel, NABALCO Alumina Refinery and Bauxite Mine, United Peripherals and ITT Components Group Europe. For many years, David was a metallurgist and welding inspector, responsible for writing and approving weld procedures and specifications in the mining and refining industries. He has also led operations in manufacturing of electric cables, insulation products, bricks and masonry.

Doug Hawkes, Deputy President, Managing Director and Principal Structural Engineer, Structural Integrity Engineering Doug has over 20 years’ experience as a practising engineer and engineering business owner. He is a Chartered Engineer in Structural Engineering and Leadership and Management, a Registered Professional Engineer of Queensland (RPEQ). Doug’s experience includes structural design, site supervision, contract management, workshop quality control assessments, and independent design auditing.

Mick Cudmore, Manager, Nix Sheet Metal Engineering Mick started his career as a welder’s assistant and has progressed over the past 40 years to a first class welder and boilermaker, leading hand, trainer, foreman, welding inspector and supervisor. He worked as a welding superintendent for a number of years, including the roles of project and construction manager, client’s representative and technical advisor on welding matters in both steel and plastics. Mick has been associated with Weld Australia committees since 1991.

Madeleine du Toit, Professor, University of Wollongong Madeleine holds BEng, MEng and PhD degrees in Metallurgical Engineering and a Masters in Welding Engineering. She is a registered Professional Engineer in South Africa and an International Welding Engineer (IWE). Madeleine served as the President of the Council of the Southern African Institute of Welding (SAIW) from 2010 to 2014, Madeleine is actively involved in the IIW, currently as Chair of Commission IX and Chair of the Communications and Marketing Working Group.

Inside Weld Australia: Meet the Weld Australia Board of Directors

Richard Fowles, Senior Product Manager, Strategic Marketing, BOC At BOC, Richard manages a multimillion dollar welding equipment and consumables market. He was previously a senior manager in a welding consumables factory, and a Lead Assessor for ISO 3834 management systems. An IWE, Richard holds Masters in Metallurgy, Materials Engineering, and Welding Engineering. While employed at Weld Australia, he was the Australian representative at IIW International Authorisation Board (IAB) meetings.

Adam Furphy, Managing Director, Furphy Engineering Adam holds a Bachelor of Mechanical Engineering from RMIT. He joined J. Furphy & Sons in 1997—a business with a range of activities across the metal fabrication and services sectors, from manufacturing stainless steel tanks and pressure vessels to hot dip galvanizing services. Adam has a strong interest in regional education and is a current member of the LaTrobe University Council, a Trustee of the Shepparton Mechanic’s Institute and Chair of the Greater Shepparton Lighthouse Project.

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Roger Griffiths, Consultant Roger managed the Refinery inspection department for 28 years at BP Refinery, initiating and leading the development of a number of world-class innovations, including systems for digital recording and download of thickness data, and the development of a 3D plant design model into an inspection tool operated by the plant inspectors.

He has been associated with Weld Australia for over 30 years. In 2003 he received the Weld Australia Florence Taylor Award, and joined the Weld Australia Council in 2008.

“ Dan Hayward, Team Leader Integrity Engineering, Santos Dan is passionate about improving Australia’s technical and operational expertise. He has 20 years’ experience in operations management, engineering, supply chain and procurement, project management and strategy. The majority of this is in the manufacturing and oil and gas sector in Australia with significant international exposure in Japan, South Korea, US, Thailand, China and Germany. Dan holds an MBA, and Bachelors of Metallurgical and Mechanical Engineering.

Rob Johnson, Customer & Market Relationship Manager, Liberty Rob is an expert senior manager with 30 years experience in sales, marketing and business development.

Rob has held a variety of senior sales and marketing roles at Liberty since joining in 2006. He is a Board Member of the Bureau of Steel Manufacturers of Australia and the Australasian Certification Authority for Reinforcing and Structural Steels, and holds a Bachelor of Commerce. Rob was appointed to a casual vacancy on the Council in March, with his position to be confirmed at the next AGM following the normal election process.

The key objective of the Weld Australia Board of Directors is to facilitate the growth of a world class welding industry in Australia.

Moving forward, we will continue to create opportunities for all our members and advocate for welding policies and practices that protect the Australian public.” ~ David Lake, President, Weld Australia

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Australian Welding: March 2019

Meet the Weld Australia Team Weld Australia is managed by a team of experienced industry professionals, all of whom are experts in their field. Our primary goal is to ensure that the Australian welding industry remains locally and globally competitive, both now and into the future. As such, all our team members are dedicated to providing members with the best possible service and outcome. To help you ‘put a face to the name’, you’ll find a brief introduction on each of Weld Australia’s team members below.

Geoff Crittenden, Chief Executive Officer Geoff is a chartered engineer with over 30 years’ experience and a diverse background that includes CEO and senior leadership roles in the not-forprofit, consulting, engineering and healthcare industries. Geoff started his career as an engineer in the British Army, serving in Northern Ireland, Cyprus and Germany for over 15 years. Following the fall of the Soviet Union, Geoff decided upon a career change and, with his family, immigrated to Australia.

Geoff’s first role in Australia was CEO of the Association of Consulting Engineers, after which he held senior leadership positions with Transfield Worley, Cynergy Group, Tianda Pharma and the Risk Management Institute.

Alistair Forbes, General Manager Engineering, Principal Welding Engineer Prior to joining Weld Australia in 2017, Alistair was a Product Manager at BOC for 15 years, responsible for the management of the welding consumables and industrial chemicals product portfolio. Alistair was previously employed at Weld Australia (managing our technical panels) and was also a Research and Development Manager at Afrox, and a Process Metallurgist at Highveld Steel. Alistair holds a Masters’ degree in Metallurgy and is an International Welding Engineer (IWE) with over 30 years of experience.

Donna South, Marketing & Communications Manager Donna heads up marketing and communications, membership services and stakeholder relations.

She is dedicated to ensuring that Weld Australia strives to promote the interests of its members in the field of welding in Australia. She has worked in a variety of industries and roles intersecting with the industrial sectors that make up Weld Australia’s member base. Before joining Weld Australia in 2013, Donna worked in recruitment for the construction, civil, mining and engineering industries, as well as at Ausco Modular.

Paolo Corronca, General Manager Qualification & Certification, Senior Welding Engineer Paolo is a mechanical engineer with over 15 years’ experience in EPC and EPCM projects worldwide, particularly in the oil and gas industry. Paolo’s expertise includes complete control of new projects; maintenance and commissioning of heavy equipment; mechanical systems design; auditing in quality, and in the fabrication, welding, and railway industries; and equipment safety. Paolo holds a Masters in Mechanical Engineering, and is a certified IWE.

Inside Weld Australia: Meet the Weld Australia Team

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Michael Pitt, National Business Development Manager Prior to joining Weld Australia in 2018, Michael held various positions with TAFE New South Wales, including the Faculty Director for Trades and Technology.

An expert educational leader, Michael has extensive experience in change management, project development and industry liaison and collaboration. Michael began his career as a boilermaker welder, before going on to become a Welding Supervisor. Michael holds a Diploma of Teaching, a Graduate Diploma in Educational Studies, and a Masters of Education.

Bruce Cannon, Technical Publications Manager, Principal Welding Engineer With 40 years experience, Bruce joined Weld Australia in 2016. Prior to this, he worked at BlueScope Steel in resistance seam welding, flash butt welding and welding systems. He also spent many years at BHP in delayed hydrogen cracking, special testing of steels, weld repair, and welding of coated steels and quenched and tempered steels. He has extensive experience in Australian Standards, as Chair of WD-003 Welding of Steel Structures.

Bruce holds a Bachelor of Applied Science (Metallurgy) and is an IWE.

Paul James, Training Manager Joining Weld Australia in 2016, Paul is an expert training professional, with extensive experience developing learning solutions and strategies in multiple industries. He is also qualified and experienced in quality management, auditing and compliance. Paul held training and development management roles at various organisations, including the Department of Defence, Downer EDI, Thales and the Commonwealth Bank.

Before embarking on a career in learning and development, Paul was an Aircraft Maintenance Engineer in the Royal Australian Navy and the Australian Army for 22 years.

Sasanka Sinha, Senior Welding Engineer Sasanka has two Masters in Materials Welding and Joining, and Production Engineering. Prior to joining Weld Australia in 1998, he gained 20 years’ experience at companies such as Babcock and Wilcox, Marion Dresser, Komatsu and Ti–Fab. He has expertise in welding, particularly in ship building, railway wagons, pressure vessels, construction and mining equipment. The first Australian to achieve IWE qualification, he is a Chartered Professional Engineer of the Institution of Engineers, Australia, and a Registered Professional Engineer in Queensland.

Louise Petrick, Senior Welding Engineer With 15 years experience, Louise has expertise in: weld quality management; high temperature and pressure applications; failure investigation; structural applications; and power generation. Louise holds a Masters in Applied Science, a Masters in Engineering, and is an IWE. In 2014, Louise moved to Australia and joined Synergy, providing materials and welding engineering support.

Louise joined Weld Australia in 2016, offering solutions in weld design review, repairs, quality gap analysis, and specification development.

She represents Weld Australia at Standards Australia.

Victor Blain, Senior Welding Engineer Victor has over 12 years’ experience welding related including: as a welder and fabricator working on carbon steel and stainless steel structures; material testing in the energy and aerospace sectors at Hydro-Quebec and Pratt & Whitney; and in manufacturing at Bombardier Transportation. Victor holds a trade qualification in Welding and Fabrication, a degree in Metallurgy, a Bachelor of Mechanical Engineering, and is an IWE. His expertise includes: rolling stock, manufacturing, aerospace, R&D, and power plants.

Victor joined Weld Australia in 2018.

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Australian Welding: March 2019

Abhishek Trivedi, Senior Welding Engineer Abhishek has over 10 years of engineering experience in welding, metallurgy, materials and quality assurance, and has worked in the oil and gas, nuclear, defence, medical device and construction industries.

With a Bachelor of Production Engineering and a Masters of Engineering in Welding Technology, Abhishek is an IWE and holds certifications in welding supervision, inspection and internal auditing. Prior to joining Weld Australia, Abhishek held various positions at CB&I Constructors, and was a Welding Engineer at Larsen & Toubro.

Melissa Odendaal, Welding Engineer Melissa completed a Bachelor in Metallurgical Engineering and an IWE qualification at the University of Pretoria. She has worked as a welding engineer on major coalfired power stations, construction projects, and oil and gas projects, and within the fabrication industry.

Her responsibilities have included providing technical support and advice to operations and production technicians on-site, establishing and maintaining welding related QA and QC procedures using international and national codes and Standards, and upholding ISO 9001 certification.

Mehdi Tajfar, Welding Engineer Before joining Weld Australia in 2018, Mehdi worked in the oil and gas and steel structure manufacturing industries as a Welding Engineer and Welding Inspector for five years, including roles at PEIC (Petroleum Equipment Industries Company), MAPNA Group, and Macfab Engineering. Premium quality in manufacturing and maintenance have been always his passion.

Mehdi holds a Masters of Materials Engineering in Welding, a Bachelor of Materials Engineering in Physical Metallurgy. He is an IWE, an IWI-S and an ISO 3834 Lead Auditor.

Arya Sharifian, Welding Engineer A professional materials engineer with five years’ experience in steel structures and the oil and gas industry, Arya is adept at applying inspection techniques and international standards and codes.

Prior to joining Weld Australia in 2017, Arya was a welding inspector and NDT specialist at STS Consultant Engineering in Iran. Arya holds a Bachelor of Science (Materials Engineering and Industrial Metallurgy), and is an IWE, and a CSWIP Welding Inspector, certified in penetrant, ultrasonic and magnetic testing, as well as radiographic interpretation.

Adam Coorey, Welding Graduate Adam completed a Bachelor of Materials Science and Engineering in Physical Metallurgy at the University of New South Wales in 2017. Whilst at university, Adam was awarded the Perfect Engineering Prize for Best Final Year Project in Physical Metallurgy. Adam also took on several volunteer positions, assisting with the ConocoPhillips Science Experience in 2013, 2014 and 2015; and facilitating seven Science Shows for ‘A Day at UNSW’. Prior to joining Weld Australia in 2017, Adam completed an electrical engineering internship at Intelle Building Services.

Julie Fidler, Commercial Manager Julie is a highly experienced Company Secretary and administrator with comprehensive expertise across a variety of company structures including listed, unlisted disclosing, limited by guarantee not-for-profit and private. In addition to her role at Weld Australia, Julie is also the Commercial Manager and a Company Secretary of the Australian Steel Institute. Prior to joining Weld Australia, Julie held positions at Atlantic Gold, Ku-ring-gai Financial Services and the Risk Management Institution of Australasia.

Inside Weld Australia: Meet the Weld Australia Team

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Annette Dickerson, Qualification and Certification Quality Manager Annette joined Weld Australia in 2009 and holds tertiary qualifications in Applied Science (Physics) and Human Resources. She brings over 25 years’ experience in engineeringrelated industries including manufacturing, ship building, rail, aviation and aerospace, having worked in the UK, Europe, North America, Asia and Australasia.

Annette is part of the Q&C team, delivering qualification and certification programs including those for engineers, technologists, supervisors, and inspectors.

Anabel Cantero, Qualification and Certification Coordinator Anabel joined Weld Australia in 1990 and since 2000 (when Weld Australia was approved as the International Institute of Welding Australian Authorised National Body) has been an integral member of the Qualification and Certification team.

Anabel is responsible for assessing and processing applications, communicating with both applicants and examiners, and organising qualification renewals. Highly organised, thorough, and adept at quick, creative thinking, Anabel is a valuable asset to the Weld Australia team.

Sallymae Bailey, Office Manager Sallymae is a degree qualified senior executive assistant with 20 years’ experience in supporting Board and high level management in fast paced, energetic environments. Prior to joining Weld Australia, Sallymae was an Executive Assistant at an international finance consulting, advisory, modelling and training academy. Her other recent roles have included executive and office administrative support for university student services, four ASX listed resource companies, and over six years in a boutique financial services company providing consulting services to private equity managers.

Michelle Bignold, Corporate Sales Executive Michelle has over 19 years’ experience in business development.

She completed a Bachelor Degree in business majoring in Tourism and Hospitality and has worked across all aspects of the industry, including events, hotels and airlines. She is an extremely confident person who enjoys challenges and thrives on working under pressure. She was awarded a Directors Choice Award for top overall performer out of 400 sales representatives and qualified for several international incentive conferences in Queenstown, Los Angeles and Hong Kong.

Eva Chun, Membership Manager Eva joined Weld Australia in 2019 with over 25 years of marketing experience, particularly in the banking and finance industries. Eva has in-depth expertise across all facets of marketing, including advertising, customer retention and growth, event management, strategic plans, social media management, media relations, and collateral development. Prior to joining Weld Australia, Eva operated her own marketing consultancy firm, focused on helping clients launch or grow their business. Eva holds a Bachelor of Economics, and a Diploma in Market Research.

Philomena Antao, Office Administrator Philomena joined us in 2019 with over 18 years of C-Suite executive support experience. Philomena brings a deep capability set across problem solving collaboration, adaptability and employing sound judgment in order to effectively execute support and administrative responsibilities.

Philomena’s previous Executive Assistant roles were at a not for profit company, a health and rehabilitation organisation, and two international high-end luxury accessory companies. Philomena’s experience and solutions driven mindset make her a valuable resource.

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Australian Welding: March 2019

A Successful Start to the Roll Out of the AWTCs In 2018, Weld Australia secured over $4.3 million of Government funding for the establishment of six Advanced Welder Training Centres (AWTCs), located at: the TAFE SA Regency Campus in Adelaide, South Australia; the Tasmanian Minerals and Energy Council Centre of Excellence in South Burnie, Tasmania; Box Hill TAFE in Melbourne, Victoria; SkillsTech Acacia Ridge in Queensland; Caboolture TAFE Campus in Queensland; and Bendigo TAFE and Kangan Institute in Victoria. The AWTCs will use augmented reality welding simulators to upksill qualified welders and train transitionary workers to international welding certification standard ISO 9606-1 Qualification testing of welders - Fusion welding.

It has been a busy start to 2019 for the Advanced Welder Training Centre (AWTC) program. Together with our partners, Weld Australia has so far established six AWTCs around Australia, with a seventh in the process of being finalised.

The AWTCs are located in Burnie (Tasmania), Adelaide (South Australia), Box Hill and Bendigo (Victoria), Brisbane, Northern Queensland and, very soon, Caboolture (Queensland).

recently completed its first pilot training program utilising the new simulators and brand new ISO 9606 curriculum. The pilot was very well received by all in attendance. Box Hill TAFE plans to offer the two new ISO 9606 courses this year. Box Hill TAFE is also integrating the augmented reality technology into their apprentice and pre-apprentice programs to enhance learning, increase efficiency, reduce risk and consumable costs.

Each AWTC is at a different stage of development. All have recently completed their augmented reality training. Most have completed ISO 9606 training and gained Weld Australia accreditation.

The Burnie AWTC was established in conjunction with the Tasmanian Minerals and Energy Council (TMEC).

TMEC plan to use their facility to deliver the ISO 9606 training programs to industry, to upskill existing workers and to upskill new entrants to the industry. They are

Box Hill TAFE in Melbourne

also looking to delivering work-ready programs for school leavers and job seekers. TMEC is engaging with schools and TAFEs to help promote trades using the augmented reality technology.

Weld Australia’s experts have already facilitated ‘Train the Trainer’ at the TMEC Centre of Excellence. This training was focused on welding according to AS/NZS ISO 9606-1 Qualification test of welders — Fusion welding —Part 1: Steels.

SkillsTech in Brisbane has recently completed all of their training and the set-up of their AWTC, with plans for their official launch underway.

SkillsTech is working closely with major industries in their region to deliver training solutions through

Far Left: ‘Train the Trainer’ at TAFE Queensland SkillsTech.

Top Left: ‘Train the Trainer’ at the Tasmanian Minerals and Energy Council (TMEC) Centre of Excellence.

Bottom Left: ‘Train the Trainer’ at Bendigo TAFE Right: ‘Train the Trainer’ at TAFE Queensland SkillsTech.

Far Right: Geoff Crittenden (CEO, Weld Australia) at the launch of the AWTC at Bendigo TAFE.

Inside Weld Australia: Advanced Welder Training Centres

ISO 9606 and the augmented reality technology. SkillsTech also plans to incorporate their technology into welding training in their apprenticeship programs and other government subsidised courses.

As such, SkillsTech has recently commenced a campaign to market ISO 9606 and their new facility.

currently located inn Townsville, as part of the government funded Manufacturing Hub in that region.

This AWTC will eventually settle in Cairns. There has been a lot of interest in ISO 9606 in the North Queensland region and the AWTC will be focusing on delivering training to service that need.

The AWTC at Regency TAFE in Adelaide was established and their training completed late last year. They will look to incorporate the technology to the delivery of the MEM05 training package qualifications and welding units in other programs. Regency TAFE is currently organising a launch event.

The Caboolture AWTC is set to be located in the Caboolture TAFE Campus. This AWTC will employ a mixed mode delivery, offering programs on campus as well as delivering programs in the workplace.

Bendigo TAFE held the official launch of their AWTC in February. Minister for Training and Skills, and Higher Education, Gayle Tierney announced more than $2.3 million of funding through the Regional and Specialists Training Fund for Bendigo TAFE to deliver courses in welding, plumbing, horticulture and disability to meet the needs of the local community and industry. Some of this funding will be directed towards the establishment of an AWTC. Minister Tierney gave an extremely positive speech on how important welding is to the community. Bendigo TAFE is yet to complete their training but are eager to deliver the ISO 9606 programs and use the simulators in their welding trade programs.

The North Queensland AWTC is

What is AS/NZS ISO 9606-1?

AS/NZS ISO 9606-1 provides for a standardised method of testing a welder’s skill utilising welding processes, materials, consumables and procedures likely to be encountered during the fabrication of steelwork. Consistent with most welder qualification standards, it not only qualifies the welder for the conditions of test but also for all other conditions considered easier to weld in accordance with the standard.

Unlike welder qualification standards used in Australia, AS/NZS ISO 9606-1 is not specifically limited or linked to any specific industry sector. As such, it provides for a broad range of application without complexity or compromising quality. This affords fabricators and welders alike the opportunity to work across industry sectors without the costs associated

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with requalifying welders welding on similar joints and materials.

Accredited Courses, Units of Competencies and Weld Australia Training There are two ISO 9606 courses listed on Training.gov.au, the National Register of Vocational Education and Training (VET) in Australia. This is the authoritative source of Nationally Recognised Training and Registered Training Organisations (RTOs).

These courses were developed in Victoria in 2018. One is intended for inexperienced welders, the other for experienced welders. Both use augmented reality welding simulators as a key component of the training.

These courses are intended to be rolled out nationally.

The courses are: • 22461VIC - Course in Fusion Welding to ISO 9606 for Transition Workers • AR VU22307 - Simulate fusion welding processes using augmented reality (AR) equipment • 22462VIC - Course in Fusion Welding to ISO 9606 for Experienced Welders • AR unit VU22302 - Use augmented reality (AR) welding technology to practice fusion welding processes to ISO 9606 The augmented reality simulator training that Weld Australia provides to the AWTCs are aligned with the units of competency designed in Victoria. The performance outcomes and required skills and knowledge from the Weld Australia programs have been mapped against the Victorian units of competency.

Recognition of Prior Learning (RPL) as per the national guidelines can be applied by RTOs to recognise Weld Australia training against the Unit of Competencies. This could mean that teachers are able to meet the Units of Competency and receive a qualification with reduced training time.

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Australian Welding: March 2019

An Update from Weld Australia’s Hotline Weld Australia offers a ‘Hotline’ service to all Corporate Members. The purpose of the Hotline is not to provide a solution, but to advise the enquirer on practical next steps. For further advice, Weld Australia’s highly experienced welding consultants can speak to you over the phone or visit your site in person. If you have a Hotline query complete our online contact form and we will respond as soon as possible: www.weldaustralia.com.au/hotline.

The Weld Australia Hotline was recently contacted by a member organisation seeking information around the following question:

multi‑process joints, especially welding from one side. As such, how should we proceed so as to satisfy the requirements of the standard?

I am required to modify an existing structure whose material properties are known. The structure is only accessible from one side and all welding will be conducted outdoors.

At this stage, I am planning to weld the root passes with the manual metal arc (MMAW) process (low hydrogen) and complete the fill and cap runs using the self‑shielded flux cored (FCAWss) process.

Weld Australia advised that it is common to combine welding processes in a procedure, and AS/NZS 1554.1 does not preclude a procedure being qualified in combination or as two individual procedures later used in combination.

AS/NZS 1554.1 Structural Steel Welding—Welding of steel structures does not clearly address

In general terms, qualification of two welding processes used in combination within a joint could therefore proceed by either: a. Qualifying the joint as a special

test (see Clause 4.2(d) and Table 4.7.1); or, b. Qualifying each process and procedure separately (see Clause 4.2 and Table 4.7.1).

This said, in the situation specifically raised by the enquirer, there is a fundamental metallurgical problem if you are considering welding FCAWss onto MMAW, or MMAW onto FCAWss, primarily within the first pass of the intermixed weld metal zone. The problem is specifically related to the composition of the FCAWss weld metal used.

In the report FEMA 355B published by the United States of America’s Federal Emergency Management

Inside Weld Australia: Hotline Update

49

“

Weld Australia advised that it is common to combine welding processes in a procedure, and that AS/NZS 1554.1 does not preclude a procedure being qualified in combination or as two individual procedures later used in combination.”

Agency (FEMA), they stated: “It is noted that the chemical composition of FCAW-S weld metals is substantially different than weld metals deposited by other processes and consumable types.”

“FCAW-S consumables produce very little shielding gas and rely on the addition of large amounts of deoxidisers (primarily aluminum) to react with oxygen and nitrogen from the atmosphere during metal transfer.”

“Thus, most FCAW-S welds typically contain between 0.8 and 1.6 wt. pct. aluminum. Since aluminum is a strong ferrite former, the addition of austenite stabilisers such as carbon, manganese, or nickel are required to avoid coarse ferritic microstructures that may form if the intermediate austenite transformation is repressed.”

“As a result, many FCAW-S weld deposits can contain substantially higher carbon (up to 0.45 wt. pct.), lower manganese (as low as 0.5 wt. pct.), and lower oxygen (as low as 30 ppm). Significantly higher nitrogen (up to 700 ppm) is found in most FCAW-S weld metals when compared to weld metals produced by other arc welding processes.”

In other weld metals, including those

used in the MMAW process or the gas-shielded flux cored process for example, the carbon content of the weld metal is typically around 0.06% to 0.08%, with manganese typically >1.2%. In simplistic terms, this usually results in significantly better weld metal impact properties.

With this differential in weld metal chemistries, the literature reports that there is a large decrease in toughness within the region of intermixed weld metals, particularly where the FCAWss weld metal used contains these elevated levels of carbon (such as in a zone of embrittlement).

For this reason, Clause 4.3.2 of AS/NZS 1554.1 requires weld metal impact tests on a test weld with the impact tests taken from the zone of intermixing. Should the impact tests yield satisfactory results then the following can be applied where each process is separately qualified: 1. Process 2 (in this case the FCAWss) is going to be used in a manner similar to welding onto a material backing bar so for prequalification status (if required), the conditions for the preparation should comply with the requirements for prequalification.

2. Process 1 (MMAW root passes) when welded from one side only without material backing, is not prequalified. Provided that the weld procedure is appropriately qualified as-welded from one side then proceed using the qualified MMAW WPS for the weld root.

Assuming that the procedure has been qualified, it can be used in this manner for the root passes because the surface of the MMAW weld then becomes the material backing the enquirer is welding onto.

For further reading on problems with intermixing of weld metals, refer to FEMA report FEMA 355B.

This Hotline update covers a specific query encountered during the last few months. Whilst accuracy in welding is critical, it is impossible to report in detail the full circumstances of the query. As such, Weld Australia recommends that further technical advice is sought in relation to specific, individual circumstances.

Australian Welding: March 2019

50

2019 Training Calendar Weld Australia delivers a comprehensive range of training and certification services, all of which are designed to help Australian welders and fabricators achieve and maintain a competitive advantage.

As the premier welding certification body in Australia, an International Institute of Welding (IIW) Authorised Nominated Body (ANB) and an Authorised Training Body (ATB), Weld Australia offers individual certifications, including: Welding Inspector, Welding Specialist, Welding Technologist, Welding Engineer, AS 1796 Welding Supervisor Certificate 10, and AS 2214 Welding Supervisor.

International Welding Inspector - Basic Location

Dates

Adelaide

27 - 31 May 2019 11 - 15 Nov 2019

Brisbane

10 - 14 Jun 2019 2 - 6 Sep 2019

Mackay

8 - 12 Apr 2019

Melbourne

13 - 17 May 2019 16 - 20 Sep 2019

Perth

10 - 14 Jun 2019

Sydney

17 - 21 Jun 2019 9 - 13 Sep 2019

International Welding Specialist Location

Dates

Adelaide

Week 1: 3 - 7 Jun 2019 Week 2: 8 - 12 Jul 2019 Week 3: 5 - 9 Aug 2019 Week 4: 9 - 13 Sep 2019 Week 5: 30 Sep - 4 Oct 2019

Brisbane

Week 1: 24 - 28 Jun 2019 Week 2: 22 - 26 Jul 2019 Week 3: 19 - 23 Aug 2019 Week 4: 23 - 27 Sep 2019 Week 5: 21 Sep - 25 Oct 2019

Mackay

Week 1: 3 - 7 Jun 2019 Week 2: 8 - 12 Jul 2019 Week 3: 5 - 9 Aug 2019 Week 4: 2 - 6 Sep 2019 Week 5: 30 Sep - 4 Oct 2019

Perth

Week 1: 25 - 29 Mar 2019 Week 2: 29 Apr - 3 May 2019 Week 3: 20 - 24 May 2019 Week 4: 17 - 21 Jun 2019 Week 5: 15 - 19 Jul 2019

Sydney

Week 1: 8 - 12 Apr 2019 Week 2: 6 - 10 May 2019 Week 3: 3 - 7 Jun 2019 Week 4: 8 - 12 Jul 2019 Week 5: 5 - 9 Aug 2019

International Welding Inspector - Standard Location

Dates

Adelaide

IWI-S Part 1: 17 - 21 Jun 2019 IWI-S Part 2: 1 - 3 Jul 2019

Brisbane

IWI-S Part 1: 1 - 5 Apr 2019 IWI-S Part 2: 15 - 17 Apr 2019

Mackay

IWI-S Part 1: 24 - 28 Jun 2019 IWI-S Part 2: 1 - 3 Jul 2019

Melbourne

IWI-S Part 1: 15 - 19 Jul 2019 IWI-S Part 2: 29 - 31 Jul 2019

Perth

IWI-S Part 1: 13 - 17 May 2019 IWI-S Part 2: 27 - 29 May 2019

Sydney

IWI-S Part 1: 1 - 5 Apr 2019 IWI-S Part 2: 15 - 17 Apr 2019

“

The practical and theoretical knowledge of the trainers was excellent, the opportunity to draw on their knowledge was fantastic.�

Welding Workshop Supervisor (Blended Learning Program) Location

Dates

Australia-wide 7 Jan 2019 - 20 Dec 2019

Inside Weld Australia: 2019 Training Calendar

51

“

This is the second IWI course I have taken and on both accounts I have been very impressed with the presenters. The level of knowledge from all the teachers is impressive.”

International Welding Engineer Location

Dates

Wollongong

Module 1: 10 - 14 Dec 2018 Practical Phase: 4 - 8 Feb 2019 Module 2: 11 - 15 Feb 2019 Module 3: 13 - 17 May 2019 Module 4: 22 - 26 July 2019

International Welding Technologist Location

Dates

Wollongong

Module 1: 10 - 14 Dec 2018 Practical Phase: 4 - 8 Feb 2019 Module 2: 11 - 15 Feb 2019 Module 3: 13 - 17 May 2019 Module 4: 22 - 26 Jul 2019

Quality Control Welding Coordinator (QCWC) Location

Dates

Sydney

19 - 23 Aug 2019 Welding Technology Appreciation for Engineers (3DE)

Location

Dates

Brisbane

21 - 23 May 2019

Melbourne

2 - 4 Apr 2019

Perth

9 - 11 July 2019

Sydney

4 - 6 Mar 2019

Weld Australia reserves the right to cancel or change dates of any training course due to insufficient registrations or other reasons beyond its control, and reserves the right to refuse enrolments.

The Benefits of Training & Qualification Weld Australia training and certification is a strong addition to your career portfolio. It demonstrates to employers that you possess advanced welding knowledge, essential to ensuring the highest levels of workmanship. Qualification demonstrates to employers that you are dedicated to continually learning and growing in your field. These are qualities that are essential for success in team leadership roles or for more complex projects.

Online & Blended Learning In conjunction with the American Welding Society (AWS), Weld Australia offers online courses to help develop your welding knowledge and to better inform you for your professional development.

The content has been developed by senior people within the profession and is regularly updated. These courses are available any time, day and night, and are designed as self-paced modules which will allow the student to complete them in their own time.

Courses include: • Economics of Welding • Fabrication Maths (Basic and Advanced) • Metallurgy (Basic and Advanced) • Non-Destructive Testing • Welding Fundamentals (Basic and Advanced) • Welding Safety • Welding Sales Representative • Welding Symbols In-House Training Weld Australia can present any of its courses to your employees in-house at the location of your choosing.

We can also tailor training courses specifically for your company and employees.

Further Information For further information, or to enrol in a Weld Australia training course today, please contact: training@weldaustralia.com.au or +61 2 8748 0150, or visit www.weldaustralia.com.au.

52

Australian Welding: March 2019

Member Directory Weld Australia is dedicated to providing members with a competitive advantage through access to industry, research, education, government, and the wider welding community.

When you join Weld Australia, you become part of a network of engaged companies and individuals, with which you can share technology transfer, best practices, and professional opportunities. For further information, please contact membership@weldaustralia.com.au or +61 (0)2 8748 0100.

Weld Australia Industry Group Members Weld Australia hosts and administers several Industry Groups, providing a forum for technology transfer and R&D, linking members with industry and research organisations. The Weld Australia Industry Groups: represent a source of vital technical welding information; optimise welding practices through standard development and tools; and assist members to prepare specifications.

AGL Energy www.agl.com.au 131 245 customer.solutions@agl.com.au

Transport and Main Roads (Queensland) www.tmr.qld.gov.au +61 7 3066 6358 TMRStructuralMaterials@tmr.qld.gov.au

ANSTO www.ansto.gov.au +61 2 9717 3111 enquiries@ansto.gov.au

Navantia Australia www.navantia.com.au (02) 6269 5900 navantia.australia@navantia.es

ASC www.asc.com.au +61 8 8348 7000 David.Price@asc.com.au

NRG Gladstone Operating Service www.nrggos.com.au +61 7 4976 5211 cmcguinn@nrggos.com.au

Ausgrid www.ausgrid.com.au +61 2 4951 9555 cchiodi@ausgrid.com.au

Stanwell Corporation www.stanwell.com 1800 300 351 www.stanwell.com/contact-us

Austal www.austal.com +61 8 9410 1111 info@austal.com

Synergy www.synergy.net.au +61 8 9781 6720 Doug.Harman@synergy.net.au

CB&I www.cbi.com +61 8 93245555 www.cbi.com/contact

Thales Australia www.thalesgroup.com +61 2 8037 6000 MaritimeBusinessSupport@thalesgroup.com.au

CS Energy www.csenergy.com.au +61 7 3854 7777 energyinfo@csenergy.com.au

Transport for NSW www.transport.nsw.gov.au +62 2 8202 2200 stakeholder.relations@transport.nsw.gov.au

Energy Australia www.energyaustralia.com.au 133 466 Wayne.Hill@energyaustraliansw.com.au

Vales Point Power Station (Delta) www.de.com.au +61 2 4352 6111 info@de.com.au

LYB Operation & Maintenance Loy Yang B Power Station www.loyyangb.com.au +61 3 77 2000 contactus@loyyangb.com

VicRoads www.vicroads.vic.gov.au +61 3 8391 3216 vicroadstechnicalservices@roads.vic.gov.au

53

Inside Weld Australia: Member Directory

Premium Corporate Members ALS Industrial www.alsglobal.com/au +61 2 4922 2400 powerservices@alsglobal.com Applied Ultrasonics Australia www.appliedultrasonics.com.au +61 2 9986 2133 info@appliedultrasonics.com.au BlueScope Steel www.bluescopesteel.com.au 1800 800 789 steeldirect@bluescopesteel.com Baker & Provan www.bakerprovan.com.au +61 2 8801 9000 info@bakerprovan.com.au

Hardchrome Engineering www.hardchrome.com.au +61 3 9561 9555 office@hardchrome.com.au Howden Australia www.howden.com +61 2 8844 9100 sales@howden.com.au HRL Technology Group www.hrlt.com.au 1800 475 832 info@hrl.com.au Kemppi Australia www.kemppi.com +61 2 87852000 sales.au@kemppi.com Liberty www.libertygfg.com 1800 178 335 capital@libertygfg.com

BOC www.boc-limited.com.au +61 2 8874 4400 contact@boc.com Callidus Welding Solutions http://callidusgroup.com.au +61 8 6241 0799 info@callidusgroup.com.au CIGWELD www.cigweld.com.au 1300 654 674 enquiries@cigweld.com.au

Lincoln Electric www.lincolnelectric.com +61 2 9772 7222 sales@lincolnelectric.com.au LMATS http://lmats.com.au +61 8 9200 2231 admin@lmats.com.au Main Roads Western Australia www.mainroads.wa.gov.au 138 138 enquiries@mainroads.wa.gov.au

Coregas http://coregas.com.au +61 2 9794 2222 info@coregas.com

Mitsubishi Hitachi Power Systems www.anz.mhps.com

+61 7 3878 0888 general@anz.mhps.com MMG www.mmg.com +61 3 9288 0888 info@mmg.com QENOS www.qenos.com +61 3 9258 7333 enquiry@qenos.com Quest Integrity Group www.questintegrity.com +61 7 5507 7900 Info-APAC@questintegrity.com Santos www.santos.com +61 8 8116 5000 reception.ade@santos.com Tronox Management www.tronox.com +61 8 9411 1444 info@tronox.com UGL Pty Limited www.ugllimited.com +61 2 8925 8925 uglinfo@ugllimited.com Welding Industries of Australia (WIA) www.welding.com.au 1300 300 884 info@welding.com.au Wilmar Sugar www.wilmarsugarmills.com.au +61 7 4722 1972 info@wilmar.com.au

Join Weld Australia Today.

Help Secure the Future of

Australian Welding +61 (0)2 8748 0100

|

membership@weldaustralia.com.au

|

www.weldaustralia.com.au

54

Corporate Members 3M Australia: 3m.com.au A & B Welding: abwelding.com.au A&G Engineering: agengineering.com.au Abrasion Resistant Materials: arm.com.au Able Industries Engineering: ableind.com.au Adept Inspections & Training: adeptengineering.com.au Aerison: aerison.com Aitken Welding: aitkenwelding.com Alltek Welding: alltek.net.au Ancon Building Products: ancon.com.au Antec Group: antec.com.au ARL Laboratory Services: arllabservices.com.au ASME Projects: asmeprojects.com.au ATTAR: attar.com.au Austal: austal.com Austedan Fabrications: austedan.com.au Austral: australtechnologies.com.au Australian Rail Track Corporation: artc.com.au Australian Welding Supplies: awsi.com.au BAE Systems: baesystems.com Barker Hume Homes: N/A Baxter Institute: baxter.vic.edu.au Beenleigh Steel Fabrications: beenleighsteel.com.au Ben Baden Services: craneconnection.com.au Berg Engineering: bergengineering.com.au Bisalloy Steels: bisalloy.com.au BMC Welding: bmcgroup.com.au Bombardier Transportation: bombardier.com/en/transportation.html Bradken: bradken.com Brezac Constructions: brezac.com.au Broadspectrum: broadspectrum.com Brosco Enterprises: brosco.com.au Browns Precision Welding: brownswelding.com.au Brunton Engineering & Construction: brunteng.com Caltex Refineries (QLD): caltex.com.au CCR Group: ccrgroup.com.au Central Engineering: centralengineering.com.au Chess Engineering: chessindustries.com.au CPT Engineering: cptengineering.com.au CQ Field Mining Services: cqfma.com.au

Australian Welding: March 2019

CQ Steel Industries: cqsteel.com.au Crisp Bros Haywards: haywards-steel.com Cruisemaster Australia: cruisemaster.com.au Cullen Steel: cullensteel.com.au D&L Engineering Services: fabinox.com.au DGH Engineering: dghengineering.com.au Diverse Welding: diversewelding.com.au DJM Fabrications: djmfab.com DT Hiload Australia: dthiload.com E&A Contractors: ottowayfabrication.com.au Excel Marine: excelmarine.net.au Extrin: extrin.com.au FIELD Engineers: fieldengineers.com.au Flexco: flexco.com.au Fortress Systems: fortressresistors.com Foxheat: foxheat.com Furphy Engineering: furphys.com.au G & G Mining Fabrication: ggminingfab.com Global Manufacturing Group: gmqld.com.au Hamilton Maintenance Group Hilton Manufacturing: hiltonmanufacturing.com.au HVAC Queensland: hvac.com.au Industrial Installation & Maintenance: iimaust.com.au Ingal EPS: ingaleps.com.au Jacmor Engineering: jacmor.com.au JB Specialised Engineering: jordbellows.com.au JR’s Marine Engineering: jrsgroup.com.au JVA Engineering: jvaengineering.com.au Kangaroo Training Institute: kangarootraininginstitute.com.au Kenro Products: kenrometal.com.au Keppel Prince Engineering: keppelprince.com Knox Engineering: knoxeng.com LaserBond: laserbond.com.au Lendlease: lendlease.com/au Loclur Engineering: loclur.com.au LSW Group: lswgroup.com.au Mainetec: mainetec.com.au Mechanical Maintenance Solutions: mms.auz.net Mechanical Testing Services: N/A Melco Engineering: melcoeng.com.au Midway Metals: midwaymetals.com.au

Millmerran: intergen.com Monadelphous Group: monadelphous.com.au Monash University: monash.edu Newmont Asia Pacific: newmont.com Nix Engineering Group: nixengineering.com.au Obadare: obadare.com.au Orrcon Manufacturing: orrconsteel.com.au OSD Pipelines: osdlimited.com Precision Metal Group Aust: precisionmetalgroup.com QSM Fabrication: qsmfabrication.com.au Quality Process Services: qpspl.com.au Queensland Nitrates Plant: N/A Radio Frequency Systems: rfsworld.com RJB Industries: rjb-industries.com Robert Vernon: N/A Robot Technologies-Systems Australia: robottechnologies.com.au Rockpress: rockpress.com.au Russell Mineral Equipment: rmeglobal.com S&L Steel: slsteel.com.au Samaras Group: samarasgroup.com Saunders International: saundersint.com Schenck Process Australia: schenckprocess.com SMW Group: smwgroup.com.au Smenco: smenco.com.au Snowy Hydro: snowyhydro.com.au South32 Temco: south32.net Southern Cross Industrial Supplies: scis.com.au SSS Manufacturing: sssmanufacturing.com Steel Mains: www.steelmains.com Structural Integrity Engineering: siepl.com.au Supagas: supagas.com.au SWA Water Australia: swawater.com.au Taurus Mining Solutions: taurusminingsolutions.com The Bloomfield Group: bloomcoll.com.au Topline Steel Fabrications: N/A Trade and Investment NSW: industry.nsw.gov.au Uneek Bending: uneek.com.au Victorian Testing & Inspection Services: victesting.com.au Walz Construction: walzgroup.biz Welding Guns of Australia: unimig.com.au WGASA: wga.com.au

55

Inside Weld Australia: Upcoming Events

Upcoming Events Whether you need to brush up on skills learnt years ago, want to try your hand at something new, or crave some networking opportunities, there is an industry event for you.

For further information on the events listed below, or any Weld Australia events, please email events@weldaustralia.com.au or phone +61 (0)2 8748 0100.

April 2019 System Engineering Test and Evaluation Conference 29 April to 1 May, Canberra https://sete2019.com.au May 2019 National Manufacturing Week 14 to 17 May, Melbourne nationalmanufacturingweek.com.au Risk Engineering and Project Controls Conference 15 to 17 May, Sydney https://risk-pcc19.com.au 20th Jubilee International Conference on Joining Materials 26 to 29 May, Helsingor, Denmark http://iiwelding.org June 2019 ICWAM 2019 5 to 7 June, Metz, France http://www.icwam.com 13th International Conference on the Mechanical Behaviour of Materials 10 to 14 June, Melbourne https://www.icm-13.com Transport Australia Conference 26 to 28 June, Sydney https://www.transport2019.com.au

APICAM 2019: 2nd Asia-Pacific International Conference on Additive Manufacturing 30 June to 3 July, Melbourne https://www.apicam2019.com.au July 2019 72nd IIW Annual Assembly and International Conference 7 to 12 July, Bratislava, Slovakia http://iiwelding.org 13th International Conference on Bulk Materials Storage, Handling and Transportation 9 to 11 July, Gold Coast https://www.newcastle.edu.au August 2019 22nd International Conference on Composites Materials 11 to 16 August, Melbourne https://iccm22.com September 2019 Coasts and Ports 2019 10 to 13 September, Hobart www.coastsandports2019.com.au October 2019 2019 APGA Convention and Exhibition 12 to 15 October, Adelaide http://www.apga.org.au

Weld Australia & IIW Exam Dates 2019 IWE and IWT • 13 May: IWE EA2 exam and IWT TA2 exam in Wollongong • 22 July: IWE EA3 exam and IWT TA2 exam in Wollongong National Examinations All exams are to be held in state capital cities where sufficient registrations are received: • 12 June: IWS and National Welding Supervisor Paper A • 13 June: Welding Supervisor B1 and B2 Code exams • 6 November: IWS and National Welding Supervisor Paper A • 7 November: Welding Supervisor B1 and B2 Code exams Exam applications must be made online through the WeldQ system, with applications closing six weeks prior to the exam date. For enquiries, contact qnc@weldaustralia.com.au.

Event Spotlight: National Manufacturing Week Celebrating its 20th anniversary, National Manufacturing Week is Australia’s largest gathering of manufacturing decisionmakers under one roof. This year’s theme is ‘Industrial Evolution’ to represent the transformation of Australia’s manufacturing sector into a highly-integrated, skills-based, and collaborative environment.

This free-to-attend expo and conference will run from 14 to 17 May 2019 at the Melbourne Convention and Exhibition Centre.

For further information, visit: nationalmanufacturingweek.com.au

Australian Welding: March 2019 56 Weld Australia’s Expert Advisory

Services And Technical Support: Independent Advice You Can Trust Weld Australia has a team of highly qualified welding engineers and materials specialists available to provide expert advisory services on all welding and materials related matters. With expertise in a wide range of industries, from manufacturing to composites, we have a unique capability to solve your joining problems. Our advice can help you substantially increase the operational life of your plant and equipment, thereby reducing your maintenance and repair overheads.

Our Areas of Expertise • • • • • • • • • • • •

Welding procedure development Welding coordination and management systems Material performance and weldability Welding processes and related equipment Welding health and safety Failure investigation Expert witness in welding and related matters On-site welding technology assistance On-site auditing of welding quality systems Welding codes and standards Inspection and testing Non-destructive testing

Resources

Manufacturing

• • • • • • • • • • • •

Mechanical testing Heat treatment in welding Welding quality management to ISO 3834 Welding specialists (IWE, IWT, IWS) for site work Pipelines-in-service welding, repairs and hot tapping Specialised welding and associated technologies (laser, ultrasonic peening and underwater welding) R&D and application of technology Engineering critical assessment fracture mechanics Structural and pressure equipment design Finite element analysis Weld cost estimating Life estimation

Infrastructure

Defence

Power Generation

Helping secure the future of Australia’s welding industry.

+61 (0)2 8748 0100 | info@weldaustralia.com.au | www.welaustralia.com.au | Building 3, Level 3, 20 Bridge Street, Pymble, NSW 2073