Australian Welding | June 2020

AUSTRALIAN 1

WELDING Digital Manufacturing in the

Hunter Class Frigate Program Page 20

Rheinmetall Moves into

Military Vehicle Centre of Excellence Page 24

Global Strength, Local Service:

NEPEAN Engineering & Innovation

Page 30

Q2 | June 2020 Official Journal of Weld Australia www.weldaustralia.com.au

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Australian Welding: June 2020

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: office@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 Guy Brooks T: +61 (0)2 8748 0150 E: g.brooks@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: June 2020

Contents

20

Digital Manufacturing in the Hunter Class Frigate Program

24 30

Rheinmetall Moves into Military Vehicle Centre of Excellence

NEPEAN: Global Strength, Local Service

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.

34

Incat High-Speed Ferries Stay the Course

A Message From Weld Australia’s Chair

4

A Message From Weld Australia’s CEO

6

Inside the Industry Breaking News Welding Fume Minimisation Guidelines Fair Work Ombudsman The Changing Face of Australian Standards Workplace Health & Safety in the Wake of COVID-19 Digital Manufacturing in the Hunter Class Frigate Program Rheinmetall Moves into Military Vehicle Centre of Excellence Macfab Engineering Certified to AS/NZS ISO 3834 NEPEAN: Global Strength, Local Service Set for Success: PMG Expands Defence Industry Footprint Incat High-Speed Ferries Stay the Course Welding 4.0: Improved Productivity & Lower Costs Frontline Manufacturing Poised for Expansion Inside Weld Australia An Update from Weld Australia’s Hotline An Update from Weld Australia’s Industry Groups Weld Australia’s Training Goes Online Key Developments at the AWTCs Member Directory

Cover: 8 Chifley Square in Sydney. The distinctive appearance of the highrise is due to the massive, colourful steel elements supplied by NEPEAN Engineering & Innovation.

For further information, see page 30.

8 12 14 16 18 20 24 28 30 32 34 38 40

42 44 46 47 48

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Australian Welding: June 2020

A Message From Weld Australia’s Chair “

As our Chief Executive Officer, Geoff Crittenden, has communicated, Weld Australia’s aim is to help ensure that every single one of our member firms, as well as every individual member, has a job when all this is over.

David Lake Chair, Weld Australia

On behalf of the Weld Australia Board of Directors and the entire Weld Australia team, I would like to send a message of support to all of our members. We acknowledge the deep uncertainty that the industry is facing in the wake of the COVID-19 pandemic. Many of our members have already reported lost or cancelled project work and, as a result, have had to stand down workers or reduce staff hours.

I want to reassure all our members that Weld Australia is here to support and assist you, wherever we can. If you need help or advice, please reach out. If we cannot help, then we will do our best to put you in touch with someone who can.

As our Chief Executive Officer, Geoff Crittenden, has communicated, Weld Australia’s aim is to help ensure that every single one of our member firms, as well as individual members, have a job when all this is over.

Weld Australia Initiatives The entire Weld Australia has responded rapidly to the changing market conditions presented by the COVID-19 pandemic. We have pivoted our business operations as quickly as possible to ensure that we are focused on providing the resources and services that our members need most.

I would like to take this opportunity to congratulate Geoff Crittenden and his team on the swift roll-out of several innovative initiatives over the last few months.

Training Courses Weld Australia accelerated the development and launch of two new online courses: those associated with the International Welding Specialist (IWS) and International Welding Inspector – Basic (IWI-B) certifications. Both of these courses have proved extremely popular, with courses filled in record time.

The social distancing requirements provided a unique opportunity to explore the delivery of quality training outside of a classroom environment. The new online format of these two courses will make training more accessible, and open up opportunities to students who are unable to attend face-to-face training, particularly those in remote and regional areas.

Qualification and Certification Weld Australia spent several weeks working closely with the International Institute of Welding (IIW) on measures to make certification and qualification processes more accessible, given travel and social distancing restrictions.

As a result, the IIW has relaxed some requirements. Weld Australia is now able to: perform site audits for AS/NZS ISO 3834 Quality requirements for fusion welding

of metallic materials certification remotely; and conduct online examinations, (combined with an interview via videoconferencing facilities) for some personnel qualifications, including: • International Welding Specialist (IWS) • International Welding Technologist (IWT) • International Welding Engineer (IWE) Personnel Certification Renewals Extended to Six Months Given the exceptional circumstances surrounding the COVID-19 pandemic, Weld Australia understands that action is required on personnel certification that have recently expired. Weld Australia has implemented a policy to give certified personnel an extension of six months from their certification expiry date in which to submit their renewal applications.

Don’t forget: Always put on protective clothing before starting to weld!

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Lasting Connections

THE BEST FOR THE BEST.

Weld Australia COVID-19 Discussion Forum Our existing LinkedIn Group is now focused on the challenges of the COVID-19 pandemic. The Group is an open platform for the welding industry to collaborate and support one another, discuss particular struggles, and learn how other businesses are coping. If you’re not already a member, be sure to join our LinkedIn Group.

Weld Australia COVID-19 Resources Hubs We have also established a COVID-19 Resource Hub which contains a raft of information from reputable sources, including Federal bodies such as the ATO, FairWork Ombudsman and Safe Work Australia, as well as all the state governments.

Welding Inspection and Supervision Services Weld Australia developed a new procedure to carry out welding inspection and supervision services, as well as qualification of welding procedures and personnel—remotely. The procedure has been developed in accordance with IAF (International Accreditation Forum) guidelines. All services are carried out with the cooperation of a competent person on-site, utilising videoconferencing and video recording for record keeping purposes.

Welding Industry Training Fund Weld Australia is petitioning all State Government Ministers responsible for education and training to support the Welding Industry Training Fund through grant funding.

Over the next six to 12 months, it is possible that Australian welders will spend extended periods of time at home. Weld Australia wishes to seize this opportunity to deliver a range of online courses designed to upskill welders at all levels. In this way, we will strengthen the core of our industrial base and speed up the process of recovery post COVID-19. In light of current financial uncertainty, such a scheme would not be viable unless it was offered to individuals at no cost.

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Australian Welding: June 2020

A Message From Weld Australia’s CEO “

Welders build the very world in which we live. However, it’s not just the pervasive nature of the welding process that makes it so essential—welding is also vital to the strength of Australia’s economy.”

Geoff Crittenden Chief Executive Officer, Weld Australia

The Essential Nature of Welding Welding is the most ubiquitous process on the planet. It is fundamental to the construction of bridges, high-rise buildings, mining equipment, ships, and even household appliances, such as fridges and washing machines.

Next time you’re driving down the road, take a look around you: crash barriers, light poles, road signs, the re-bar in the concrete bridge, even the very car you’re driving. All of these elements rely on welding.

Welding played an enormous role in the second industrial revolution.

Without welding, we wouldn’t have the modern motor car, high-speed trains, or jet planes. We wouldn’t be able to generate power. We wouldn’t have advanced manufacturing facilities. Our world today simply wouldn’t look the same.

Welders build the very world in which we live.

However, it’s not just the pervasive nature of the welding process that makes it so essential—welding

is also vital to the strength of Australia’s economy.

Essential to Employment Australia’s welding and fabrication industry is responsible for the employment of over 78,900 people, 91% of whom are employed on a full-time basis.

While not an absolute, part-time and casual roles are more likely to be more insecure than full-time roles, and do not always afford employees with the same types of benefits.

Generally, full-time, high-quality roles reflect a stronger industry and greater competition for employees.

With an overwhelming percentage of Australian welders employed on a full-time basis, it clear the industry is strong, and an essential provider of secure employment opportunities.

Essential to Innovation Australia’s welding and fabrication industry is highly diverse, with a large number of businesses that boast a total output capacity of over 1.6 million tonnes per annum.

Approximately 94% of businesses operating within Australia’s welding

and fabrication industry are small enterprises with less than 20 employees.

Small businesses are an important source of innovation in Australia’s economy. With a proven ability, capacity and agility to respond to changes in today’s competitive global marketplace—particularly when compared to their larger competitors—the role of small businesses in boosting innovation, productivity and efficiency is vital.

Through innovation and expansion, small businesses are a solid source of employment and competitive edge for Australia’s economy on the world stage.

Essential to Downstream Industries With its highly diverse profile, welding is critical to myriad aspects of Australia’s economy. It is a key player in various economically significant downstream and related industries.

In Australia, three industries are the main consumers of steel fabricated products, comprising almost 90% of

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A Message from Weld Australia’s CEO all demand. These industries are: • Construction at 50.3% • Manufacturing at 20.5% • Mining at 17.2% Combined, these three industries purchased over $11.6 billion of steel fabricated products in 2013-2014.

The construction, manufacturing and mining industries are all essential to the strength and prosperity of Australia’s economy and, without welding, none of them would be able to operate.

Construction Industry Since around 2007, the construction Industry Value Add has grown at 3.8% per annum. Based on data from the Australian Bureau of Statistics, employment in the industry has grown from around 933,100 persons to nearly 1,098,500, making construction the single largest employing industry in the Australia economy. The construction industry generates over $360 billion in revenue, making it responsible for around 9% of Australia’s Gross Domestic Product (GDP). And, welding is an essential input.

Manufacturing Industry Manufacturing directly and indirectly employs over 10% of the Australian population. With manufacturing industry output amounting to over $110 billion annually, this is equivalent to approximately 6% of Australia’s GDP. And, welding is an essential input.

Mining Industry Historically, the mining industry has been important to Australia’s wealth and prosperity—a trend that continues today. Mining contributes approximately $248 billion per annum and employs over 350,000 people. And, welding is an essential input.

The Role of Compliance It is because of the all-pervasive and essential nature of welding that compliance is so vital.

Welding is often mistaken as a simple process. In reality, welding requires immense skill. The engineering principles that inform the process are unbelievable. Welding requires both highly skilled craftsmen and scientists who are able to solve complex engineering problems.

Welding requires strict adherence to all applicable Australian Standards. It is impossible to undertake complete verification of a welded joint without destroying it. Unfortunately, inspection after completion does not guarantee weld serviceability. As such, quality must be built into the welding process, right from the very beginning.

Welding must be done correctly the first time. A weld cannot be adjusted once it is complete. The only course of action is to scrap the weld entirely, and start again. As such, the welding processes set out in Australian and International Standards are crucial— they must be followed exactly.

If Australian and International Standards are not followed exactly, then there is a significant chance that a structure will fail.

The problem is, a huge proportion of welding in Australia does not comply with Australian Standards.

This is because welding is an extremely forgiving process. With a bit of practise, just about anyone can join two pieces of steel together.

The thing is, these pieces of steel might stick together for five, 10 or even 20 years—but they might not.

And, when they fall apart, invariably, someone gets hurt.

In Australia, you’re not allow to drive a car, connect a gas pipe, or install a new light fitting without a license. Yet, you can fabricate and erect enormous steel beams, construct a bridge for thousands of cars to travel across every day, or fabricate caravans to be towed down busy highways—all without a license. It defies all health and safety requirements. It defies logic.

References • • • • •

https://joboutlook.gov.au/ Occupation?search=alpha&code=3223 https://www.industry.gov.au/sites/default/ files/2019-05/adc_steel_fabrication_ report_november_2017.pdf https://www.rba.gov.au/publications/ workshops/other/small-bus-finroundtable-2012/pdf/01-overview.pdf https://nationalindustryinsights.aisc.net. au/industries/construction https://www.amgc.org.au/wpcontent/uploads/2018/11/AdvancedManufacturing-a-new-definition-for-anew-era.pdf

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Australian Welding: June 2020

Breaking News Bisalloy and Rheinmetall Teaming Agreement Extended Bisalloy Steel Group recently announced the extension of its long-standing teaming agreement with Rheinmetall Defence Australia (Rheinmetall) for the further development and production of high performance armour steel for military vehicles.

Rheinmetall and Bisalloy are currently working together in Australia and Germany to create specialised grades of BISALLOY® Armour Steel for application on the BOXER 8×8 Combat Reconnaissance Vehicles (CRV) to be delivered to the Commonwealth of Australia’s LAND 400 Phase 2 program. Bisalloy is two years into the development of new grades of armour steel in order to meet the exacting protection levels required for each BOXER 8×8 CRV. Once certified, Bisalloy steel will produce the best protection for Australian soldiers to ensure they survive and win in combat. Bisalloy is also working closely with Rheinmetall as part of the company’s offer – the LYNX KF 41 Infantry Fighting Vehicle (IFV) – for the $10 billion LAND 400 Phase 3 program, which would see the supply of 400 IFVs to the Australian Defence Force (ADF).

According to Bisalloy Steel Group Chief Executive Officer and Managing Director, Greg Albert, “Bisalloy has long worked in partnership with Australian steel producers, defence scientists and manufacturers of military vessels and vehicles to produce what we believe are some of the best armour plate products in the world. Our work with Rheinmetall will ensure Bisalloy’s capabilities have created the best possible protection for the Australian soldier but also significant export opportunities for Australia.”

Image: Bisalloy Steel Group recently announced the extension of its long-standing teaming agreement with Rheinmetall Defence Australia.

Navantia Celebrates End of AWD Program and Acceptance of Third AWD by Navy Navantia recently celebrated the formal acceptance of the third and final Air Warfare Destroyer (AWD), NUSHIP Sydney, by the Royal Australian Navy at the Osborne Naval Shipyard in South Australia. The delivery of the Sydney also marked the end of the 13 year program, which was established to deliver three of the most lethal and capable warships the Australian Navy has ever possessed.

The Acceptance and End of Program Ceremony was presided over by the Australian Minister for Defence, Senator the Hon Linda Reynolds MP, Chief of Navy, Vice Admiral Michael Noonan AO, Deputy Secretary National Naval Shipbuilding, Tony Dalton, and Director General Naval Construction Branch, Commodore Steve Tiffen.

Minister Reynolds described the AWD (which are Hobart class Guided Missile Destroyers), as being “in a class of their own. They offer scalable response options for Australia and the best of naval power to the Royal Australian Navy. They are magnificent national assets.

Since the wise appointment of Navantia to provide shipbuilding management services, there was a 45% increase in productivity from ship two to ship three, 50% increase in welding and 35% increase in pipe installation.”

The AWD program is the foundation of Australia’s continuous naval shipbuilding and integration industry and was delivered under an Alliance-based contract arrangement between the Commonwealth of Australia, represented by the Department of Defence, and industry partners ASC Shipbuilding and Raytheon Australia, supported by Navantia.

Image (L to R): Chief of Navy Michael Noonan, Defence Minister Linda Reynolds, and Commander Edward Seymour on the bridge of NUSHIP Sydney.

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Inside the Industry: Breaking News

Thales to Export Six More Bushmasters to the Netherlands with Award of $14 Million Contract According to a recent report by Defence Connect, Thales Australia has announced a $14 million contract with the Royal Netherlands Army to design and deliver a specialist Dutch Medevac-variant of the Bushmaster protected mobility vehicle, supporting more than 60 Australian businesses while securing jobs and investment along the extensive Bushmaster supply chain. Long term Australian suppliers including Wollongong-based Bisalloy Steels, AME Systems, Melbourne-based DVR Engineering and KAB Seating in Dandenong will be joined by a substantial number of additional Australian SMEs and Dutch company Visser Horti Systems, which specialise in the design of clinical white space capabilities for the RNLA. The vehicles are scheduled for delivery in 2021.

Chris Jenkins (Chief Executive,Thales Australia), welcomed the announcement, saying, “This recent order is a tribute to the skills and expertise not only in Thales’ Protected Vehicle Centre of Excellence in Bendigo, but in the Australian industry that are our critical partners in manufacturing this world-class vehicle.”

The Royal Netherlands Army now operates a fleet of almost 100 Bushmasters after an initial purchase of 25 vehicles as an urgent operational requirement in 2006. Additional vehicles were acquired between 2007 and 2016. The vehicles have been in service within the Royal Netherlands Army for over 10 years, with an outstanding operational record where the Bushmaster’s superior protection, mobility and combat effectiveness were proven to be critical.

Matchmaking Platform to Boost Local Manufacturing Supply Chains Australian businesses wanting to play their part in the response to the COVID-19 pandemic will have greater access to potential partners and customers thanks to an industry matchmaking site backed by the Federal Government. Developed by the Government’s Advanced Manufacturing Growth Centre (AMGC), the COVID-19 Manufacturer Response Register will bring together manufacturers, suppliers and customers via a self-managed platform.

Minister for Industry, Science and Technology Karen Andrews said finding a solution to connect local supply and demand for personal protective equipment (PPE) was at the forefront of the Government’s response to the COVID-19 crisis. “Industry asked for this and we have delivered. This digital platform is the missing puzzle piece that will unlock widespread collaboration across the manufacturing sector and boost domestic capability by creating and expanding local supply chains,” Minister Andrews said. “The matchmaking platform has already resulted in local businesses pivoting to produce essential medical supplies for COVID-19 – keeping Australians in work and building long term capability in the recovery phase.”

The platform will initially combine AMGC’s COVID-19 Manufacturer Response Register database of 2500 submissions with a further 600 local businesses identified through the Department of Industry, Science, Energy and Resources’ recent Request for Information on PPE production capability. The COVID-19 Manufacturer Response Register platform can be accessed via www.amgc.org.au.

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Australian Welding: June 2020

Breaking News Coregas Completes Major Fabrication Industry Installation Coregas recently completed the installation of one of the largest industrial reticulated gas pipeline systems in the company’s history. Coregas installed and commissioned four 700m reticulated pipelines (for argon, oxygen, LPG and air supply) and over 220 regulated outlets on behalf of structural steel fabricators, Genis Steel (SA), in Adelaide.

BAE Systems Australia Supports Boeing’s Loyal Wingman Australian Industry Team BAE Systems has been selected to supply the unmanned flight vehicle management solution and simulation capability for the Loyal Wingman - Advanced Development Program led by Boeing Australia for the Royal Australian Air Force (RAAF). The company is also delivering flight control computers and navigation equipment.

Genis Steel recently expanded into South Australia, opening a state-of-the-art fabrication facility at the Lionsgate Business Park in Elizabeth South. The large facility—once home to Holden’s press shops—boasts over 15m clear heights and a 100 tonne lifting capacity.

According to Vince Manuele (Managing Director South Australia, Genis Steel), “The supply of gas is essential to Genis Steel’s operations. If we run out of gas, certain areas of production stop. So, our gas supply needs to be efficient, dependable and stress-free. For this to happen, our gas supplier must be very proactive, easy to deal with, and always prepared to fix my issues— Coregas is,” said Manuele.

BAE Systems Australia Chief Executive Officer, Gabby Costigan, said, “I am delighted to be working with Boeing Australia to bring a new defence capability to life that also offers enormous potential for the RAAF as well as future export markets. This project highlights our commitment to leading the development of new technologies and collaborating to advance autonomous capabilities. It is also an exciting opportunity to work together again, delivering a world-leading program using home-grown engineering expertise.”

The reticulated gas pipeline system installed at Genis Steel encompasses Coregas smart metering technology that will ensure Genis Steel is able to access critical level alerts and utilise automatic replenishment for optimum stock levels. According to Nathan Lindsay (Regional Sales Manager South Australia, Coregas), the comprehensive gas system will provide Genis Steel with the capacity and performance required to help maintain their position as leaders in Australia’s heavy engineering and steel fabrication industry. “Without a doubt, the Genis Steel reticulated gas system is one of the most comprehensive and detailed installations in which I have ever been involved.”

Image: Coregas recently completed the installation of one of the largest industrial reticulated gas pipeline systems in the company’s history for structural steel fabricators, Genis Steel. .

BAE Systems Australia joins over 35 Australian companies in manufacturing the first military aircraft in Australia in more than 50 years. The aircraft rolled out today is the first of three prototypes for Australia’s Loyal Wingman program and serves as the foundation for the Boeing Airpower Teaming System product being developed for the global defence market.

BAE Systems Australia has worked with Boeing on a number of projects over the past 30 years. Both companies have a shared national heritage having partnered on a number of early unmanned flight vehicles. They include the Jindivik and Turana Target Drones, GTV Glide Bomb and the Ikara unmanned torpedo delivery system.

Image: BAE Systems will supply the unmanned flight vehicle management solution and simulation capability for the Loyal Wingman - Advanced Development Program.

Inside the Industry: Breaking News

ANSTO Set to Improve Rail Transport with Additive Manufacturing Technology ANSTO will contribute to a recently announced Australian Research Council Linkage Project that will develop additive manufacturing technology, laser cladding, to maintain rails in train networks. The research has the potential to significantly reduce rail maintenance costs and enhance safer transport.

First Offshore Patrol Vessel Coming Together The Federal Government’s Offshore Patrol Vessel (OPV) has reached another milestone with the two halves of the first Arafura Class OPV coming together to form a complete hull. Built by Luerssen Australia and its South Australian partner ASC, it marks the largest industrial manoeuvre at Osborne Naval Shipyard in South Australia.

The laser cladding technique uses laser energy to melt a metal alloy powder, which is injected into the surface of the component and bonds the cladding in a metallurgical process to the surface of the part.

Minister for Defence, Senator the Hon Linda Reynolds MP said the Australian Naval Infrastructure (ANI) operations team manoeuvred the two mega-blocks of the ship together, weighing 1,000 tonnes in total, with only millimetres between them.

ANSTO’s Industry Engagement Manager, Professor Anna Paradowska, will be a principal investigator on the project, which will be led by a team from Monash University under metallurgical expert Associate Professor Ralph Abrahams with industry partner, LaserBond. Yarra Trams is involved as a partner organisation and will assist with in-service evaluations of the technology.

Investigations on ANSTO’s materials and engineering beamline, the strain scanner Kowari at the Australian Centre for Neutron Scattering, will provide measurements of residual strain and residual stresses on materials that have been repaired using the laser cladding technique.

“We expect to use Kowari to determine the residual stresses within the interior of bulk material and a range of investigations of structural integrity. I have considerable experience in collaborative investigations of laser cladding repair techniques for application on rails, aircraft and mining components,” said Paradowska.

“It is a source of great pride to see a unified purpose among industry partners Luerssen, ASC and ANI, with defence industry continuing to show resilience to deliver during these challenging times,” Minister Reynolds said.

“The Morrison Government is forging ahead with our landmark naval shipbuilding programs to not only deliver the important capabilities needed for the ADF, but provide a significant positive impact to the economy and continue to deliver jobs.”

The first of the OPVs, Arafura, is planned to enter service from the early 2020s and will conduct border protection and maritime patrol missions alongside other Australian and regional partners. Luerssen Australia is the Prime Contractor working with key shipbuilding partners ASC in South Australia and Civmec in Western Australia to deliver the OPV capability for Defence. The program of 12 vessels will replace and improve upon the capability delivered by the Armidale Class and Cape Class Patrol Boats.

The two halves of the first Arafura Class OPV coming together to form a complete hull. © Commonwealth of Australia 2020

Australian Welding: June 2020

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Welding Fume Minimisation Guidelines Weld Australia is aware that in March 2017, the International Agency for Research on Cancer (IARC) reclassified welding fume from Group 2B Possibly Carcinogenic to Humans to Group 1 Carcinogenic to Humans. Their assessment was subsequently published in IARC’s Monograph 118 in July 2018. The International Institute of Welding (IIW), through their Commission VIII experts, is evaluating the findings published by IARC and a position statement is being prepared.

Following discussions with Commission VIII, Weld Australia advises that current fume management recommendations remain valid and recommends the Fume Minimisation Guidelines and Technical Note 7 - Health and Safety in Welding are followed.

According to David Chippendale (Director of Marketing and Sales, AWS), “The important point to understand is that while the risk posed by welding fume is serious, keeping yourself safe can be straightforward.”

“Aside from cancer, welding fume can also cause serious long-term health effects like lung function abnormalities, including bronchial asthma, chronic obstructive pulmonary disease, pneumoconiosis and other pulmonary fibrosis. As

well as stomach ulcers, kidney damage and nervous system damage. Recognising welding fume as carcinogenic and the other associated risks should encourage all employers of welders to consider reviewing their risk assessments for welding activities and revise where necessary their control measures.”

Risk Assessment In compliance with National and State Work Health and Safety (WHS) Regulations, employers should conduct a thorough risk assessment to ensure that welders, and people working nearby, are protected from exposure to fumes from welding and welding-related processes (such as thermal cutting, gouging, and so on).

The following actions should be considered in the risk assessment: 1. Where practicable, remove

A Highly Successful Webinar Weld Australia’s newly formed Welding Safety Council recently facilitated a highly successful webinar on Welding Fume, Cancer and Other Hazards. Attended by over 100 people, the panellists included Bruce Cannon (Principal Welding Engineer, Weld Australia); Dr Paul Taylor (Director Chemical Policy, Safe Work Australia); Jackii Shepherd (Director Occupational Hygiene Policy, Safe Work Australia); Barry Chesson (Principal, Australian Institute of Occupational Hygienists); and Daniel Strachan (National Key Account and Sales Manager, Australian Welding Supplies). Attendees received a wealth of valuable information.

the welder from the source of the fume by mechanising or automating the welding process.

2. In conformance with Weld Australia’s Fume Minimisation Guidelines, arrange the work piece so that the welder’s head is not in the plume.

• Unless welding in the horizontal (PC or 2G), overhead (PD, PE, 4F, 4G) or vertical (PF, PG, 3F, 3G) position, the welder’s head is likely to be positioned within the plume, and fume management methods or personal protective equipment (PPE), or both, may be required.

• All welding processes generate fume. The plume may not be visible to the welder or with some processes, the observer.

Inside the Industry: Welding Fume Minimisation Guidelines

13

Weld Australia’s Free Fume Minimisation Guidelines are Now Available Weld Australia recently released a new Technical Guidance Note—Fume Minimisation Guidelines: Welding, Cutting, Brazing and Soldering. This free Technical Guidance Note includes all the information required to help protect your workforce from the hazards associated with welding fumes.

Be sure to download your free copy of the Fume Minimisation Guidelines from Weld Australia’s website: https://weldaustralia.com.au.

3. Relying on a light cross-draught in the vicinity of the welder’s face to ensure that the fume is either drawn or blown away from the welder’s breathing zone can be unreliable. Whilst mechanically assisted ventilation (such as a fan) can be utilised, crossdraughts sufficient to disperse fume may cause weld quality issues. Other fume management equipment such as fume extractors (fixed, downdraft or portable) may be required.

4. Utilise PPE such as respirator masks and air fed helmets if alternative methods of fume control are not reasonably practicable.

In addition, care should be taken to ensure that other workers are not exposed to the fume by allowing it to accumulate in areas away from the welding or welding related process. Specialist advice may also be sought from an Occupational Hygienist (such as the Australian Institute of Occupational Hygienists), particularly in the preparation and implementation of the risk assessment, and the verification of the application of the controls.

“If you are unsure whether the welding fume at your workplace exceeds the relevant exposure standard, you must ensure that air monitoring is carried out. For expert guidance on air monitoring in Australia, contact the Australian Institute of Occupational Hygienists as appropriate,” said Chippendale.

“One major misconception is that employees should be responsible for the purchase of their welding PPE. Under the Australian Work Health and Safety Laws, the employer is financially responsible for providing PPE to workers. As an employer, once you have selected the appropriate PPE, you must provide the worker with information, training and instruction in the proper use and wearing of that PPE – or engage reputable PPE suppliers who can do this on your behalf, such as AWS.” Risk Mitigation Where assessment indicates a significant health risk, decisions must be made on: • Appropriate control measures to minimise risk to health where prevention of exposure to hazardous material is not practicable.

• Instituting periodic airborne contaminant monitoring.

• Instituting health monitoring, including biological monitoring, to assist in assessing the effectiveness workplace controls.

• Training shall be provided by the employer to all employees with potential exposure to hazardous chemicals on the health impacts and control measures, and should be commensurate with the identified risk.

How Welders Can Help Ensure Their Own Safety Employees are required to: • Cooperate with the employer

•

to ensure that activities within the workplace comply with the statutory requirements.

Report promptly to supervisors or managers any matter that might diminish the employer’s ability to achieve compliance.

“As a welder, you should aim to educate yourself on the risks, understand the appropriate PPE available and look to involve yourself in the consultation process and ultimate selection of suitable PPE at your workplace,” said Chippendale.

“Welding helmets with integrated powered air purifying respirators (PAPR) are one of the most widely used forms of respiratory protection amongst welders. They have a RMPF of 50, meaning that they supply breathing air a minimum 50 times cleaner than the welder would otherwise be breathing unprotected and also protect the welders’ eyes and face. When compared to disposable and reusable halfface mask respiratory protection, PAPRs provide superior respiratory protection and do not require fittesting.”

“Generally speaking, PAPRs provide suitable protection to welders across the most common materials (aluminium, stainless steel, galvanised steel etc) and applications (MIG, TIG, Stick) where there is a good environment with forced ventilation,” said Chippendale.

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Australian Welding: June 2020

Returning to Work and the Workplace Post-COVID-19 As COVID-19 restrictions ease, industries and businesses are starting to operate again. This means that many employers and employees are planning and facilitating their return to work or to the workplace. The Fair Work Ombudsman has a range of resources availble for employers and employees alike, and is encouraging employers and employees to work together cooperatively as they transition back to work. This includes planning for things like employees starting to work again after being stood down, making changes to start or finish times, or returning to usual workplaces after working from home or another location.

Planning the Return to Work Before employers and employees return to work, it’s important that businesses have a plan to keep their workplace safe, healthy and free of coronavirus. It’s also important to review this plan regularly so it stays up-to-date as restrictions change.

The National COVID-19 Coordination Commission has an online planning tool to help employers develop this plan. These plans will help keep workers, customers and the community safe as businesses reopen or increase their activities.

As part of this planning, employers and employees need to consider their obligations under workplace health and safety laws in their state or territory. For more information, download Safe Work Australia’s

COVID-19 Toolkit, and see the article on page 18.

Lifting Stand Down As businesses start operating again, many employers will need to lift the stand down directions they’ve given their employees. When an employer is lifting a stand down, it’s best practice to communicate early with affected employees in writing.

Consultation and cooperation between employers and employees has significant benefits and can help workplaces cope better with change.

For further information, see the Fair Work Ombudsman’s Consultation and Cooperation in the Workplace Best Practice Guide.

Consultation when lifting a stand down may also be a requirement under an applicable award or

agreement, employment contract or workplace policy. All awards and enterprise agreements contain consultation provisions, which could apply in these circumstances.

Directing Employees to Return to Work Employers can give directions for employees to work their normal hours if it’s reasonable, legal and safe (except if they’re on approved leave). Employers should check if any enforceable government directions say whether an employee can or should work from home or another location. When directing an employee to perform work, employers need to follow their work health and safety obligations and consider any flexible working arrangements that already apply.

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Inside the Industry: Business Essentials

Alternative Working Arrangements Employers should continue exploring alternative working arrangements in their workplace, particularly if social distancing rules apply, including: • Staggering employees’ start and finish times • Rotating working from home (if possible) to allow for more space in the workplace • Scheduling breaks or shift changes to avoid crowding at exits, lifts and break rooms • For employers and employees covered by JobKeeper: • Giving employees a JobKeeper enabling direction about the location of work to enable rotating working from home arrangements • Making an agreement to work different days or times to enable staggered start and finish times Record-Keeping All employers need to keep certain records about their employees and their working arrangements.

Employers should make sure their records are up to date to enable

a smooth transition back to the workplace.

Directing Employees to Perform Work If an employee has been stood down, including because of a JobKeeper enabling stand down direction, their employer can lift or replace this direction so that the employee can return to work or work up to their usual hours.

The normal rules about following directions to work apply. An employee can’t refuse an employer’s legal and reasonable direction to perform work. This includes having regard to work health and safety obligations and considering any flexible working arrangements.

Changes to Duties When Returning to Work As employees return to work, employers may need to make changes to their usual duties because they’re operating differently.

Employers should check whether there are any rules about doing this in any applicable award, agreement or employment contract before making any changes.

Recent variations to some awards allow employers to direct employees to perform duties that are within their skill and competency. This includes if the duties aren’t part of an employee’s usual classification. See Temporary Changes to Workplace Laws During Coronavirus.

Employers who are part of JobKeeper scheme can also give eligible employees a JobKeeper enabling direction to perform any duties that are within their skill or competency, if the direction is reasonable. See Changing Duties, Location or Days and Times of Work Under the JobKeeper Scheme.

Resolving Issues When Returning to Work Employers and employees are encouraged to work together to find solutions that benefit both the workplace and affected individuals.

For more information on dealing with conflicts and issues, visit Resolving Workplace Issues During Coronavirus.

All information above was supplied by the Fair Work Ombudsman.

FREE Webinar: Returning to Work and the Workplace Post-COVID-19 As COVID-19 restrictions ease, industries and businesses are now looking to return to more familiar working conditions and environments following several months of disruption.

This free webinar, presented by Aaron Rilstone (Director - Stakeholder Strategy & Small Business, Fair Work Ombudsman) will explore how employees and employers can work together collaboratively as they transition back to work and prepare for more difficult months ahead. Aaron will talk about: • Award changes • Temporary amendments to the Fair Work Act • JobKeeper • Stand downs • FAQs and trends the FWO is seeing • Tools, guides and resources to assist Date: Friday 3 July 2020

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Time: 10.30am (AEST)

Register now via www.weldaustralia.com.au

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Australian Welding: June 2020

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, steel structures, welding of structures, non-destructive testing and pipelines.

Pressure Equipment The revision of AS/NZS 3992 Pressure equipment—Welding and brazing qualification was completed late in 2018. The public comments have now been resolved and the ballot process is complete. At the date of publication, the Standard was due to be published in early June 2020.

As indicated in the March 2020 edition of Australian Welding, the preparation of the revised draft of

AS/NZS 3788 Pressure equipment— In‑service inspection, was completed in December 2019. A project proposal to formally revise the Standard is currently being prepared for submission to Standards Australia to initiate the formal revision process.

Steel Structures Committee BD-001’s work on the revision of two of its Standards, AS/NZS 5131 Structural steelwork —Fabrication and erection, and

AS 4100 Steel structures is now complete, with all public comment and balloting finalised. At the time of publication, it was anticipated that the drafts will be published in June 2020.

Welding of Structures Work on the amendment to correct an error within AS/NZS 2980 Qualification of welders for fusion welding of steels—Additional requirements for Australia and New Zealand has been completed on schedule. The amendment was published in May 2020.

Preparation of a public review draft of the revision of AS/NZS 1554.2 Structural steel welding—Part 2: Stud welding (steel studs to steel) has been completed. The draft was released for public comment on 1 June 2020. As previously indicated, the draft has taken cognisance of the relevant ISO standards. To this end, ISO 13918 has been adopted as AS/NZS ISO 13918 Welding - Studs and ceramic ferrules for arc stud welding for stud materials. It provides for the use of stainless steel studs and studs for wear applications.

For further information about Australian Standards, simply contact Weld Australia on +61 2 8748 0100.

Weld Australia members can also utilise our Hotline, available via our website: www.weldaustralia.com.au

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Inside the Industry: Australian Standards

Non-Destructive Testing As previously reported, Committee MT‑007 has reviewed Australia’s aged non-destructive testing Standards and has adopted the equivalent ISO Standards as AS ISO Standards.

The non-destructive testing processes affected include magnetic particle, liquid penetrant, eddy current and ultrasonic thickness testing. The new editions were published in April 2020. In all cases, whilst the impending adoptions align the test methods with international requirements, imperfection acceptance criteria as defined in the application Standards, remain unchanged.

As previously indicated, consideration on the replacement of AS 2207 Non‑destructive testing— Ultrasonic testing of fusion welded joints in carbon and low alloy steels and the AS 2177 series (Non‑destructive testing— Radiography of welded butt joints on metal) by their ISO equivalent has been deferred at this point in time.

Pipelines Committee ME‑038 has revised AS/NZS 2885.2 Pipelines—Gas and liquid petroleum Part 2: Welding. A modified public review draft closed for public comment and committee ballot in January 2020. Comments received have been resolved.

AS/NZS 2885 Pipelines—Gas and liquid petroleum Part 3: Operation and maintenance has also been revised and public comment received is being resolved.

ISO Adoptions A number of welding related ISO Standards have been adopted

by Australia, including ISO 14731 Welding coordination – Tasks and responsibilities, ISO 6947 as AS/NZS 3545 Welding positions, and SA/SNZ ISO TR 15608 Welding— Guidelines for a metallic materials grouping system.

ISO 5173 Bend tests has been adopted as AS/NZS 2205.3.1, and has superseded both AS 2205.3.1 and AS 2205.3.3. It was published on 5 June 2020. ISO 3821 has also been adopted as AS/NZS 1335

Gas welding equipment—Rubber hoses for welding, cutting and allied processes, and was published in May 2020.

ISO Update ISO TC44/SC10 has commenced the revision of the ISO 3834 series of Standards. This is primarily to take cognisance of changes to ISO 9001 and the 2019 edition of ISO 14731.

Similarly, ISO TC44 and SC11 have commenced the revision of ISO 9606-1 Qualification testing of welders—Fusion welding—Part 1: Steels with the intention of combining all five parts into the one Standard.

This will simplify the ongoing maintenance and review requirements for the Standards, particularly as parts 2 to 5 of ISO 9606-1 are in need of revision.

Australia is participating in the revision process on both subcommittees and an initial meeting was held in April 2020. Follow‑up meetings are set for June 2020.

Register on the AWCR Today How to Register 1.

2.

3.

4.

5.

6.

The Australian Welder Certification Register (AWCR) was developed and is managed by Weld Australia. It provides a national framework for qualifying and testing welders to International Standard AS/NZS ISO 9606-1, and provides a raft of benefits for welders and industry alike.

Go to www.awcr.org.au Click on ‘Click Here to Register’ Click on ‘Create An Account’ Enter your contact details Verify your email address Login and complete your profile

AWCR

Australian Welder Certification Register

+61 2 8748 0100 | www.awcr.org.au | awcr@weldaustralia.com.au | www.weldaustralia.com.au

Australian Welding: June 2020

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Workplace Health and Safety in the Wake of COVID-19 The COVID-19 pandemic has had a significant impact on health and safety practices in the workplace across almost all industries, including welding and fabrication. While some restrictions may be beginning to ease, the threat of the pandemic remains. As such, Work Health and Safety laws still necessitate that employers take precautions to care for the health, safety and welfare of workers in order to prevent infection and spread of the virus.

Work Health and Safety Laws Work Health and Safety (WHS) require employers to take care of the health, safety and welfare of their workers, including staff, contractors and volunteers, and other people who may visit the workplace, such as clients and suppliers.

In particular, WHS laws dictate that employers must: • Provide and maintain a work environment that is free from risks to health and safety • Provide facilities that are adequate and accessible for workers’ welfare, so that they may carry out their work • Monitor the health of workers, as well as the conditions of the workplace, in order to prevent injury or illness Duty to Workers According to Safe Work Australia,

For further information about Work Health and Safety, please visit the Safe Work Australia website: safeworkaustralia.gov.au The website has a broad range of material available, some of which is even broken down into specific industries of operation, including Building and Construction, Mining, and Trades.

You can also visit the Weld Australia COVID-19 Hub.

employers must, within what is reasonably practicable, take all possible precautions to eliminate the risk of exposure to COVID-19 to help ensure the health and safety of workers. If the complete elimination of the risk is not possible, the risk must be minimised as much as is reasonably practicable.

Employers can help protect workers from the risk of exposure to COVID-19 by, for example: • Arranging for staff to work from home if possible • Enforcing physical distancing practices between workers where possible • Enforcing good hygiene practices for workers, for example through workplace policies and ensuring that there is access to hygiene facilities that are well stocked and adequate • Ensuring that workers who are

•

sick or display any symptoms are required to stay at home Thorough and regular cleaning and disinfecting of the workplace

Duty to Other People in the Workplace Employers must also ensure the work of their business does not put the health and safety of other people (such as customers, clients and visitors) at risk of contracting COVID-19.

Employers can help protect others from the risk of exposure to COVID-19 by, for example: • Ensuring physical distancing for visitors to the workplace, through measures such as contactless payments and deliveries • Requiring non-essential patrons, such as family, friends or visitors, to stay away from the workplace • Limiting the number of people in

Inside the Industry: Health & Safety

the workplace at a given time, in accordance with the size of the workplace Duty to Provide Information, Training and Supervision Additionally, WHS laws require employers to provide necessary information and training to workers to help them mitigate the risk of COVID-19 spread and exposure.

Training and information provided may include: • Posters or diagrams that provide guidance regarding how to properly wash hands • Training that demonstrates to workers how to properly fit and wear any necessary personal protective equipment (PPE) • Training workers on how to properly clean and disinfect the workplace throughout the day • Providing instructions to workers, who are working from home, on how to set up a safe at-home workplace Duty to Consult Additionally, employers must consult with their workers regarding health and safety matters related to COVID-19, allowing them to raise any WHS concerns and taking these views into account. Consultation with workers is required when: • Conducting a risk assessment • Making decisions regarding control measures for risk management of COVID-19

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• •

Making decisions about workplace facilities and their adequacy for COVID-19 control measures Proposing any kind of changes that may affect the health and safety of workers Changing procedures that affect the WHS of workers

Similarly, workers should take reasonable care to not compromise their health and safety, or the health and safety of others, by following workplace procedures and instructions and reporting any unsafe or unhealthy situations.

Personal Protective Equipment Personal protective equipment (PPE) is anything that can be worn to minimise risks to workers’ health and safety. In the case of COVID-19, PPE is used to prevent the spread and contraction of the virus and should be used to supplement other control measures, such as good hygiene practices, physical distancing, and regular and thorough cleaning of the workplace.

PPE that can help to prevent the spread of COVID-19 includes masks, gloves, eye protection and screens. Some masks, gowns and disposable suits are restricted to healthcare settings and so are not applicable for use in welding industry workplaces.

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What To Do If Your Workplace Has a COVID-19 Case Anyone with a confirmed or suspected case of COVID-19 should not be in the workplace. If someone is displaying COVID-19 symptoms or has been in contact with someone who has COVID-19, then there is reasonable cause for concern.

If this occurs, employers should: 1. Isolate the person and provide them with appropriate PPE. 2. If the person is displaying serious symptoms that require immediate medical attention, call 000. If not, seek advice via your state or territory COVID-19 hotline.

3. Confirm with the affected person who they have been in contact with in the workplace, and in which areas they have spent time.

4. Ensure that the person has a means of transport home.

Where possible, this mode of transport should be private to minimise others’ exposure.

If the person needs to take public transport, they should take precautions to minimise contact with others.

5. Any areas in the workplace in which the person may have spent time should be closed off until they have been thoroughly cleaned and disinfected. Where possible, doors and windows should be opened to increase airflow.

6. Anyone that has been in close contact with the affected person should be identified and told that they may have been exposed to COVID-19, and that they should quarantine.

7. Review risk management controls, with workers and representatives consulted, on whether changes or additional precautions are required.

If the suspected COVID-19 case is confirmed, the workplace will be contacted by the state or territory public health unit regarding further steps and instructions relating to quarantine requirements.

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Australian Welding: June 2020

Digital Manufacturing in the Hunter Class Frigate Program BAE Systems Australia’s subsidiary, ASC Shipbuilding, was awarded the $35 billion contract by the Australian Government to design and build nine anti-submarine warfare frigates for the Royal Australian Navy. ASC Shipbuilding is developing and piloting cutting-edge manufacturing technologies that will be used at the world-class Osborne Naval Shipyard in South Australia, where the Hunter class frigates will be built.

The Hunter Class Frigate will be based on BAE Systems’ Type 26 Global Combat Ship design, the world’s first bow-tostern digitally-designed anti-submarine warfare frigate.

Digital Manufacturing in the Hunter Class Frigate Program

BAE Systems Australia’s shipbuilding business, ASC Shipbuilding, is partnering with Flinders University and local small and medium enterprises (SMEs) to drive digital transformation through advanced robotics, assistive manufacturing and readiness for Industry 4.0 utilisation, both inside the shipyard and more widely in the Australian supply chain.

Earlier this year, ASC Shipbuilding welcomed a $1.45 million grant from the Government-funded Innovative Manufacturing Corporate Research Centre (IMCRC), matched by the shipbuilding business and in addition to the $5 million it has already invested in developing digital technologies, to turn the digital shipyard concept into reality.

According to David Chuter (CEO and Managing Director, IMCRC), “Digital technologies such as artificial intelligence, robotics, cognitive automation and advanced analytics are redefining the Australian manufacturing sector and therefore the nature of its work.”

“Australian manufacturers, particularly SMEs, need to learn how to embrace and contribute to new work environments that blend advanced technologies and digital skills with uniquely human skills.”

“The project researches pathways to successfully adopt new technologies and develop human capabilities that—while focused on shipbuilding—can help Australian industry as a whole prepare for a future that is driven by digital transformation,” said Chuter.

technologies for application in the shipyard and beyond. The latest technologies from industries such as mining, automotive and construction and will be adapted, trialled and tested to suit the Hunter class frigate’s design. These technologies enable connectivity between manufacturing equipment and databases that will provide real-time insights into shipyard and supply chain performance, leading to enhanced productivity, safety and quality outcomes.

Flinders University President and Vice-Chancellor, Professor Colin Stirling, said, “Thanks to this strategic investment, Flinders University’s research expertise in advanced manufacturing will help to ensure that the Hunter class frigates will be built by ASC Shipbuilding using world-leading technologies.”

“Our strengths in industry 4.0 and cutting-edge digital laboratories will enable the development and testing of bespoke technologies to advance the specialised construction processes required for this nationally significant project.”

“The IMCRC’s commitment recognises the value of the partnership that Flinders University has forged with ASC Shipbuilding and is further testament to the calibre of our researchers, our exceptional facilities and our leadership in innovation,” said Stirling.

The $2.9 million cash investment will create seven new research positions at Flinders University—bringing the total number of researchers to 16—at the digital test and trial collaboration hub at Tonsley Innovation District in Adelaide’s south.

Advanced Manufacturing Technologies Work is almost finished on the $500 million upgrade of Adelaide’s new high-tech shipyard, with five new structures rising from its Port River site. The five new sheds are currently being fitted with cuttingedge equipment; the site’s builders Australian Naval Infrastructure and Lendlease are on track for a complete handover in July.

From March 2020 until 2022—when steel is cut on the first Hunter class frigate—the researchers will work with the shipbuilding workforce to trial advanced manufacturing

According to Sharon Wilson (Continuous Naval Shipbuilding Strategy Director, ASC Shipbuilding), “One of the sheds has a fully automated panel line, complete

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with the latest in automatic welding, cutting and plasma machines.

Steel enters the highly automated fabrication hall at one end, is cut and welded into the 75-odd units that make up each of the frigates, and semi-blocks come out at the other end of the hall. The Federal Government really has invested in state-of-the-art technology.”

“Through this funding and research projects at Tonsley, we will be looking at how we connect our people to the work. We want to make technology as accessible in the shipyard as it is in normal, everyday life.”

“We will also investigate how to connect our machines and equipment to our systems, as well as the individual parts that we produce for the frigates. Our machines are sourced from a range of different suppliers. As such, the way in which they capture information, connect to our system, and connect to one another differs. In order to produce an accurate digital twin, all these elements must work together in unison.”

“Finally, we’re focused on humanistic issues of technology uptake. If you cannot get your people to embrace advanced technology and digital processes, rather than oppose it, the uptake just won’t be successful.”

“Basically, we’re working on bringing the shipyard to life using all the digital tools available,” said Wilson.

Importantly, the learnings that ASC Shipbuilding discovers through their research will be shared throughout Australia’s manufacturing industry.

“One of the main outcomes of this collaborative research project is that we will be able to share our learnings with Australian SMEs who are not in the position to go on the journey themselves. This is how Australian industry can become more resilient and competitive on the global stage—by learning, sharing research, and developing together,” said Wilson.

Australian Welding: June 2020

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Digitisation allows for project partners to see plans in real time, identify and resolve issues faster, improve risk management and optimise production.

Image: Flinders University Pro-Vice Chancellor Professor John Spoehr, Minister for Industry, Science and Technology Karen Andrews, and Premier Steven Marshall at the IMCRC funding announcement.

Why the Hunter Class Frigate?

The Hunter Class Frigate Program lends itself particularly well to this type of research. According to Wilson, there are two primary reasons for the program’s compatibility.

“Working with an old shipyard, that is constrained in terms of both internet accessibility and physical space, makes it difficult to optimise efficiency and effectiveness. The brand new, state-of-the-art shipyard at Osborne will foster opportunities to optimise ship production.”

“The second reason is that we have years of learning from our United Kingdom operations on the development of digital shipyard design. This is so much more than just a CAD model—it is a comprehensive tool set that outlines not just what has been selected, but why.”

“

Working with an old shipyard, that is constrained in terms of both internet accessibility and physical space, makes it difficult to optimise efficiency and effectiveness. The brand new, state-of-the-art shipyard at Osborne will foster opportunties to optimise ship production.”

“A frigate is a very complex piece of equipment, comprised of many interrelated systems. We have invested a huge amount in digital design in the United Kingdom, so we have exceptional insights into what is working there, and what is not.

These insights can now be applied to our Australian operations.”

BAE Systems Australia has been investing in both people and capability in the digital manufacturing space for some time now. The primary example is the Joint Strike Fighter project. BAE Systems Australia and the Advanced Manufacturing Growth Centre (AMGC) developed a new approach to supply chain digitisation that avoids having to use expensive, proprietary software, which is currently one of the major barriers to Australian SME manufacturers participating in global supply chains.

Australia received its first two F-35 aircraft in December 2018, in what is the largest air force acquisition in Australia’s history. BAE Systems supplies 300 titanium components per month from its advanced manufacturing facility at Edinburgh Parks in South Australia for each F-35 vertical tail.

According to Wilson, “Joint Strike Fighter project really started the ball rolling—it requires extremely precise manufacturing, with parts brought in from all over the world that must fit together exactly every time. The application of digitisation was perfect.”

Local SME Involvement During the Hunter Class Frigate program’s prototyping phase, five prototyping blocks will be built at the Osborne Naval Shipyard South. During this phase, Australian businesses can bid for an estimated $20 million in contracts across two specific supplier categories.

“Last year we ran a ‘Factory of the Future’ showcase in Melbourne, which was highly successful in bringing together lots of SMEs and researchers with advanced manufacturing technologies.”

Digital Manufacturing in the Hunter Class Frigate Program

“Some of the companies we’re working with include universal site monitoring company MOVUS, Weld Australia for welding simulators, Speed3D, Dematek, Sabre Autonomous Solutions and MG Engineering,” said Wilson.

ASC Shipbuilding expects the Australian industry content for the Hunter class frigate build will be well north of 60%, creating and securing thousands of jobs for decades.

At the end of the program, the Commonwealth Government will retain a sovereign share in ASC Shipbuilding with the option to call back the entity at the end of the program, ensuring the retention of intellectual property and a highly skilled worker which can continue to support continuous naval shipbuilding.

Thousands of Australian businesses could be involved in Australia’s largest surface shipbuilding program.

To date, 1,100 companies have pre-qualified to be part of the Hunter Class supply chain, with the Australian steel industry in particular benefiting from the 48,000 tonnes of steel required to build the ships.

The Program will grow and develop the capability of local industry, to underpin an enduring Australian shipbuilding capability, as well as a strong, vibrant defence industry— both of which will play a key role in the growth of the national economy.

The Hunter Class Frigate The Hunter Class Frigate will be based on BAE Systems’ Type 26 Global Combat Ship design, the world’s first bow-to-stern digitallydesigned anti-submarine warfare frigate.

Modified to meet Australian requirements, the Hunter Class Frigate will be constructed on an acoustically quiet hull and feature unique sonar capabilities, modular digital design and open systems architecture to facilitate through-life support and upgrades as new technology develops. The Hunter Class Frigate has been designed for maximum versatility and flexibility in operational roles, from humanitarian and disaster relief operations to high-intensity warfare.

The integrated mission bay and hangar is capable of supporting multiple helicopters, unmanned vehicles, boats, mission loads and disaster relief stores. A launcher can be provided for fixed wing UAV operation and the flight deck is capable of landing a Chinook helicopter for transport of embarked forces.

Progress on the Program On 29 June 2018, the Australian Government announced BAE Systems was selected as the preferred tenderer to deliver nine frigates to the Royal Australian Navy and that BAE Systems would acquire ASC Shipbuilding. Since then, progress has been rapid. The Head Contract, Sovereign Capability Option Deed and acquisition of ASC Shipbuilding was negotiated, agreed to and executed in less than six months from the down-select.

Since the Head Contract was signed in December 2018, the program has grown to nearly 500 people across Australia and the United Kingdom. To date, more than 1,100 suppliers from across Australia have registered through the Industry Capability Network to supply into the Hunter program. Combat Systems integration partners—Lockheed Martin Australia and SAAB Australia—have been selected to partner with BAE Systems Australia to deliver the Combat System Integration on the Frigates.

The Hunter program will create and sustain 5,000 jobs in BAE Systems, ASC Shipbuilding and the defence supply chain over the life of the program. At its peak in 2028, the program will contribute around $1 billion in GDP to the Australian economy. Program mobilisation and design activities are well underway, including preparation for prototyping, which is to commence in 2020, before steel is cut on the first frigate in 2022.

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Australian Welding: June 2020

Rheinmetall Moves into Military Vehicle Centre of Excellence Rheinmetall Defence Australia is establishing its Asia Pacific headquarters at its new $170 million Military Vehicle Centre of Excellence (MILVEHCOE) in Ipswich, Queensland. Representing the largest financial infrastructure investment in the company’s 130 year history, the MILVEHCOE will be the design, development and manufacturing hub for the Commonwealth Government’s $5.2 billion LAND 400 Phase 2 project, as well as Rheinmetall’s other defence projects, including the integration and sustainment of 3,500 logistics trucks under the LAND 121 Phase 3B/5B project.

Rheinmetall’s focus on establishing a military vehicle capability in Queensland dates back to the tender period for LAND 400 Phase 2.

Rheinmetall entered into a long-term partnership with the Queensland Government to relocate to the state, should it be successful in the bid. The Queensland Government is now using its expertise in large infrastructure projects to oversee the MILVEHCOE’s construction, and will deliver the facility on budget and ahead of schedule.

Situated over 11 hectares, the MILVEHCOE will feature state-ofthe-art technology from across Rheinmetall’s defence businesses including electronics, electrooptics, armour, turrets, vehicles and simulators. It will reflect Rheinmetall’s position as a global high-technology

manufacturer and is envisaged as a campus of high quality industrial production and testing facilities and administration buildings.

The facilities will include manufacturing, electronics and administration buildings, a training centre, a 100m indoor firing tunnel for testing of weapons up to 35mm, a high security prototype work shop and Systems Integration Lab, a vehicle test track, and a threestorey electromagnetic compatibility (EMC) test chamber large enough to accommodate a main battle tank.

Rheinmetall’s Queensland-based employees are moving into the facilities in a staged manner and will all be on site by August this year.

According to Gary Stewart, (Managing Director Rheinmetall

Defence Australia and Chief Executive Vehicle Systems Asia Pacific), “MILVEHCOE encompasses a very wide range of manufacturing processes and subsequent technology, from contemporary vehicle and component assembly processes to advanced composite armour manufacturing to very complex electronics and optics assembly and testing, and everything in between.”

“To provide some insight, the technology employed will range from fully ERP integrated Bluetooth enabled torque tools, to closed loop controlled 5000T composite armour presses, to the latest CANBUS fully synchronised paired crane systems, to automated optic alignment and PCB test systems. Rheinmetall uses a connected production

Rheinmetall Moves into Military Vehicle Centre of Excellence

“

Construction of the MILVEHCOE will further underpin defence manufacturing within South East Queensland, and make use of the existing heavy vehicle manufacturing and employment hub and highly skilled workforce within the area.”

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Far Left: Rheinmetall Defence Australia has established its Asia Pacific headquarters at the $170 million Military Vehicle Centre of Excellence (MILVEHCOE) in Ipswich, Queensland.

Left: A TAFE Queensland student trials the new Lorch welding kit during the set up of the welding workshop.

Below: An artists’ impression of Rheinmetall Defence Australia’s completed MILVEHCOE.

system integration, based on the latest ERP and BMS systems. This includes initiatives such as real time production process and material integration through tablet interfaces, with similar real time capabilities to be leveraged in our facility management and maintenance area,” said Stewart.

Rheinmetall’s assembly process will be undertaken in the new production facility using a production line approach. Cranes will be used to move the component parts between assembly stations. The assembly activities are highly manual and follow the sequence of welding, component manufacturing, system assembly and integration. The vehicles will receive a base coat of paint and then a final coat of camouflage paint in spray painting booths.

Why Queensland?

The location of the MILVEHCOE, around 30km south west of the Brisbane central business district, offers many advantages.

“The construction of the MILVEHCOE in Queensland will provide opportunities for local industry to participate in this landmark project during the construction phase, and by providing products and services to Rheinmetall’s military vehicle programs,” explained Stewart. “It will also open the way for these companies to participate in Rheinmetall’s global supply chain.”

Programs Under Way at Rheinmetall’s MILVEHCOE LAND 400 Phase 2 Under the $5.2 billion LAND 400 Phase 2 project, Rheinmetall is progressing the ‘Australianisation’ of the BOXER 8x8 Combat Reconnaissance Vehicle fleet, while simultaneously delivering first vehicles to the Australian Defence Force. The first 25 Boxer vehicles are being manufactured in Germany, while full production on the remaining 186 vehicles will commence at the MILVEHCOE from early 2021.

LAND 400 Phase 3 Rheinmetall was successfully shortlisted by the Federal Government to progress through to the next stage of tender evaluation for the $15 billion LAND 400 Phase 3 project. Rheinmetall specifically designed the Lynx KF41 infantry fighting vehicle to meet the tender requirements.

Should Rheinmetall be successful in the tender, the outcome of which is expected in 2022, up to 400 infantry fighting vehicles would be manufactured at the MILVEHCOE. LAND 121 Phase 3B/5B Rheinmetall is delivering more than 2,500 high mobility 4x4, 6x6, 8x8 and 10x10 trucks to the Australian Army as part of the LAND 121 Phase 3B program. Due for completion this year, the project will underpin a world class logistics backbone for the Australian Defence Force for decades.

Rheinmetall will continue to increase Australian industry participation in the LAND 121 program this year with the next phase – LAND 121 Phase 5B. Under this program, Rheinmetall will deliver a further 1,044 military logistics trucks and 742 modules to the Australian Defence Force.

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Rheinmetall and Bisalloy Work Together to Create Specialised Armour Steel Rheinmetall and Bisalloy are working together in Australia and Germany to create specialised grades of BISALLOY® Armour Steel for application on the BOXER 8×8 Combat Reconnaissance Vehicles (CRV), to be delivered to the LAND 400 Phase 2 program.

Bisalloy is two years into the development of new grades of armour steel, in order to meet the exacting protection levels required for each BOXER 8×8 CRV. Once certified, Bisalloy steel will produce the best protection for Australian soldiers to ensure they survive and win in combat.

According to Stewart, “Wollongong-based Bisalloy is moving through a two year qualification process in Germany and Australia to supply Australian armour steel at grades of protection expected by Rheinmetall’s customer, to protect Australian soldiers in combat.”

“Rheinmetall commenced this process before it was selected to deliver LAND 400 Phase 2, and the final steps to achieve qualification will be made by the German Government this year.”

“Critically, this investment

by Bisalloy and Rheinmetall presents both companies with the opportunity to manufacture armour steel not only for the Australian BOXER and LYNX KF41 vehicles locally, but crucially, also for international programs. This recognises that the qualified Australian steel will be only one of three companies globally with the capability to deliver the highest protection armour steel required by defence forces in nations, including Australia and Germany,” said Stewart.

Australian Welding: June 2020

Rheinmetall’s MILVEHCOE under construction.

Rheinmetall’s MILVEHCOE under construction.

“LAND 400 and other defence projects are of strategic importance to the growth and diversification of Queensland’s economy.”

“Construction of the MILVEHCOE will further underpin defence manufacturing within South East Queensland and make use of the existing heavy vehicle manufacturing and employment hub and highly skilled workforce within the area.

Locating the facility in the BrisbaneIpswich corridor near major transport routes and existing heavy vehicle manufacturers will achieve supply chain efficiencies and attract further investment and growth in the defence and advanced manufacturing sector,” said Stewart.

Welding Capability As part of its commitment to developing Australian Industry Capability (AIC), Rheinmetall is building its industry network across Australia and establishing a local capability to underpin a national military vehicle industry.

According to Stewart, “Primarily, the company’s armoured steel welding capability will remain a highly skilled manual process using

the latest German MAG welding equipment, in-house engineered jigs, fixtures and templates to control Geometric dimensioning and tolerancing (GD&T) to some very tight requirements.”

“The MILVEHCOE will also have multi axis positioners capable of managing welded assemblies of up to 12T and 12m in length with in-house non-destructive testing, metrology and shot blasting capability,” said Stewart.

Upskilling to Ensure Australian Soldiers are Protected “Prospective Australian companies were tasked with achieving internationally recognised standards in order to enter the Rheinmetall global supply chain,” said Stewart.

Preparations are underway for a significant uplift in welding qualifications for Australian companies to weld Australian armoured steel. Rheinmetall’s weld procedures, Assessment Plan, and its Australian and German Training Plans presented an opportunity for registered training provider, TAFE Queensland, to become a recognised provider of certification

Rheinmetall Moves into Military Vehicle Centre of Excellence

to ISO 9606 Qualification testing of welders - Fusion welding. By establishing a more highly skilled workforce, local SMEs are better placed to tender for lucrative contracts from the Australian Defence Force and international Defence Primes, where ISO 3834 and ISO 9606 certification are non-negotiable tender compliance requirements.

Rheinmetall and TAFE Queensland are also in negotiations to deliver the entry levels of the German welding standard DIN 2303 Welding and allied processes - Quality requirements for production and maintenance companies for military products. If successful, TAFE Queensland will be the only provider of this level of training in Australia.

It will provide TAFE Queensland with the capability to deliver entry level DIN 2303 competencies in Australia to the 30 production welders at Rheinmetall’s MILVEHCOE. This would reduce the amount of time Australian welders are required to be trained in Germany, reducing training costs for Rheinmetall and shortening the timeframes Australian welders are away from their families.

The collaboration between Rheinmetall and TAFE Queensland will also support the estimated 40 year maintenance contracts in the

forward operating defence hubs of Cairns and Townsville.

Working with Local Small-toMedium Enterprises (SMEs) While the first 25 BOXER vehicles are being largely built in Europe as part of Rheinmetall’s Early Capability Delivery requirement with the Australian Defence Force, the vehicles now include products and services from 28 Australian SMEs. “This growing list of suppliers has met performance and quality standards that are critical to a demanding verification and test environment that ensures Australian soldiers are protected, and the Australian Army receives a capability that will be in operation for the next 30 years and beyond,” said Stewart.

“Each SME that meets these performance thresholds has made a long term investment in quality systems, procurement relationships and continuous improvement.

Rheinmetall is working with a growing number of Australian SMEs drawn from the 1,000-plus companies we have engaged since 2015 in every corner of the continent. The quality of the products and services offered by these companies has enabled us to exceed expectations on local content in these early BOXER vehicles,” said Stewart.

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Rheinmetall will continue these industry engagement briefings throughout 2020 in co-ordination with peak bodies including the Defence Teaming Centre, the Australian Industry Defence Network, the Australian Defence Alliance, regional support bodies and state government Defence agencies.

“SMEs now progressing through the qualification process took the critical step—up to five years ago —to look long term and decide how working in the Defence industry could potentially contribute to their company’s business plan, from acquisition through to support and retirement of Australian Defence Force assets,” said Stewart.

COVID-19 notwithstanding, the remainder of 2020 will see several global supply chain announcements for companies expanding their reach beyond local defence contracts and exporting into global programs where Rheinmetall businesses are delivering products and services to military forces offshore.

This presents exciting opportunities for those companies and represents a significant step change to just six years ago when Rheinmetall first entered the Australian market to deliver trucks and modules under the LAND 121 Phase 3B – Medium Heavy Capability program.

The production facility at Rheinmetall’s MILVEHCOE is already operational.

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Australian Welding: June 2020

Macfab Engineering Certified to AS/NZS ISO 3834 Based in Albury, on the New South Wales—Victoria border, Macfab Engineering fabricates and installs a diverse array of structural steel for some of Australia’s largest construction companies and transport authorities. With a commitment to superior quality workmanship, Macfab Engineering was recently certified to AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials.

Mud’s Inspection and Welding Services (trading as Macfab Engineering) was established in 1996

by Wayne (aka Mud) and Michelle Clarke. Originally, the company manufactured ute trays. However, during its first ten years in operation, Macfab metamorphised into a supplier and installer of structural steel, predominantly undertaking projects for Transport for New South Wales and tier one construction companies across New South Wales and Victoria.

Macfab Engineering has a purposebuilt factory and administration building that is fully equipped to handle structural steel, stainless steel, mild steel, aluminium and sheet metal fabrications.

Above: Dudley Street Rail Bridge Project, Melbourne.

Right: Macfab Engineering’s 3,350m2 facility in Albury on the New South Wales—Victoria border.

According to John Bourke (General Manager, Macfab Engineering), “The total factory floor space is 3,350m2 and the office is 750m2. Due to ongoing production demand, we operate on a day and an afternoon shift, as well as many Saturdays.”

“We employ around 80 people, including over 50 tradespeople, 10 apprentices, engineers, welding supervisors, welding inspectors, and administration staff.”

In recent years, Macfab Engineering has implemented measures to improve its production time and quality standards. These measures have included investments in several highly efficient machines, such as a Peddinghaus Ocean Avenger drill line, a Peddinghaus plasma plate

cutter and a Daito multi-head drill, cut, etch and coping machine.

However, it is not just investments in high-tech machinery that are the secret to Macfab Engineering’s success—it is also their willingness to work together with their customers to find affordable, effective solutions.

“The owners of Macfab Engineering have always had a ‘can do’ attitude that seems to radiate throughout the company. When customers come to us with their engineering problems or their short lead times, we genuinely work hard to alleviate these issues by coming up with solutions. This seems to be appreciated by our customers, with us being given a lot of repeat business over the years, and our reputation spreading by word-of-mouth,” explained Bourke.

Macfab Engineering Certified to AS/NZS ISO 3834

Macfab Engineering manufactured, galvanised and installed structural steel at Bentleigh Train Station.

“The other motto that we work by is that ‘in manufacturing if you are not running, you are falling behind your opposition’. This has been the catalyst to Macfab Engineering expanding and improving our manufacturing facilities, commissioning our Peddinghaus and Daito structural steel equipment, improving our quality systems and employing welding supervisors and inspectors. Similarly, continuing our Transport for New South Wales prequalification and gaining AS/NZS ISO 3834 certification are other ways through which we have improved our business.”

An Impressive Project Portfolio Given Macfab Engineering’s dedication to customer service and quality workmanship, it is little wonder that they have worked with some of Australia’s largest construction companies, and on some of the country’s largest transport projects.

Macfab Engineering was responsible for the fabrication and installation of the safety screens, barrier rails and stainless-steel drainage items for many of the bridges along the Hume Highway, including those at Tarcuttta, Holbrook, and Woomargama.

The company fabricated and installed the safety screens and barrier rails for the Ballina Bypass, the Frederickton to Eungai upgrade, and the Nambucca to Urunga upgrade. They also manufactured

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Macfab Engineering fabricated and installed the safety screens and barrier rails for the Ballina Bypass.

the noise walls for the Regional Rail Link in Victoria, and the M5 Motorway in Sydney, as well as sign structures for the M2 Motorway.

Macfab Engineering has also worked on several railway stations, including the Bentleigh, Mitcham, North Melbourne, Balaclava, Bayswater, Ballan and Thomastown railway stations in Melbourne, and the Dudley Street Rail Bridge Project.

“Recent months have been challenging for Australian manufacturing, while we have been dealing with the COVID-19 crisis. We are proud that we have been able to support all our employees during this challenging period. We have a number of large projects scheduled for production, but we are also actively looking for more work,” said Bourke.

Just some of the projects that Macfab Engineering has on the books at the moment include the Batemans Bay bypass, Albion Park Rail bypass, McKanes Bridge upgrade, Bulga Bridge upgrade, and overhead structures for the Melbourne rail upgrade.

ISO 3834 Certification According to Bourke, Macfab Engineering decided to undertake certification in order to improve their internal processes.

“We saw the achievement of AS/NZS ISO 3834 certification as a way of improving our manufacturing

and quality processes. We certainly hoped that improving the quality of our welded products would give us access to a wider range of clients, increase the technical knowledge of our welders and hopefully also improve our profitability.”

“The certification process is certainly systematic and comprehensive, so it did take time to ensure we had all the required issues covered. We were fortunate that we had several managers who put in a lot of effort to ensure that we gained certification.”

“As a number of people were engaged in the certification process, it led to several spirited discussions and the enhancement of our welding knowledge.”

“Macfab Engineering was appreciative of the support of Weld Australia who provided us with a good framework to systematically work through, and they never tired of our questions.”

For other companies considering embarking on the certification process, Bourke has some sage advice. “We decided very early that we wanted to view gaining ISO 3834 certification as being a beneficial experience, rather than as a ‘tax’. By this, I mean we wanted to improve our business, profitability, welding and quality by gaining ISO 3834 certification. It was not just something we were doing because we had to. This mindset made the journey a positive one,” said Bourke.

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Australian Welding: June 2020

NEPEAN: Global Strength, Local Service Opening its doors in 1974, one of Weld Australia’s newest members, NEPEAN Engineering & Innovation is now one of Australia’s largest privately owned engineering service providers. With an elite design and project management team that understands the diverse nature of engineering, NEPEAN produces goods locally from their state-of-the-art facilities in south-west Sydney and delivers to customers all over Australia and globally.

For over 45 years, NEPEAN Engineering & Innovation has maintained a culture that recognises and respects the importance of all participants in the business, focused on building lasting relationships with employees, sub-contractors and customers.

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

With humble beginnings, it grew from a small engineering company into a highly successful and respected integrated engineering business.

Today, NEPEAN employs over 1,500 people across eight countries worldwide, and is led by CEO Miles Fuller, son of David. NEPEAN Engineering & Innovation employs over 150 employees at our site in Narellan.”

“

We’ve always worked with the best customers, providing the highest quality products for some of the most complex projects.

We regularly work with industry experts like Lendlease and Hutchinson Builders on projects requiring upwards of 2,000 tonnes of steel.”

NEPEAN Engineering & Innovation has the depth, diversity, capability and experience to successfully deliver on the largest and most complex engineering projects. Their engineering services are supported by extensive facilities, including over 50,000m2 of workshop space, inhouse design, a fully equipped stateof-the-art CNC and machine shop, steel fabrication workshop, laser cutting, sheet metal, shot blasting, painting and powder coat finishing.

“With large CNC machines, precision manufacturing and structural steel capabilities, through to laser cutting, our own blasting and painting facilities and installation capabilities, we are truly an integrated engineering business—we really do have everything under the one roof,” said Buckley.

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

NEPEAN Engineering & Innovation recently completed work on the 60 Martin Place building in Sydney for Lendlease. NEPEAN manufactured, erected and assembled many components, including three 43 tonne steel transfer trusses, measuring 4.5m high and 21m long, that were installed in the building’s plantroom. NEPEAN also fabricated and installed a challenging five-level steel frame clad staircase in the building’s foyer.

NEPEAN Engineering & Innovation: Global Strength, Local Service

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As part of the NorthConnex project—designed to link the M1 Pacific Motorway at Wahroonga to the Hills M2 Motorway at West Pennant Hills—integration work was essential along the Hills M2 Motorway. NEPEAN Engineering & Innovation was awarded the subcontract for structural steel works through the head contractor, the Lendlease Bouygues Joint Venture. With the project requiring approximately 300 tonnes of steel, NEPEAN met all project logistics and design development requirements, as well as tight scheduling, to deliver a highly successful project.

Another of NEPEAN’s most recognisable projects is 8 Chifley Square in Sydney. The highly distinctive appearance of the highrise is largely due to the massive, colourful steel elements supplied by NEPEAN – the braces on the façade and the struts that help create a fivestorey public space at ground level.

Through their Mastermesh® Brand, NEPEAN also supplied over 3,000m2 of perforated metal panels to clad two external stairs on both façades.

The two largest mega struts supplied

by NEPEAN on 8 Chifley Square weighed a massive 37 tonnes and 30 tonnes, with each strut measuring 18.5m in length. The installation window for the 37 tonne mega strut was just three to four hours, and only one hour for the 30 tonne strut, including all reinforced steel cage connections.

A Competitive Advantage According to Buckley, “Our success is aligned with our customers’ success. To ensure we can deliver successful outcomes to all our clients, we employ and train the best. To continually develop our organisation and deliver quality project outcomes, it is vital to invest in our people. We have had five apprentices commence in 2020, along with two graduate engineers and additional engineering and professional staff.”

“Team members resourced to each job are hand-picked according to specific project requirements in

terms of experience, specialist skills and problem-solving capabilities. We are proud of the deep relationships with our employees, with many engineers, project managers and tradespeople employed with our company for over 25 years,” said Buckley.

Buckley believes that NEPEAN’s new Weld Australia membership will help them deliver quality outcomes and upskill their workforce further.

“NEPEAN only aligns itself with the best, so it was a natural fit to align ourselves with Weld Australia. Weld Australia has a great reputation and great resources for our workforce.

We will benefit from being aligned with the industry leading association, and our employees will be able to learn from Weld Australia’s resources and deliver better outcomes for our clients,” said Buckley.

An Optimistic Outlook Buckley believes that the future of Australian manufacturing is strong, and expects the industry to rebound from the COVID-19 impact, with NEPEAN well-placed to support existing and new customers. “I am really optimistic about the

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

Above (Below): A welder working at NEPEAN Engineering & Innovation’s facilities in south-west Sydney.

Left: 8 Chifley Square in Sydney. The distinctive appearance of the highrise is due to the massive, colourful steel elements supplied by NEPEAN.

manufacturing sector as a whole as a result of the COVID-19 pandemic.

Over the last few months, we’ve really seen companies going back to Australian manufacturing as a core principle, instead of relying on cheaper imports from overseas.

Clients are, once again, starting to recognise the value of a guaranteed local supplier, and seem to be willing to pay that little bit more for Australian quality and service.”

“In fact, one of the biggest challenges for us at the moment is expanding to meet our customers’ needs. Just within the last few weeks, we have put on two shifts.

Our facilities are now operating around the clock to ensure we can keep up supply for customers demand,” said Buckley.

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Australian Welding: June 2020

Set for Success: PMG Expands Defence Industry Footprint Weld Australia member, Precision Metal Group (PMG) has become the first Australian company to achieve certification to the German military welding standard DIN 2303 Welding and allied processes Quality requirements to be met by production and maintenance companies for military products. As a result, PMG is growing rapidly as it expands its footprint in the Australian defence industry supply chain.

Headquartered in Wetherill Park, New South Wales, PMG recently signed a Memorandum of Understanding with German seating systems group, Probatec AG, for the manufacture and export of highquality seating for military vehicles.

The partnership will see PMG commence specialised product exports into Germany in 2020. It will also underpin an agreement between the two companies to work together—through technology transfer to Australia—to deliver seating for the fleet of BOXER 8x8 Combat Reconnaissance Vehicles (CRV) that Rheinmetall Defence Australia is delivering to the Federal Government under the Land 400 Phase 2 program.

Military-grade seating is critical for the protection of soldiers positioned in the back of armoured combat vehicles. This seating, known as blast attenuation seating, prevents spinal compression injuries, and protects troops and the vehicle crew.

PMG Chief Executive Officer, Jason Elias, said the partnership with Probatec AG will expand the company’s footprint in the defence industry globally, and create jobs in Western Sydney.

“Our agreement with Probatec AG establishes a local manufacturing capability that can deliver world class seat parts and products that will protect soldiers in Australia and overseas,” said Elias. “We have started testing and training our team to develop the products Probatec AG requires and have already commenced exporting parts to Germany.”

Probatec AG is based at Amburg in Germany and has been a long-term supplier of military seating systems to Rheinmetall. Elias said gaining certification to DIN 2303 enabled PMG to enter the international defence supply chain and establish contact with Probatec AG, with a view to working together.

A Two Year Certification Journey “It has been a rigorous two-year journey to achieve the necessary accreditation to apply for this project,” said Elias. “However, the hard work has paid off, and now PMG is the only company in the country, and most probably in the southern hemisphere, to hold both international certification for AS/NZS ISO 3834-2 and the German military certification of DIN 2303 Q2 BK1.”

Together, these two certifications place PMG at the forefront of welding in Australia; PMG can now support Rheinmetall with its Australian supply chain.

“Gaining the certification was difficult, and without the whole team – and other key players – working together on the common goal it could not have been achieved,” said Elias. “The key challenge was to ensure our team was educated and upskilled. That’s why we travelled to Europe and brought that knowledge

Set for Success: PMG Expands Defence Industry Footprint

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back with us to Australia. We were then in a position to complete the DIN 2303 certification process, and start tendering and working with the primes.”

Elias said the defence project heralds a new era for PMG. “The work has introduced many new roles within the business. Working in the defence sector is different and challenging. Our goal now is to go bigger, get better and manufacture more complex fabrications.”

“It will also prove that Australia can manufacture to a high quality and even become a manufacturing hub, recognised in the international arena.

If PMG—a small SME company— can achieve this, then the sky’s the limit. Miracles can happen, but sometimes they take a little longer.”

As well as gaining the necessary certifications, Elias said developing plans and strategies to leverage their existing, and a new, workforce was the hardest challenge to overcome.

“Our vision is to undertake long-term projects and, through these projects, increase our facilities and workforce.

The number of engineering cadets will increase; we’ll double apprenticeships and cadets and employ more women in nontraditional roles. We still have many steps to work to with Rheinmetall and the journey has just begun.”

A European Delegation According to Elias, a PMG delegation travelled to Europe and met with several companies currently delivering to defence forces internationally. The purpose of the trip was to gain an understanding of the growth and changes required to support the defence spend in Australia. It also helped PMG gain an improved understanding of customer expectations around quality. First stop on the trip was Hamburg, Germany, where PMG visited Amco Metal Services, collaborating on specialist materials for the Australian Defence Force.

London was the next leg of the trip, where PMG met with members of

Above: (L to R) Jason Elias (CEO, PMG), Minister for Defence Industry the Hon Melissa Price MP, and Gary Stewart (Managing Director, Rheinmetall Defence Australia).

PMG partnered with Rheinmetall Defence Australia (RDA) to supply prototype brackets and machined parts for the first BOXER CRV, which was delivered to the Federal Government in September 2019. PMG manufactured, assembled and delivered a total of 72 different parts, with multiple quantities per part. PMG’s scope of works included precision laser cutting, specialised welding, precision machining of parts, powder coating, assembly, inspection and quality control.

the defence force at Australia House, and gained valuable information at the Defence and Security Equipment International conference. Then it was back to Germany, where the group was able to collaborate and build knowledge on shipbuilding for the Australian market.

“A visit to the EMO trade fair also proved productive, with PMG ordering new machines, shifting the company into industry 4.0 technology, from the Australian machinery supplier Hare and Forbes,” Elias said.

“The trip has allowed us to partner with many leading companies and increase Australian content to current contracts within the defence force field. These insights will support the work we already have underway at PMG to ensure we deliver the best possible products for our Defence customers in Australia.”

Far Left: PMG team members with a prototype of the seating for the BOXER 8×8 CRV. Left: PMG team members working on the seating for the BOXER 8×8 CRV. Above: The PMG facility in Wetherill Park, Sydney.

Elias has three key pieces of advice for manufacturers looking to move into defence: “Understand the certification and accreditation required for your specific processes and your products. Introduce international Standards into the dayto-day operations of your business.

Focus on upskilling and knowledge transfer from abroad.”

“To get involved in Australian defence industry contracts, small and medium sized enterprises (SMEs) need to learn about, and understand, the nature of the defence sector and adapt to the specific requirements in Australia.

In this way, SMEs will be successful moving forward,” said Elias.

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Australian Welding: June 2020

Incat High-Speed Ferries Stay the Course Firmly cemented as experts in cutting edge environmentally friendly vessels, Weld Australia member, Incat Tasmania, provides lightweight ship solutions for ferry operators, special service providers and militaries.

From fast, flexible and efficient vehicle-passenger ferries to high-speed support vessels, crew ships and dynamic platforms, Incat sets the global benchmark in aluminium ship technology.

Incat evolved from other boat building companies, including the Sullivans Cove Ferry Company (SCFC) formed by Robert Clifford in 1972. SCFC built conventional steel mono-hull vessels, and operated small ferries across Hobart’s Derwent River. SCFC gained prominence transporting more than nine million passengers in the two years following the 1975 Tasman Bridge collapse, the sole bridge link between the eastern and western shores of Hobart.

According to Incat’s CEO, Tim Burnell, “When the Tasman Bridge collapsed in 1975, Robert Clifford— who is still our Chairman today—was a ferry operator.

He provided the only means for people in Hobart to cross the river. Robert quickly realised that he needed platforms to transport more people, more quickly. So, he started playing with catamaran designs in steel, but determined that he needed more efficiency.”

After extensive research, Incat specialised in aluminium construction. “From designing and building his own ferries, Robert soon started building ferries for other companies. The company evolved from there, tackling larger and larger vessels, from passenger-only ferries, to ferries that could accommodate cars, then trucks and cars, right through to military vehicles,” said Burnell.

In 1983, the design for Incat’s wave piercing vessel was conceived, with the 8.7m prototype craft Little Devil undergoing trials in 1984. The results encouraged Incat to proceed with the 28m wave piercing catamaran, Spirit of Victoria, which entered commercial operation in mid-1985. Incat’s current range of wave piercing catamarans still reflect the characteristics of these early craft. Incat remains a proudly family-owned company,

Right: Incat’s wave piercing catamarans are created through a production line system at their dedicated 70,000m2 undercover facility. Multiple vessels can be handled simultaneously in two dry-docks, which include the ability to house construction of larger vessels over 150m in length.

with three generations of the Clifford family involved in the company’s operations. “Incat is a pioneer in the large, high-speed ferry industry. We are known and respected for our workmanship and our quality. Today, we have close to 600 people in our workforce, plus subcontractors. So there’s around 450 people on-site for day shift, with less on afternoon shift. Although our shipyard is in Tasmania, our clients are spread out all over the world, from the Caribbean and Europe, through to Asia.

We are definitely a worldwide entity,” said Burnell.

High Quality, Intricate Aluminium Welding With Incat specialising in the manufacture of aluminium vessels, their team is expert in welding this lightweight, yet incredibly strong and durable, material. This is no mean feat—learning how to weld aluminium is more challenging than steel, as aluminium requires pre-preparation, attention to detail, and specialised equipment.

Incat High-Speed Ferries Stay the Course

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Aluminum and its alloys rapidly develop an oxide film on the surface upon exposure to air. This oxide is what gives aluminium its corrosive resistance. However, the oxide has a melting temperature of around 2,000°C, while aluminium has a low melting point around 660°C. This means that it is essential to remove the oxide before welding, so that good weld penetration is achieved.

The thermal expansion and contraction of aluminium during welding is another factor that requires careful pre and post-weld planning to manage distortion. Incat’s specialist welders use this expansion and contraction to their advantage when welding in areas that have fine tolerances.

“Incat’s welding processes are not hugely automated.

We have some machines that perform double-sided automated welding, which we actually developed inhouse about 20 years ago. Our welding and fabrication processes are very labour intensive and this is unlikely to change—the quality and the intricacy of our welding necessitates a very hands-on process,” said Burnell.

“Aluminium welding requires a different skill set as compared to carbon steel welding. It’s not a skill set that people can pick up quickly, or straight away.”

Like any thriving business, a core of dedicated and loyal staff can be found at the centre of Incat’s success. With high levels of job satisfaction, Incat ensures a low staff turnover rate and a skilled workflow, where many team members’ experience stretches back over two decades across a range of trades.

“We still have people working with us who were apprentices here 25 years ago—they have honed their welding skills over time and, today, deliver superior quality workmanship on each and every Incat vessel.”

“The expert skills of our team members enable us to deliver a quality product that customers appreciate—it is the reason why so much of our work is repeat business.

Above (Top): Incat’s shipyard on Prince of Wales Bay at Derwent Park near Hobart, Tasmania.

Above (Below): A welder works on one of Incat’s aluminium vessels.

One of our customers has been with us for over 25 years, and has ordered nine vessels,” said Burnell.

Project Success Incat currently has four contracts in either the design or build phase, ranging from a 76m vessel to a 130m vessel.

One of these contracts entails the construction of a 100m vessel for the Government of Trinidad and Tobago, which is due for delivery later this year. The passenger and cargo ferry will have capacity for 1,000 people, including 224 VIP seats, and 239 cars.

With the contract signed in March 2020, Incat is also designing a new generation fast ferry for the Southern Korean state-sponsored coastal passenger transport company, Seaworld Express Ferry. The 76m bespoke high-speed wave piercing catamaran ferry will accommodate up to 700 passengers and 79 cars when it enters service on the new route between Jindo and Jeju in early 2022.

Australian Welding: June 2020

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“

Saint John Paul II is a magnificent ship. She has surpassed our expectations and, after 30 years of operating fast ferries on international routes, our expectations are extremely high.”

Benefitting from Incat’s recent redesign of its tried and proven hull-forms, incorporating a completely new bow arrangement, the ferry will lead the market in terms of seakeeping for vessels of its size.

all the sections for each vessel. The components then move into our pre-fabrication facility, where we commence the assembly of two-dimensional building frames, before moving into three-dimensional modules.”

“With a significant improvement to both the waterline length and vessel trim compared with those earlier craft, the 76m ferry will also benefit from vastly improved speed and fuel consumption. The new design very much reflects thirty years of experience building market leading high speed vehicle-passenger ferries,” said Burnell.

The benefits of pre-fabrication are immense. Components can be rotated and, by selecting orientation, the number of down-hand welds can be increased to shorten welding time and improve welder comfort. Bulk plating, where the longitudinal structure extrusions are welded to the shell plate, means that welding is only required at transverse frames once the components are lifted into position.

“Our contract with Seaworld Express Ferry was signed during the COVID-19 pandemic, which is a huge endorsement of not only our product and services, but the future of the market. To have the contract signed in the current market was very pleasing,” said Burnell.

A Perfected Production Line Incat’s world beating wave piercing catamarans are manufactured via a production line system in their shipyard on Prince of Wales Bay at Derwent Park near Hobart, Tasmania. The facility incorporates more than 70,000m2 of undercover production halls, with two drydock areas capable of accommodating up to six vessels under construction.

“Our facility operates a production line system that was modelled on the method Boeing uses to build and assemble their planes,” said Burnell.

A team of naval architects, engineers and designers develop and refine each vessel design. The team works together, from concept stage through research and development, structural design and analysis, drive line technical specification and layout, naval architecture services and complete drafting.

High-strength marine grade aluminium is sourced in extruded profile sections and plate from specialist suppliers around the globe. Plate arrives at Incat’s dedicated facility where nesting plans are generated and plate is cut to begin vessel construction.

“We have two automated routers; machines that cut

“Once the pre-fabricated modules reach a specific size—the majority are about 12m long—they are transferred to the other side of the shipyard, into the undercover production halls, marking the beginning of the lineal assembly process,” said Burnell.

Construction begins in the centre of the vessel, allowing rapid growth in a controlled manner. As the fabrication and welding teams progress throughout a vessel, Incat’s quality assurance and control team check and approve the completed sections of the structure.

Next, Incat’s fit-out teams move in. Fitters, plumbers, electricians, painters, structural fire protection personnel and electronics, hydraulics and pneumatics engineers all set about completing the various components and systems on board.

The forward end of the vessel is completed and the unique Incat catamaran shape starts to become recognisable. At this stage, main machinery, such as engines, water-jets, generators and T-foils are installed.

Once the equipment is carefully positioned and secured, the vessel’s structure is closed off for the final time, ready for painting.

With machinery installation and outfitting complete, the vessel is ready for launch. Once the vessel is launched and secured dockside, radars and aerials are fitted and final commissioning of systems takes place. Builder’s trials and sea trials for the customer are completed, and the vessel is ready for handover and delivery.

Incat High-Speed Ferries Stay the Course

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Incat Wins Ship of the Year 2020 Built by Incat, Virtu Ferries’ 110m high-speed ferry, Saint John Paul II, has won the coveted High Speed Ferry award in Cruise and Ferry Review’s first ever Ship of the Year awards.

Cruise and Ferry is a trusted and reliable source for news on the passenger shipping industry. The Ship of the Year award was created to recognise passenger ships that showcase innovative new green technologies, impressive interior and exterior designs and unique onboard amenities and guest experiences.

Photo courtesy of Brand Tasmania.

Saint John Paul II is the largest vessel of its kind operating in the Mediterranean, and the second largest in the world. Onboard facilities include five lounges, gift shops, gaming lounge bars and shops. She offers a total of 1,134 VIP, business and economy seats on two decks, including 996 seats inside and 138 seats outside, as well as a designated truckers’ lounge with additional facilities. The vehicle deck is designed to carry 23 heavy commercial trucks or 167 cars.

Incat’s CEO, Tim Burnell, said, “It is a huge honour for Incat to be associated with this award and a fantastic endorsement of our dedicated workforce at Incat. We warmly congratulate Virtu Ferries, they were a committed partner in this project and without their commitment to detail and perfection Saint John Paul II would not be the ship she is. We wish her every success in the future.”

Photo courtesy of Adam Gibson, Department of State Growth, Tasmania.

Virtu Ferries’ Managing Director, Francis Portelli, thanked those who voted Saint John Paul II Ship of the Year 2020 in the High Speed Ferry category. “Saint John Paul II is a magnificent ship. She has surpassed our expectations and, after 30 years of operating fast ferries on international routes, our expectations are extremely high,” he said.

Photo courtesy of Adam Gibson, Department of State Growth, Tasmania.

Saint John Paul II is a 110m wave piercing catamaran built for Virtu Ferries, which operates between Malta and Sicily. Saint John Paul II is the largest RoPax catamaran on the Mediterranean, the full span of the garage deck is designed to carry 23 heavy commercial trailers, equivalent to 490 truck lane metres or 167 cars.

The ship has a service speed of 38 knots. The 900 passengers in Business or Economy Class enjoy the 90 minute journey between Malta and Sicily, the ship offering five luxury lounges plus outdoor seating.

Photo courtesy of Brand Tasmania.

38

Australian Welding: June 2020

Welding 4.0: Improved Productivity & Lower Costs Intelligent and productivity-boosting networking of man and machine for an automatic flow of data within the production chain: Industry 4.0 is now becoming established in welding and fabrication production thanks to the new and innovative ewm Xnet Welding 4.0 welding management system.

In this way, concepts such as the smart factory and digital transformation can become a reality, and welders and fabricators can improve their efficiency, productivity and quality.

Industry 4.0 encompasses the rapid technological change that is disrupting businesses across all industries, including welding and fabrication. Advances in communication technologies, devices connected to the internet and data analytics are occurring at a much faster pace than at any other time in history.

As a result, many people believe that we are now living through a fourth industrial revolution, or Industry 4.0. With the proliferation of smart sensors and the resultant data, businesses are now able to access

insights that have helped to optimise operations and improve efficiencies.

Industry 4.0 presents opportunities for welders and fabricators.

Technological innovations allow businesses to make better use of human skill and innovation, with machines taking over mundane tasks so that employees can focus on critical thinking, quality and creativity.

This opens up new opportunities for businesses to improve and optimise their operations.

According to Weld Australia’s Deputy President, Richard Fowles (Senior Product Manager, BOC),

“Industry 4.0 has the potential to enhance Australia’s economic competitiveness in the welding fabrication sector by improving the efficiency of the welding process—a critical enabler for anyone in the fabrication business.”

“By adopting industry 4.0 methods in welding, it is possible to offset labour, inspection and rework costs typically associated with the fabrication process. This will place fabricators in a better position to bid, and deliver on, projects; fabricators will have better access to accurate costing information and more confidence to comply with tough quality management demands.”

“Early adoption of Industry 4.0 philosophy will create an environment that will allow a business to grow, and be conducive to adapting rapidly emerging and evolving technologies to their advantage,” said Fowles.

The ewm Xnet Welding 4.0 Welding Management System The ewm Xnet Welding 4.0 welding management system is a modular system that effectively supports welders working on a workpiece and all their colleagues involved in the entire production process (planning, work preparation, purchasing, logistics, quality assurance and service).

The ewm Xnet provides real-time documentation of all weld seams from any number of networked machines. It also provides numerous evaluation options and electronically

Welding 4.0: Improved Productivity & Lower Costs

generated and transferred welding procedure specifications.

improve economy, quality and documentation.

The system can also undertake component management, including WPS and welding sequence plans.

“Xnet enables Welding 4.0, which basically networks the welding machine operator and their welding machine to allow the automatic flow and storage of digital data, unique to the process of welding,” said Fowles.

“By using the Xnet maintenance module, it is possible to predictively intervene for set maintenance tasks to ensure your welding assets are always available and therefore prevented from introducing otherwise avoidable weld defects,” said Fowles.

“Xnet software provides a platform for a business owner, operations manager, or Responsible Welding Coordinator to interpret the welding data in an easy visual way to stay on top of their critical enabling processes regarding quality and cost in real time. Xnet is a combination of hardware and software, coupled with a welding machine, that feeds digital data to a platform that enables the data to be easily interpreted.” ewm Xnet produces measurable benefits throughout the entire value chain of a welding company.

The system organises production, planning, quality management, welding coordination personnel and management. In this way, it considerably helps to

Above: The ewm Xnet Welding 4.0 management system can be used on any wireless network capable device.

Right: The XButton—a Robust hardware key for access authorisation.

Left: A LAN gateway on the side of an ewm Titan machine—a necessary hardware component to deliver digital information to the Xnet software.

“An example is an arc on time based intervention for cleaning torch liners that will ensure consistent welding wire feeding. By having an online real time maintenance management system for your welding assets, it reduces the cost of rework required to correct welding defects. It also saves having to pay for costly machine repairs and downtime, by regularly maintaining the welding equipment.”

“Xnet was originally designed to be used with ewm machines, but, by using the ewm Universal Logger, any other brand of welding machine can now be connected to Xnet and therefore gain entry to the world of Industry 4.0,” said Fowles.

For further information, visit: https://www.ewm-group.com

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The ewm Xnet Modules Customisable for the requirements of specialist production, ewm’s Welding 4.0 welding management system features three interrelated modules that can be adjusted to individual requirements, depending on the type and size of the company. The system is also flexible, with additional modules easily retrofitted at any time.

Module One: Record and manage welding data and determine consumption values in real time, with welding and efficiency data display.

Consumption values for power, gas and welding consumables are recorded to recognise potential savings. Plus, early warnings via the maintenance module enable prompt repair work and minimised consumption of parts.

Module Two: Create and manage welding procedure specifications, assign welding procedure specifications to welders, and undertake welder qualification management.

Documentation of welding parameters and welders on every run ensures long-term records of weld quality, while preset welding parameters reduce the number of error corrections.

Module Three: Manage components through barcode scanning to control what material is welding with which procedure, and create welding sequence plans. Mandatory specifications from component management and the WPS manager ensure that the correct parameters are always set.

Module Four (or XButton): Robust hardware key for access authorisation to control welder access rights to a machine in line with welder qualifications.

40

Australian Welding: June 2020

Frontline Manufacturing Poised for Expansion Established in 1996 as a metal press shop, Frontline Manufacturing has developed into a full-service manufacturing company, with capabilities including CNC machining, laser and plasma cutting, fabrication and assembly. With a focus on innovation, cost effectiveness and quality assurance, the company provides a broad range of speciality high quality metal components and assemblies, specialising in high tolerance products and repeatability. With their recent certification to AS/NZS ISO 3834.3, Frontline Manufacturing has already gained traction in the defence industry and has set their sights on further expansion.

According to Matthew Ellis (Special Projects Manager to Defence, Frontline Manufacturing), “Frontline was established in 1996 as a tool making business. We have evolved over the last 20 years from a small component producer to a sub-assembly one-stop-shop, delivering a very diverse array of manufacturing projects, employing around 30 people.”

two state-of-the-art Panasonic robotic welding cells for repetitive component welding. With two Amada laser cutters, Frontline can cut sheets up to 3,000mm. In addition, having recently invested in a Ficep Gemini plasma cutter, complete with full milling and drilling capability, Frontline can cut plates up to 12,000mm, at thicknesses exceeding 70mm.

“Frontline Manufacturing offers a broad range of capabilities—welding is just one of the services we deliver.

We have a number of fully qualified engineers, and a fully functional machine shop, fitted out with nine CNC machines. We can just about do everything in-house, from laser and plasma cutting, through to folding and welding and final machining,” said Ellis.

Using Mazak technology, Frontline facilitates low, medium and high volume 2D and full 3D machining with pin-point accuracy. Tooling lists and manufacturing programs and procedures are tracked and stored on their database and, for ongoing jobs, they create detailed product drawings to ensure parts are made correctly every time. In most materials, Frontline is able to work to tolerances of 0.025mm.

With a diverse range of nine CNC lathes and mills, they can offer both

In addition to 14 manual MIG and TIG welding bays, Frontline operates

“

Combined with our certification to AS/NZS ISO 3834, our new state-of-the-art equipment will enable us to move into the heavy plate and heavy component sector.”

vertical and horizontal machining, as well as combined milling and turning capabilities.

Success in Defence Frontline was one of the first defence-based companies in Queensland to achieve certification to AS/NZS ISO 3834.3 Quality requirements for fusion welding of metallic materials. The certification was just one aspect of a rapid transformation undertaken by the company in the last 12 months, since it moved into its new facility in Meadowbrook, Brisbane. Frontline has upgraded all of its welding machines to pulse technology and expanded its robotics capabilities to improve repeatability and be globally competitive. The company has also upskilled several staff to welding supervisor and International Welding Engineer (IWE) level, and appointed a Responsible Welding Coordinator.

Frontline Manufacturing Poised for Expansion

41

Right (Top): Frontline Manufacturing’s facilities in Meadowbrook, Queensland.

Right (Bottom): A member of Frontline’s 30-person strong workforce.

Left: Frontline Manufacturing operates 14 manual MIG and TIG welding bays.

With Frontline keen to move even more into defence industry work, certification was a necessity, explained Ellis. “AS/NZS ISO 3834.3 certification was a requirement set down by Rheinmetall. So, if we wanted to pursue work in that area of the defence industry, and supply products into the LAND 400 Phase 2 program, we had to undertake certification,” said Ellis.

“Apart from the requirement from Rheinmetall, it made good sense to further enhance our quest for excellence within our continuously growing welding department.”

“The certification process itself was complex but rewarding. The support we received from Weld Australia was great, particularly the help from Paolo Corronca (National Manager, Engineering, Weld Australia).”

With certification to AS/NZS ISO 3834.3 under their belt, Frontline Manufacturing has been successful in moving into the defence industry.

“These days, defence industry work makes up about 70% of our revenue,” said Ellis. “But, breaking into the market was very slow. It took a number of years of knocking on doors, asking for opportunities and visitations. It’s a very competitive industry; you have to be able to differentiate yourself from all the other suppliers out there. That is not always easy. We have worked on some very interesting projects, but we have a lot more to offer the industry and will continue to present Frontline Manufacturing as a turn key supplier to primes, both domestically and, eventually, globally.”

Frontline has supplied prototype bracketry for the $5.2 billion LAND 400 Phase 2 program, under which Rheinmetall will deliver 211 8x8 Boxer Combat Reconnaissance Vehicles (CRV) to the Australian Army.

In addition, Minister for Defence Industry Melissa Price recently announced that Frontline was one of 11 Australian businesses to receive funding under the Sovereign Industrial Capability Priority Grants program. The program supports eligible Australian small-to-medium sized companies who can provide significant contributions to defence industry needs.

Frontline Manufacturing received $710,000 for a specialised brake press intended to offer folded armour plate used on armoured fighting vehicles and ships.

Frontline is now looking to expand into other markets. “Our most recent acquisition is a high-definition plasma cutter with milling capabilities.

Combined with our certification to AS/NZS ISO 3834, our new stateof-the-art equipment will enable us to move into the heavy plate and heavy component sector. We’ll be in a position to provide a strong medium to heavy capability—not just welding services, but components that are welded, cut and folded, all to exceptionally high tolerances, from medium sized parts to very large subassemblies” said Ellis.

Approaching Certification For other companies considering AS/NZS ISO 3834 certification, Ellis

has some sage advice. “Certification is really only one stepping stone.

There are a lot of other decisions and considerations that you need to make behind the scenes,” said Ellis.

“For instance, the personnel that sit behind your certification could be the most challenging component of the whole process. We had to train and upskill our staff to ensure we met the requirements around a Responsible Welding Coordinator.

The compliance becomes a lot more specific and of course the auditing can be quite intensive.”

“Recruiting people who are qualified as Responsible Welding Coordinators or International Welding Engineers is difficult. So, when considering certification to AS/NZS ISO 3834, make sure you have the right staff available first— either within your organisation or externally. Understand the people you need to make certification possible.”

“As the manufacturing industry evolves, hopefully the realisation is that we need to invest more in our people, as they also need to do themselves, continuously developing their skills, so we are all ready to contribute to our very important sovereign manufacturing capability,” said Ellis.

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Australian Welding: June 2020

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 on practical next steps. 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 recently received a query from a member regarding the correct methodology to assign steel type number as per Table 4.6.1(B) in AS/NZS 1554.1 Structural steel welding—Part 1: Welding of steel structures. The Weld Australia member was looking for a means by which, when using a non-prequalified material (like the common AISI grades such as 1020, 1030, 1040 bars, or ASTM A106B pipe), to allocate a steel type number.

The enquirer also asked how the steel type tables within AS/NZS 1554.1 were compiled. The following is the response provided to the member.

Steel types in Table 4.6.1(B) of AS/NZS 1554.1 are based on a combination of nominal yield strength and impact properties specifications.

This table then links into Table 4.6.1(A) for electrode selection.

Depending on the end use specification requirements and design service temperature, you may need to take particular care when selecting a welding consumable that ensures the appropriate impact requirements can be met at this low

temperature, or alternatively, conduct appropriate qualification tests including weld metal impacts at the required design service temperature.

In many cases, the non-prequalified materials listed (such as AISI 1020, 1030, 1040 bars, or ASTM A106B pipe) are chemistry only grades, not structural grades. As such, they do not fit into any structural strength or impact grading type associated with Tables 4.6.1(A) and (B) because strength and impact requirements are not defined in their standards.

They cannot be listed as ‘prequalified’ in the AS/NZS 1554 series, however, this does not preclude their use in the Standard.

These materials are just not prequalified for structural applications.

This restriction also links into the requirements of AS 4100 Steel structures.

The chemistry-only grades do have weldability groups and these can be found in Weld Australia’s Technical Note 1. These same weldability groupings carry across into Table 5.3.4(A) in AS/NZS 1554.1 for

pre-heat determination. Alternatively, Weld Australia’s Technical Note 1 can be used to calculate pre-heat.

As for the steel type tables and how they have been formulated, there is logic to Table 4.6.1(A) and (B). This same logic also follows into similar tables in other parts of the AS/NZS 1554 series. For Part 1, it is as follows: • Steels 1-3 are those with a specified yield of up to 300MPa. • Steels 4-6 are those with a specified yield of 350 to 400MPa. • Steel type 7 are those with a specified yield of 450MPa. • Steel type 8 are those with a specified yield of 500MPa. The variations then are impact gradings as follows: • Steels 1, 4, 7A are nominally impacts required at +20°C or not required.

• Steels 2, 5, 7B are nominally impacts required at 0°C (L0 steels).

• Steels 3, 6, 8C are nominally impacts required at -15°C (L15 steels) or colder.

Supervision, Inspection and Qualification Services

Now Available Remotely In the wake of COVID-19 restrictions, Weld Australia has developed a new procedure to carry out welding inspection and supervision services, as well as qualification of welding procedures and personnel—remotely.

The procedure has been developed in accordance with IAF (International Accreditation Forum) guidelines. All services are carried out with the cooperation of a competent person on-site, utilising videoconferencing and video recording for record keeping purposes.

If you need help with remote welding inspection, supervision or qualification services—we’re here to help. All you need do is call Paolo Corronca (National Manager Engineering) on 0438 012 099. www.weldaustralia.com.au

|

engineering@weldaustralia.com.au

44

Australian Welding: June 2020

An Update from Weld Australia’s Industry Groups Weld Australia’s Industry Groups provide a forum for technology transfer and research and development, linking members with industry and research organisations. Weld Australia works with Industry Group members to ensure they remain diverse and resilient in the ever-changing and increasingly challenging global markets.

Power Generation Industry Group The Power Generation Industry Group’s Asset Integrity Board met in early April via videoconferencing. The meeting was attended by representatives from AGL Energy, Alinta, Delta Electricity, Energy Australia and Weld Australia.

• • •

To begin, attendees discussed the various measures that have been implemented in the wake of COVID-19.

These actions have included: • Separate shifts and modified shift rosters with virtual shift handovers • Establishment of separate control rooms (up to four) • Cleaners wiping down all surfaces before and after each shift • Maintenance crew on split shifts, with separate teams

• •

• •

• • •

Training and accounts personnel moved off site Traders and corporate working from home Subject matter experts in particular areas split onto separate teams Shortened and delayed outages Separate contractor welding crews established for outages and crews located in separate huts Social distancing and segregation of teams Use of PPE where employees must work in close proximity Cut back of non-essential work, such as project work or maintenance like grass cutting Online meetings from office desks even for those on-site Implementation of health check questionnaires before attending site

A History of Success Over the past 20 years, Weld Australia has successfully built Industry Groups: • Power Generation. Covering 95% of the power stations in Australia this group provides a forum for the exchange of information; collaboration on technical projects; and technology transfer.

• Defence. This group includes representative from the main prime contractors and members of the supply chain. It focusses on local content; supply chain capability; standards; training; and advanced welding projects.

• Infrastructure. Incorporating the State Authorities this Group is focused on specifications for the delivery of welded structures and plants.

Benefits of Weld Australia Industry Group Membership • A confidential forum for discussing issues with peers • A unified body that can advocate for change among industry clients • Advantageous access to technical advice and engineering support • The opportunity to benchmark against industry best practice • A conduit between industry and research organisations • Beneficial nationally and internationally accredited training • Cost effective certification products and services • Collaborative sharing of resources and services for repair options in accordance with Australian and international standards • Opportunities to influence Australian Standards, contract terms and specifications

Inside Weld Australia: An Update from Weld Australia’s Industry Groups

The key priorities of the Group were then reviewed and agreed upon. These priorities are outlined below.

Operational Flexibility (particularly low load) and Risk Management. Most generators are moving to flexible operations but are at various stages of implementation. It was also noted that with most people currently working from home, the load profile has changed. Consumption in New South Wales, for instance, has decreased by 10% to 15%, and peaks and troughs have smoothed.

Process Safety. It was agreed that the Group will review major accident events, undertake risk assessments of safety critical systems and equipment and controls, investigate incidents, and share knowledge of the outcomes, culture and maturity assessments.

Asset Integrity Management. The Group will review advanced non-destructive testing, Rem life, emerging failure modes with aging assets, robotic welding and repair. It will also investigate knowledge management, which is required for succession planning and retiring personnel.

Finally, it was agreed that a Turbine Working Group will be established. It is expected that a Chair will be appointed for the group in the coming months, with participants invited to join thereafter. Weld Australia will draft brief that summarises the intent of the Turbine Working Group, as well as key priorities, which will be circulated to obtain buy in from the power generators.

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The purpose of the Rail Industry Group will be to: 1. Bring the welding capability of the rail industry and its supply chain to international best practice 2. Advocate for a national railcar and wagon fabrication facility and supply chain Australia’s rail manufacturing sector is undergoing a significant transition. It is slowly evolving from a more traditional manufacturing model of end-to-end rolling stock production, to a more advanced manufacturing model, and low-volume, high-value production.

The rapid advances in technology and the changing face of manufacturing generally, mean that businesses within Australia’s rail manufacturing sector are facing the immediate challenge of incorporating new technologies and processes into their operations.

A world-class rail welding industry in Australia will facilitate a shift in manufacturing focus, capitalise on international opportunities, and develop the rail supply chain capabilities.

Other Industry Groups Due to the outbreak of COVID-19, some of the scheduled Industry Group meetings were postponed.

These meetings will be rescheduled shortly via teleconferencing facilities, with members notified as soon as possible.

Weld Australia Set to Launch Rail Industry Group Welding is a core capability critical in the delivery of rail projects, as well as the maintenance, repair and refurbishment of existing assets. As such, Weld Australia’s Rail Industry Group will help improve welding capability, facilities and supply chains throughout the rail industry.

Become an Industry Group Member

Weld Australia has a wide portfolio of accomplished work in the rail industry on infrastructure, as well as multiple fleets of trams, metropolitan trains, regional trains, and freights transport. We believe now is the right time to launch a Rail Industry Group.

Contact Alistair Forbes (National Manager Corporate Businesses, Weld Australia) on a.forbes@weldaustralia.com.au to become an Industry Group member today.

Industry Group meetings are held two to three times a year in one of the state capitals. Fees are: • Existing Weld Australia Premium Corporate Members: $7,500 • Non-Members: $12,665 (includes Weld Australia Premium Corporate membership)

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Australian Welding: June 2020

Weld Australia Launches Online Training Courses Over the last few months, Weld Australia accelerated the development and launch of two new online training courses: those associated with the International Welding Specialist (IWS) and International Welding Inspector – Basic (IWI-B) certifications. Both of these courses have proved extremely popular, selling out in record time. The new online format makes training more accessible, particularly for people in remote and regional areas, who are unable to attend face-to-face courses.

The process employed by Weld Australia in transforming its faceto-face courses to an online format was quite in-depth. According to Guy Brooks (Training Manager, Weld Australia), “First, we broke down the courses into topics, and defined which sections would be most appropriate as interactive selfpaced pre-lecture modules, featuring videos, quizzes and images.”

“Next, we reviewed the lecture content. We ensured that the core lecture content would comprise all the most important and difficult subjects—those topics that needed great elaboration and that students were more likley to have questions about. Then, we compiled the postlecture content, including online review questions for each session.

This post-lecture content is available all the time so students can go back at any time to work through it.”

“Once the course structure and format was finalised, we reviewed and trialled several software systems (or authoring packages) to create the course content. We selected a system that enables us to create highly interactive and engaging content. Then, we needed a system

through which to host the courses.

We chose Moodle. All the pre-lecture content is accessible through Moodle.

We schedule all the lectures through Moodle. Everything that the students need is stored all together in the one spot—in Moodle,” said Brooks.

One of the most exciting elements of the entire system is the seamless nature of the live lectures. Weld Australia has designed and delivered an innovative technological solution that enables lecturer, Cornelis Van Niekerk, to switch smoothly between a whiteboard, a PowerPoint presentation and speaking directly to camera. The end result is a much more engaging experience.

According to Cornelis Van Niekerk, “It was interesting to explore the new online platforms that we decided on, both for delivering the self-study pre-lecture content and the online lectures themselves. It gave us the opportunity to view the course material through a new creative lens, to not only make the material more interesting, but to also make it more visually appealing so that the students are constantly engaged.”

The benefits offered by online training

are immense. “The online training offers students the opportunity to attend the course without the need to travel. All they need is a computer and a steady internet connection and they can attend the course from anywhere in Australia. They can dial into the online classroom from their work office or home. We are able to record each lecture as it is presented and upload this onto an online platform for students to view again when reviewing the work and preparing for their examinations.”

“The course work is also split up into an online self-study component in addition to the lecture material covered in the online classroom to introduce them to, and aid their understanding of, the principles discussed in class. The course is run over a longer period of time, with only two lectures per week of two to three hours per lecture. This gives the students the opportunity to attend the course without having to take weeks’ worth of leave to complete the course and to attend each module,” said Van Niekerk.

For more information, or to enrol, visit: https://portal.weldaustralia.com. au/course-timetable

“

The online platform and course content is really interactive and engaging. Cornelis is very knowledgeable, and being in a small group is great. You’re not just a number in a big system—the teacher knows who you are and remembers your name. It’s much more personal.”

Thomas Henry (a student in the first IWS online course)

Inside Weld Australia: Advanced Welder Training Centres

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TAFE Queensland Expands AWTC Program TAFE Queensland is set to expand its already successful Advanced Welder Training Centre (AWTC) program, with its recent investment in an additional 29 Soldamatic augmented reality welding simulators. With this investment, every region of TAFE Queensland across the state that offers an engineering course will have access to faster, safer and more engaging training. This training is essential to secure the welding qualifications that are in high demand by the state’s defence and advanced manufacturing industries.

According to Alistair Forbes (National Manager Corporate Businesses, Weld Australia), “The order placed

by TAFE Queensland is the largest ever, in terms of the total number of simulators. TAFE Queensland has really embraced this new, cuttingedge training technology. They have one of the most advanced welder training programs in Australia.”

The simulators will be spread across eight of TAFE Queensland’s campuses, including Ashmore, Bundaberg, Cairns, Coomera, Ipswich, Nambour, and Toowoomba.

This means every region of TAFE Queensland that offers an engineering program will utilise these new augmented reality welding simulators, dramatically improving the quality of welder training.

According to Garry Hargreaves (Corporate Solutions Manager Commercial, TAFE Queensland - SkillsTech), the augmented reality welding simulators have fundamentally changed the way welders are trained in Queensland.

“Participants get an understanding of welding principles up to 40% faster when using the welding simulators.

The simulators make training faster, more efficient, more flexible, and more engaging than traditional teaching methods. And, we use less consumables, so there is much less waste across the program,” said Hargreaves. “When we change parameters—different metals, or processes, or welding procedures— we can change the simulator settings quickly and easily, which is really useful. It offers exceptional flexibility in that regard. The simulators also

have a Learning Management System onboard so we can store participant settings and output welding videos and view the improvements throughout the program.”

“The feedback from participants has been overwhelming. The gamification aspect of augmented reality is highly engaging, especially for younger demographics. Often, we need to push participants out of the augmented reality lab because the next class is waiting to come in— augmented reality is an inherently engaging technology. Participants want to stay late, start early, and work through lunch.”

The investment in the simulators necessitated an in-depth tender process, including the evaluation of augmented reality simulators versus virtual reality simulators. “In the end, we opted for augmented reality because it works with the actual environment you’re in— overlaying digital information on the real world. This is preferable in industrial applications as it closely simulates real application of

“

Participants get an understanding of welding principles up to 40% faster. The simulators make training faster, more efficient, more flexible, and more engaging than traditional teaching methods.”

skills. In comparison, virtual reality presents the user with a fully artificial environment,’ said Hargreaves.

In investing in the simulators, TAFE Queensland was keen to ensure that the needs of local industry would be met. “Welding has gone hightech. Advanced manufacturing is a high priority in Queensland. Local industries, such as defence and space, need TAFE to deliver cutting edge skills. The installation of these additional simulators across the state will help us do exactly that.

TAFE Queensland will be able to support the trend towards more sovereign manufacturing capability in the wake of COVID-19, which has highlighted our reliance on overseas supply chains,” said Hargreaves.

The Queensland Government (via DSDMIP) pledged $800,000 to TAFE Queensland in 2018 to purchase the first 15 simulators. Since then, 10 simulators have been based at TAFE Queensland in Acacia Ridge, with the remaining five rotating across the other TAFE Queensland campuses in the north of the state.

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Australian Welding: June 2020

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 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

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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 Baker & Provan www.bakerprovan.com.au +61 2 8801 9000 info@bakerprovan.com.au 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 Coregas http://coregas.com.au +61 2 9794 2222 info@coregas.com

Hardchrome Engineering www.hardchrome.com.au +61 3 9561 9555 office@hardchrome.com.au

QENOS www.qenos.com +61 3 9258 7333 enquiry@qenos.com

HRL Technology Group www.hrlt.com.au 1800 475 832 info@hrl.com.au

Quest Integrity Group www.questintegrity.com +61 7 5507 7900 Info-APAC@questintegrity.com

Liberty www.libertygfg.com 1800 178 335 capital@libertygfg.com

Santos www.santos.com +61 8 8116 5000 reception.ade@santos.com

Lincoln Electric www.lincolnelectric.com +61 2 9772 7222 sales@lincolnelectric.com.au

Tronox Management www.tronox.com +61 8 9411 1444 info@tronox.com

LMATS http://lmats.com.au +61 8 9200 2231 admin@lmats.com.au

UGL Pty Limited www.ugllimited.com +61 2 8925 8925 uglinfo@ugllimited.com

Main Roads Western Australia www.mainroads.wa.gov.au 138 138 enquiries@mainroads.wa.gov.au

Welding Industries of Australia (WIA) www.welding.com.au 1300 300 884 info@welding.com.au

MMG www.mmg.com +61 3 9288 0888 info@mmg.com

Wilmar Sugar www.wilmarsugarmills.com.au +61 7 4722 1972 info@wilmar.com.au

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Australian Welding +61 2 8748 0100

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50

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 AF Gason: gason.com.au Aitken Welding: aitkenwelding.com Ancon Building Products: ancon.com.au Antec Group: antec.com.au ARL Laboratory Services: arllabservices.com.au ATTAR: attar.com.au Austal: austal.com Austedan Fabrications: austedan.com.au Austin Engineering: austineng.com Austral: australtechnologies.com.au Australian Rail Track Corporation: artc.com.au Australian Welding Supplies: awsi.com.au AWS Centre of Excellence: australianweldingsolutions.com.au BAE Systems: baesystems.com Barker Hume Homes: N/A Baxter Institute: baxter.vic.edu.au Ben Baden Services: craneconnection.com.au Berg Engineering: bergengineering.com.au Bisalloy Steels: bisalloy.com.au BlueScope Steel: bluescopesteel.com.au BMC Welding: bmcgroup.com.au Bombardier Transportation: bombardier.com/en/transportation.html Bossong Engineering: bossong.com.au 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 CQ Steel Industries: cqsteel.com.au Crisp Bros Haywards: haywards-steel.com Cruisemaster Australia: cruisemaster.com.au

Australian Welding: June 2020

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 Edcon Steel: edconsteel.com.au Engineering Welding and Inspection Services 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 Frontline Manufacturing: frontlinemanufacturing.com.au Furphy Engineering: furphys.com.au G & G Mining Fabrication: ggminingfab.com Global Manufacturing Group: gmqld.com.au Hamilton Maintenance Group Hanlon Industries: hanlonindustries.com.au HEQ Diesel and Gas: heq.net.au Hilton Manufacturing: hiltonmanufacturing.com.au HVAC Queensland: hvac.com.au Industrial Installation & Maintenance: iimaust.com.au Incat Tasmania: incat.com.au Ingal EPS: ingaleps.com.au IRISndt Australia: irisndt.com 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 Keyhole TIG: www.k-tig.com Knox Engineering: knoxeng.com LaserBond: laserbond.com.au Lendlease: lendlease.com/au Loclur Engineering: loclur.com.au Lorch South Pacific: lorch.eu/en LSW Group: lswgroup.com.au Lucky Strike Welding MacFab Engineering: macfab.com.au Mainetec: mainetec.com.au MaxiTRANS: maxitrans.com MC Quality Control: mcqualitycontrol.com 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 Outsource Institute: outsourceinstitute.com.au 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 RTM Engineering: rtmengineering.com.au Russell Mineral Equipment: rmeglobal.com S&L Steel: slsteel.com.au Samaras Group: samarasgroup.com Saunders International: saundersint.com Scaffstand: scaffstand.com.au 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 SVSR: svsr.com.au SWA Water Australia: swawater.com.au Synergy Aluminum Towers: synergyaccessandscaffolding.com.au Taurus Mining Solutions: taurusminingsolutions.com The Bloomfield Group: bloomcoll.com.au TEi Services: tei.com.au TICS: ticsndt.com Topline Steel Fabrications: N/A Trade and Investment NSW: industry.nsw.gov.au Uneek Bending: uneek.com.au United Pacific Engineering: unitedpacificeng.com Victorian Testing & Inspection Services: victesting.com.au Veolia: www.veolia.com/anz Walz Construction: walzgroup.biz Welding Guns of Australia: unimig.com.au WGASA: wga.com.au

Inside Weld Australia: Hotline Update

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Enrol Now: Advanced Welder Training Courses Fusion Welding Courses There are two ISO 9606 Qualification test of welders — Fusion welding —Part 1: Steels 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.

Transition Workers To complete the Course in Fusion Welding to AS/NZS ISO 9606 for Transition Workers, you must successfully complete seven units of competency (four core and three elective). Core units: • Simulate fusion welding processes using augmented reality equipment • Identify welding processes, safe welding practices and use of hand and power tools • Interpret and apply AS/NZS ISO 9606 for fusion welding processes • Perform fusion welding procedures to meet the procedures of ISO 9606-1 (Steels – carbon steels) Experienced Welders To complete the Course in Fusion Welding to AS/NZS ISO 9606 for Experienced Welders, you must successfully complete three units of competency (one core and two elective). The core unit is: Interpret and apply AS/NZS ISO 9606 for fusion welding processes.

Elective Units Other elective units available include: • Perform fusion welding procedures to meet AS/NZS ISO 9606-1 (Steels – stainless steel) • Perform fusion welding procedures to meet AS/NZS ISO 9606-2 (Aluminium and aluminium alloys) • Perform fusion welding procedures to meet the requirements of AS/NZS ISO 9606-3, 4 or 5 (Exotic metals) • Perform routine manual metal arc welding • Perform routine gas metal arc welding • Perform manual heating and thermal cutting • Read and interpret technical drawings and make measurements for a welding procedure Further Information For further information, contact: +61 2 8748 0100, training@weldaustralia.com.au or weldaustralia.com.au.

Enrol in a Fusion Welding Course Today

You can enrol in a Fusion Welding course through any of the Advanced Welder Training Centres across Australia. These are all listed below.

Queensland TAFE Queensland Caboolture Campus https://tafeqld.edu.au Tallon Street, Caboolture, Queensland TAFE Queensland SkillsTech https://tafeqld.edu.au 247 Bradman Street, Acacia Ridge, Queensland South Australia TAFE SA Regency Campus https://www.tafesa.edu.au 137 Days Road, Regency Park, South Australia Tasmania Tasmanian Minerals and Energy Council https://tasminerals.com.au 13 Wellington Street, Burnie, Tasmania Victoria Box Hill Institute https://www.boxhill.edu.au 465 Elgar Road, Box Hill, Melbourne, Victoria Bendigo TAFE http://www.bendigotafe.edu.au 23 Mundy Street, Bendigo, Victoria Federation University https://federation.edu.au Lydiard Street South, Ballarat, Victoria

Australian Welding: June 2020 52 Weld Australia’s Innovative, Expert

Engineering and Advisory Services By taking advantage of Weld Australia’s engineering and advisory services, you have access to the peak industry body in Australia’s welding industry. Your commercial enterprise can access expert advice services, delivered by highly qualified welding engineers and materials specialists. Each member of the Weld Australia advisory team is an International Welding Engineer (IWE). This qualification, issued by the International Institute of Welding, is the highest postgraduate professional welding qualification available. Our consulting services can help you substantially increase the operational life of your plant and equipment, and reduce your maintenance and repair overheads.

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

Design and qualification of welded connections Review of structural and pressure vessel designs Drafting and review of design specifications Evaluation of materials and facilities Analysis and resolution of complex welding problems Design, development and project management of fabrication solutions Optimisation of maintenance for risk mitigation Comprehensive failure investigations and engineering critical assessments

Resources

• • • • • • • •

Advising of safety practices as they pertain to welding, cutting and joining Expert evidence and witnessing services Comprehensive failure investigations Inspection and testing services Welding quality management to ISO 3834 Pipeline in-service welding, repairs and hot tapping Specialised welding and associated technologies (laser, ultrasonic peening and underwater welding) R&D and application of technology

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