Year in Review 2022 by Weld Australia

2022: A YEAR IN REVIEW SECURING THE FUTURE OF AUSTRALIA’S WELDING INDUSTRY

CONTACT

weldaustralia.com.au | office@weldaustralia.com.au | 02 8748 0100 2022 | Year in Review

2022: A YEAR IN REVIEW

Welcome to Weld Australia’s 2022 Year In Review – a look at our successes, projects and programs over the last 12 months, as well as that of our members. Throughout the year, we continued to strengthen our advocacy work, facilitated a host of member events, and were involved in a range of industry events. We continued to reinforce our membership offering, and provided high-quality training courses and certification services. It really is an exciting time to be a Weld Australia member. We are committed to using our extensive experience, combined with an innovative new approach, to achieve our primary goal—ensuring that the Australian welding industry remains both locally and globally competitive, both now and into the future. The entire Weld Australia team is looking forward to a busy, successful 2023.

11,570

Welders Registered on the Australian Welder Certification Register (AWCR)

4,429

People in the Weld Australia Community

735

People Attended Events

312

People Commenced Training Courses

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100

Newly Qualified International Welding Engineers (IWEs)

Welders Qualified to ISO 9606-1

State Division Committee Meetings

Newly Qualified International Welding Specialists

Member Events

Newly Qualified Welding Supervisors

Certification Audits Conducted

Companies Newly Certified to AS/NZS ISO 3834, EN 15085 or DIN 2303

2022 | Year in Review

ADVOCACY The Langi Kal Kal Prison Program

WELD AUSTRALIA’S ADVOCACY IN 2021 shortage—not political posturing and promises that cannot be kept,” said Crittenden. As such, Weld Australia advocated for a radical four-pronged approach to overcome the nation’s skilled welder shortage that includes: an overhaul of welding apprenticeships; tapping into hidden sources of talent; refocussing STEM training in schools; and investment in TAFEs nationally.

As the peak body for welding in Australia, our primary goal is to ensure that the Australian welding industry remains both locally and globally competitive, both now and into the future. In all our advocacy activities, our over-reaching vision is to facilitate the growth of a world class welding industry.

As the urgency of Australia’s COVID-19 response fell from the headlines, the lasting affects of the pandemic on the global economy became clear. These were coupled with the ongoing war in Ukraine, a severe shortage of skilled labour, and supply chain issues. However, Weld Australia’s role remained clear: to provide highquality advocacy services to members. Weld Australia’s advocacy agenda focused on training initiatives for the next generation of welders and fabricators, building a sustainable and productive local industry, and ensuring superior welding quality standards and public safety.

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Skills Shortages Weld Australia estimates that, unless action is taken now, Australia will be 70,000 welders short by 2030. This urgent issue is not unique to Australia; the US will face a shortage of 500,000 welders by 2030, and Japan estimates a shortfall of 250,000 welders by 2050. This global shortfall of welders is driving most developed nations to implement extraordinary measures to resolve it— Australia must follow suit. According to Geoff Crittenden (CEO, Weld Australia), “Australia does not have the welders to deliver the nation’s critical energy, defence, rail and infrastructure projects. We will be unable to deliver on the Federal Government’s promises, like renewable energy targets that require fabrication of wind towers, solar panel structures, hydrogen plants and battery processing plants. Access to the global supply chain for fabricated steel products is a high-risk and expensive proposition.” “We need a practical, actionable plan that can be implemented now to overcome the welder skills

Sovereign Manufacturing Capability In 2022, Weld Australia continued to push for further investment in sovereign manufacturing capability. Weld Australia has long urged the federal and state governments to support local manufacturers, welders and fabricators in their procurement processes. Local procurement has the power to create thousands of jobs, a solid local supply chain, and an industry equipped to export worldclass products all over the world. According to Crittenden, “There is a real opportunity for the federal and state governments to invest in creating a robust, resilient manufacturing industry that can compete on the world stage. Government procurement practices that support local welders and fabricators will create thousands of jobs, supporting local economies in a post COVID-19 world.” “With a long-term procurement commitment from the state governments, Australian manufacturers will have the confidence to reinvest in their own capabilities, strengthening the industry from within. This type of business innovation strengthens businesses and creates new and better jobs, which together support a move to higher living standards. Innovation investment by business is crucial to our ongoing prosperity.”

“In recovering from the COVID-19 pandemic, this type of economic expansion is essential; both the Federal Government and the Reserve Bank of Australia have emphasised how important it is for state governments to spend money. And yet, our state governments consistently spend our money overseas.” “Offshoring manufacturing, welding and fabrication work to the likes of China, South Korea and Spain weakens Australia’s economy.” “If all our governments adopted a nationally consistent procurement process that considered whole of life costs and prioritised local content, not only would it create thousands of jobs, it would deliver better quality public transport. Locally fabricated trains would adhere to all relevant Australian and international Standards, reducing expensive rework and repair. Cheap imports from overseas often cost more in the long run,” said Crittenden. Quality and Compliance The quality and accuracy of the entire lifecycle of the welding process must be carefully controlled, from design right through to inspection. This type of approach is essential because it is impossible to undertake complete verification of a welded joint without destroying it.

Australia’s prison population continues to grow at a rate that is four times that of the general population. According to the most recent figures from the Australian Bureau of Statistics, from 30 June 2020 to 30 June 2021, the total number of Australian prisoners increased by 5% to 42,970. As at 30 June 2021, the median age was 35.6 years for all prisoners. When comparing the prison population to the general adult population, prisoners are much younger—2 in 3 (65%) prisoners were under 40, compared with about 2 in 5 (40%) in the general adult population. Many prisoners have education and skill levels well below the Australian average. Almost 2 in 3 (63%) prisoners have an education level of Year 8 or below. And, possibly most concerning, once prisoners enter the correctional system, finding their way out can be tough. The Productivity Commission’s latest report on government services found that, in 20202021, the rate of prisoners returning to prison in Victoria was 43.6%. All these statistics paint a clear picture: our prison population is rapidly expanding, and is increasingly comprised of younger people and reoffenders. This gives rise to the need for practical rehabilitation and vocational education and training (VET) programs that can help alleviate recidivism. The introduction of VET programs as part of prisoner rehabilitation offers opportunities for prisoners to reduce this disadvantage, increasing the likelihood of successful re-integration into the community and reducing the risk of reoffending. A recent study confirmed that participation in VET whilst incarcerated helps prisoners to remain custody free post-release. In fact, prisoners who successfully completed VET were 59.96% more likely to remain custody free at two years post-release; and 78.23% more likely to remain custody free at five years post-release. Given the proven success of VET programs for prisoner rehabilitation, in 2022, Corrections Victoria expanded the VET Centre of Excellence model to deliver Fusion Welding to ISO 9606 certification standard to complement their Metal Fabrication industry at HM Prison Langi Kal Kal. Federation University delivers the training program with the support of Weld Australia and on-site prison industry staff.

Inspection after completion does not guarantee weld serviceability. 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 part of the program, augmented reality training was introduced to expand the welding skills of the prisoner learners to meet international standards. A welding workshop sits alongside the augmented reality training room so that participants can work on projects to use and practice their welding skills in the physical as well as virtual environments. To participate in the program, prisoners are invited to submit an Expression of Interest and then selected through an interview process. Up to eight participants can be accommodated in the intensive 14-week program.

As such, the welding processes set out in Australian and International Standards are crucial—they must be followed exactly. Standards like AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials must be implemented. Welders, welding supervisors and welding inspectors

With Australia facing a looming shortage of skilled welders—70,000 additional welders will be needed in the next 10 years—Weld Australia advocated for the national roll-out of this important program. If you’d like to get involved as a prospective employer, click on the link below and complete the quick and easy Expression of Interest form. 2022 | Year in Review

ADVOCACY

MAJOR MEDIA COVERAGE IN 2022 must be qualified to ISO 9606 Qualification testing of welders. If these Standards are not followed, then there is a significant chance that a weld will fail—with possibly catastrophic consequences. Imagine the collapse of a stadium or a bridge; how many bystanders would be seriously injured or worse? “When it comes to welding, we cannot simply wave a magic wand and make a weld safe after the fact. Welding is a highly complex process based on science and research that requires an in-depth understanding of metallurgy and materials science, as well as enormous discipline and rigorous application of the correct processes and procedures,” Crittenden explained. Weld Australia has advocated for a whole-of-industry approach to upholding these Standards. Some of the biggest players who rely on these Standards are often caught refusing to support the participation of their own staff in Standards Committees. “The welding processes set out in Australian and International Standards are crucial. Standards exist for a reason; to ensure public safety. When it comes to welding, we cannot simply wave a magic wand and make a weld safe after the fact,” Crittenden said. If these Standards are not followed, there is a significant chance that a weld will fail—with possibly catastrophic consequences. Weld Australia continues to collaborate with its members to ensure these Standards are followed. Cobotics and Automation The welding industry is fast evolving. Welding is no longer a dirty, precarious job, conducted in dark workshops. In fact, the sector has become a place for bright, talented, and technically-minded personnel to learn and create infrastructure for a modern Australia. The introduction of modern technologies, like cobots and

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automation is paving the way for the manufacturing of high-tech equipment for the aerospace and defence industries. Cobots, or collaborative robots, make automation easier for businesses of all sizes. They are designed to share the workplace with humans. They are versatile, lightweight and relatively easier to program. “Australian industry is also developing and investing in cutting-edge technology to help ameliorate looming skills shortages. Automation, robotics and collaborative robots are changing the way the welding and manufacturing industries work,” Crittenden said. These devices can play a crucial role when it comes to leaner manufacturing, eliminating errors, and reducing bottlenecks. In fact, automation has the power to deliver a $2.2 trillion boost to Australia’s national income by 2030, according to research commissioned by Google. Automation is also expected to increase safety among workers. Strategy and economic advisory business AlphaBeta, also estimated an 11 per cent drop in workplace injuries in companies where there is widespread adoption of cobots. “Weld Australia members have demonstrated extraordinary innovation and invested in leadingedge technology in order to maintain production schedules and grow their businesses throughout what has been an incredibly difficult time over the last two years. It is this ability to innovate that has continued to ensure that Australian manufacturers are resilient, profitable and readily able to compete on the world stage,” Crittenden said. Women in Welding As part of the ongoing skills shortage conundrum, Weld Australia continues to push for more women in welding. In fact, recent research found that increasing women’s participation in the paid workforce would address Australia’s current skills shortage and have long-lasting impact on productivity in Australia.

WATCH Q+A

WATCH THE DRUM

ABC’S Q+A Weld Australia recently appeared on ABC’s Q+A. Bailey Greathead asked a fantastic question around how the government plans to de-stigmatise apprenticeships versus university.

ABC’S THE DRUM Geoff Crittenden (CEO) and Michael Pitt (National Manager Education and Training) spoke about VET programs for prisoner rehabilitation on ABC’s The Drum.

RADIO INTERVIEWS Geoff Crittenden secured a range of radio interviews this year, including: • 2CC Canberra - Afternoon on 3 August (recording unavailable) • ABC Radio Ballarat - Breakfast on 24 August • 2GB / 3AW Radio - Money News with Luke Grant on 30 August • ABC Radio Canberra - Drive on 30 August • 2BS Bathurst Radio - Drive on 27 September • ANM Hunter Valley - Drive on 20 October (recording unavailable) • ABC Illawarra - Mornings on 20 October (recording unavailable) • ABC North West Queensland on 25 October (recording unavailable)

The analysis, conducted by Impact Economics and Policy, shows that unlocking women’s workforce participation could fill job vacancies and address critical skills shortages predicted between now and 2026. The report also found that halving the workforce participation gap between men and women would represent an additional 500,000 fulltime skilled workers with post school qualifications. “Gender equity and diversity in the construction and manufacturing industry workforce is a persistent problem that exacerbates skills shortages, reduces economic

WATCH THE TODAY SHOW CHANNEL 9’S TODAY SHOW Channel 9’s Today Show broadcast live from TAFE Queensland’s Acacia Ridge training centre this year. The broadcast demonstrated the benefits of welding simulators for training.

productivity, and constrains innovation. Encouraging the participation of women in maleoriented industries such as construction, manufacturing and welding is long overdue in ending the cycle of employment disparity, gender pay gap, and representation of women in management positions.” “We need a proactive, targeted approach that engages and recruits women into the trades, new and innovative trade training programs designed specifically for women, and measurable gender diversity targets set by the Federal Government,” Crittenden said.

2022 | Year in Review

MEMBER SURVEY

WELD AUSTRALIA 2022 MEMBER SURVEY: RESULTS ANALYSIS Weld Australia conducted a Member Survey in 2022. The results demonstrate that significant concerns remain for Australia’s welding industry. In particular, Australia’s fabricators are being forced to turn down work due to a severe shortage of skilled welders.

According to Geoff Crittenden (CEO, Weld Australia), “Distributed in June 2022 and completed by approximately 140 companies, our 2022 Member Survey indicates that skills shortages, local content and sustainability remain high on the agenda for the welding industry.” “When asked what they are most concerned about, almost 64% of senior managers cited lack of skilled

staff in an extremely constrained recruitment market (see Figure 1). This comes as little surprise, with Australia facing a looming shortage of skilled welders—70,000 additional welders will be needed by the end of the decade.” “With a considerable volume of work being onshored in the wake of international supply chain disruptions, most Australian fabrication companies are so strapped for skilled welders that they are working at anywhere between 30% and 50% of their full capacity. They are being forced to turn down jobs because they simply don’t have the manpower to complete the work. This is having a major impact on production and causing delays throughout downstream industries including building and construction, mining, oil and gas, and manufacturing,” said Crittenden.

Given the concern over Australia’s looming skills crisis, it makes sense that 95% of respondents support the concept of free TAFE, increased funding to upgrade TAFE facilities, or both initiatives. Clearly, the welding industry is looking to the government to help increase the supply of skilled labour over the coming years.

Less than 1 month 9.1%

Reliability & affordability of power supply 4.5%

It is little wonder that half (see Figure 2) of the survey respondents have a pipeline of work that extends for six months or longer—this protracted pipeline is necessary in the face of these ongoing skills shortages. By way of context, this is a marked increase on Weld Australia’s 2020 member survey results. In the wake of the COVID-19 pandemic, the most common answers were a pipeline of work that extended less than one month (at 28%), one month (19%), and two months (16%).

Lack of skilled labour

Inflation & rising costs

Over 6 months 27.3%

“Our members are also investing in their own welder training programs. BHP, Komatsu, JRS Manufacturing, Maxi-Trans and Precision Manufacturing Group have all established their own schools. While industry appreciates the rollout of government-funded TAFE places, it remains to be seen whether this initiative will translate into high completion rates. Moreover, while encouraging more students into TAFE is always a positive, government spending also needs to focus on resources for TAFEs, teachers and equipment—TAFEs need the right tools to teach this sudden influx of students,” said Crittenden. Industry is also investing in advanced welding technology to help overcome skills shortages. Over 28% of respondents indicated that their company or the company they work for has purchased robots or cobots, and 25% has invested in Industry 4.0 capabilities (see Figure 6). A range of other types of technology was also mentioned, from drones and automated welders, through to various software solutions. Despite the skills shortages, local procurement and content targets remain top of mind for the welding industry. 100% of respondents confirmed that they would support Federal and State Government policies to increase Australia’s

Survey Respondent Demographics The majority of survey respondents were based in Queensland (at 28%), followed closely by New South Wales (23%), Victoria (19%) and Western Australia (16%). The largest age group was over 65, accounting for 16% of respondents. In line with industry trends, 78% of respondents were over the age of 40 (see Figure 3). The most commonly cited highest level of education was an apprenticeship or vocational training at 30%, followed by International Welding Specialist at 23%, Bachelor Degree at 13% and Masters Degree at 9%. Salaries are relatively healthy compared to Australia’s average wage (of $67,860 per annum); 20% of respondents indicated that their salary is between $100,000 and $125,000, and 17% take home over $150,000 per annum. Overwhelmingly, respondents are employed full-time (72%). Another 16% indicated that they are business owners and 9% are either employed part-time or as a sub-contractor. The remaining 3% are retired. At 23%, the majority of respondents have worked for their current employer for over 20 years (see Figure 4). Over 51% of respondents work for a business in the fabrication, manufacturing or engineering industry, 12% work for a business in the mining and resources industry, 10% in the education and training industry, and 7% in testing and NDT. The vast majority of these businesses are quite large; 32% of respondents indicated that the company they work for has over 500 staff. However, SMEs were also well represented, with 16% of respondents confirming that the business they work for has under 10 staff members (see Figure 5).

1 month 4.6%

63.7%

22.7%

2 months 22.7% Weak international supply chains 9.1%

3 months 4.5%

6 months 22.7% 4 months 9.1%

Figure 1. As a business owner, or senior manager, which issue are you most concerned about?

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Figure 2. How many months ahead does your pipeline of work extend?

Figure 3. What is your age?

Figure 4. How long have you worked for your current employer?

Figure 5. What is the size of your business, or the business you work for?

2022 | Year in Review

share of fabricated steel product to at least 75% as part of a joint government-industry plan to grow the manufacturing industry. “Importantly, whether it is imported or locally manufactured, all fabricated steel erected in Australia must comply with Australian Standards. Weld Australia is committed to ensuring that no Australian lives are lost through an accident caused by noncompliant welding, without causing undue regulatory burden on industry. We firmly believe in quality welding for structural safety,” said Crittenden. Inflation and rising costs were also of concern for approximately 23% of respondents, followed by weak international supply chains (9%) and reliability and affordability of power supply (4%). Environmental Sustainability and Corporate Responsibility Australia is rapidly moving from carbon fuelled power generation to a renewable energy system. In June 2022, Prime Minister Anthony

Albanese announced more ambitious climate targets. Albanese pledged to cut carbon emissions by 43% from 2005 levels by 2030, up from the previous government’s target of between 26% and 28%. Given these targets, private companies will play a key role, making sustainability a priority for many businesses. As such, our 2022 member survey asked a series of environmental sustainability focused questions. Welders are environmentally responsible. 30% of respondents support the target of zero emissions before 2050; 20% prefer cutting emissions by 35% by 2030; and another 17% support cutting emissions by 43% by 2030. In addition, 74% of respondents would support a Federal Government package to help employees transfer from carbon intensive to carbon free industries.

solar panels to supplement power supply, another 53% have installed LED or sensor lighting, 46% have waste reduction programs in place, 46% operate recycling, up-cycling or repurposing programs, and 13% have a net zero carbon plan in place. When asked if an electric or hybrid ute was available in Australia at a competitive price would you buy them for your company or employees as fleet cars, 50% of respondents answered in the affirmative. Interestingly, 63% of respondents would buy an electric or hybrid UTE for themselves. Corporate responsibility remains a growing area of focus for the welding industry. Over 63% of respondents indicated that they have initiatives aimed at improving opportunities for women; 63% promote opportunities for apprentices and trainees; 63% have diversity and inclusion initiatives in place; 59% have mental health and fitness initiatives in place; and 31% have a Reconciliation Action Plan.

Clearly, Australia’s welding industry is already taking steps to reduce its carbon emissions. While 41% of respondents have already installed

Weak

Very Strong

18.2%

27.3%

Strong

Weld Australia reintroduced its Welding Excellence Awards in 2022. The Awards embody and promote the highest standards of craftsmanship, quality and professionalism. The 2022 Welding Excellence Awards presented a fantastic opportunity for welders, fabricators and educators across Australia to showcase their people and their operations. Winners will be awarded in each state for each of the award categories below. Award ceremonies will be held around the country in November and December.

Company of the Year The Company of the Year Award recognises superior performance across a comprehensive range of business metrics including: innovation, quality assurance, market success, corporate social responsibility, health and safety, sustainability, and training and development of employees. There are three sub-categories: • Company of the Year – Fabrication • Company of the Year – Gas & Gear • Indigenous Company of the Year Welding Professional of the Year This Award recognises professionals who are making a valuable contribution to the Australian welding and fabrication industry. The individual should demonstrate a high level of skill, knowledge or craftsmanship, be dedicated to their profession, and have professional development plans in place. There are three sub-categories: • Welding Professional of the Year – Welding Coordinator Welding Professional of the Year – Welding Supervisor • Welding Professional of the Year – Welding Inspector Project of the Year The Project of the Year Award recognises excellence in welding and fabrication projects, with a focus on exceptional craftsmanship, a commitment to Australian and International Standards, environmental sustainability and innovation. Projects must have been completed in the 12 months preceding 1 October 2022.

54.5%

Young Trades Person of the Year This Award recognises people under the age of 25 who are making a valuable contribution to the Australian welding and fabrication industry. The individual should demonstrate a high level of skill, knowledge or craftsmanship, be dedicated to their profession, and have professional development plans in place. Young Indigenous Trades Person of the Year This Award recognises indigenous trades people under the age of 25 who are making a valuable contribution to the Australian welding and fabrication industry. The individual should demonstrate a high level of skill, knowledge or craftsmanship, be dedicated to their profession, and have professional development plans in place. Training and Education Award – Organisation The Training and Education Award recognises the outstanding achievements of a STEM or VET provider or program. Entrants may include secondary education and tertiary education providers. Criteria include delivery of quality, innovative training programs, involvement with industry, recruitment and retention of students, and corporate social responsibility. Training and Education Award – Individual Teacher This Award recognises the outstanding achievements of a STEM or VET teacher at TAFEs, independent RTOs and private companies. Entrants will be judged on criteria such as delivery of quality, innovative training programs, high level of knowledge or craftsmanship, strong links with students, and dedication to their profession.

WITH THANKS TO OUR SPONSORS Figure 6. Has your business, or the business you work for, invested in advanced welding technology?

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Figure 7. How would you rate the prospects of your business over the next six to 12 months?

2022 | Year in Review

Welding Vision Technology Event.

EVENTS

WORKSHOPS, SEMINARS AND MEMBER EVENTS IN 2022 Each year, Weld Australia facilitates a variety of member-focused events to help ensure that the Australian welding industry remains strong, competitive and upto-date with advancements in everything from technology, through to Australian Standards. Our events give members the opportunity to network and collaborate with like-minded individuals throughout the industry. With COVID-19 restrictions easing, Weld Australia was able to introduce face-to-face events back into the calendar.

Talking Standards Webinar Online, March The Western Australia State Committee presented an interactive webinar discussing AS/NZS 9606 Qualification testing of welders – Fusion welding – Steels. The webinar covered everything there is to know about this Standard, it’s application within the workplace and important facts to remember. Attendees were invited to voice any questions or concerns they had about the Standard and were welcome to take advantage of the Western Australia State Committee’s expert knowledge on the matter.

Students from the Pipeline Repair, Hot Tapping and In-Service Welding Course..in Sydney

Pipeline Repair, Hot Tapping and In-Service Welding Courses.

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Skilling for the Future Online, March Weld Australia’s Training Manager, Guy Brooks, guided attendees through the importance of training and how to decide what training and qualifications are the right choice. Starting with a broad overview of the status of welder skills and training in Australia, Guy noted there is a shortage of labour present as the world recovers from the COVID-19 pandemic. The session highlighted the importance of upskilling and emphasised the benefits of investing in training and certification. Pipeline Repair, Hot Tapping and In-Service Welding Courses Sydney, March and Adelaide, April Presented by William A. Bruce (Director, Welding and Materials Technology at DNV), the Pipeline Repair, Hot Tapping and In-Service Welding course was held in both Sydney and Adelaide across four days. The course offered a review and critical analysis of various aspects of pipeline modification and repair while addressing the concerns associated with welding onto inservice pipelines. The course was completed by over 25 students. Cobot Case Study Online, April As the application of collaborative welding robots—or cobots for short— gains traction in the industry, it is important to consider the benefits of cobots and how they might be used in welding long term. This interactive online session presented by Novarc Technologies, looked at some reallife case studies on applications of cobots in industry and considered the positive impact of cobots, such as resolving ergonomic issues, cost reductions and improving safety.

2022 Standards Update Online, April Weld Australia hosted a session for over 200 attendees on Australian Standards. The session was facilitated by Bruce Cannon, Weld Australia’s Principal Welding Engineer. Bruce discussed the revisions that have been made to Australian and New Zealand welding-related standards in the last 12 months, including why the changes were made and how to get involved in the public review process of Standards. A highly informative and engaging webinar, all feedback received from attendees was very positive.

AS/NZS ISO 3834: Helping Secure the Future of Australia’s Welding Industry Mackay, May Weld Australia delivered a three-part workshop for the Mackay Manufacturing Hub on the benefits of certification to AS/NZS ISO 3834 certification. Paolo Corronca (National Manager Engineering), Victor Blain (Engineering Team Manager - South and West) and Ross O’Bryan (Engineering Team Manager - East) facilitated the training. Certification helps Australian businesses demonstrate their ability to deliver a compliant, superior quality welded product on time and to budget.

Welding Vision Technology Event Online, May Weld Australia hosted a Welding Vision Technology Event presented by Xiris Automation. Attendees learnt how Xiris Weld Cameras are being applied in industry and welder training. The webinar covered topics such as: an introduction to weld cameras, weld monitoring software innovation and integrations, using weld cameras in welder education, metal process research and industrial processes, and innovation via thermal analysis. Xiris helps manufacturers detect, recognise, and interpret quality defects in manufactured goods.

The Cost and Economics of Welding Online, June Every year, welding manufacturing operations lose millions of dollars in profits due to the improper calculation of costs and inefficient welding practices. Facilitated by Victor Blain, this member event covered learnings from the industry. It helped attendees learn how to identify and manage the costs of production to reduce expenses and ensure quality; how to calculate the costs of welding; and understand the main factors influencing weld costs to highlight where it is possible to optimise the welding process and save money.

2022 | Year in Review

EVENTS Weld Australia, Garry developed a GCAA Welder Competency training program for Glencore’s full-time boilermakers and third party repairers performing these weld repairs. Automation Technology Night Adelaide, August Held on-site at the TAFE SA Regency Campus, this presentation highlighted the latest welding automation technology and its broad range of applications to improve welding ergonomics and increase productivity and quality. The event also covered various cost saving applications that can easily double the production rate of a welding workshop by increasing the arc time and reducing labour, gas and filler metal costs compared to manual welding.

Photo Introduction to K-TIG. K-TIG is a highly refined, keyhole variation of GTAW both with or without filler. It excels in Austenitic Stainless Steels, Carbon steels, Titanium, Zirconium, Duplex and Super Duplex, Nickel, Monel, Inconel and Hastelloy.

Welding Technology Showcase Mackay, June Weld Australia celebrated the launch of newly formed Mackay Committee with a technology showcase at BOC Mackay’s centre of welding. The event was co-hosted by BOC, Independent Welding Supplies, Diverseco and the Mackay Manufacturing Hub. Attendees had the opportunity to hear from Weld Australia CEO, Geoff Crittenden, who opened the event, followed by a panel of welding industry experts who delivered interactive and engaging demonstrations. The event was a great opportunity for the local industry. Introduction to K-TIG Online, August K-TIG is a highly refined, keyhole variation of GTAW both with or

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Welding Technology Showcase in Mackay.

The Need for AS/NZS ISO 3834 and AS/NZS 5131 Certification Melbourne, September Held in conjunction with the ASI, this event covered both AS/NZS ISO 3834 and AS/NZS 5131, outlining the benefits and processes involved in gaining the two certifications. Presenters included Victor Blain, Bushan Salunke (General Manager, Steelwork Compliance Australia) and Michael Dawson (State Manager, ASI). AS/NZS 5131 defines good practice for fabrication and erection of structural steelwork for projects in Australia and AS/NZS ISO 3834 specifies the production control requirements for fusion welded product.

without filler. It excels in Austenitic Stainless Steels, Carbon steels, Titanium, Zirconium, Duplex and Super Duplex, Nickel, Monel, Inconel and Hastelloy. This presentation, delivered by Bill Kelly (Chief Technical Officer, K-TIG) included a close up look at the K-TIG process, with a practical demonstration of the system and how it can be applied in both piping and pressure vessel applications. AS 1796: Overview for Users Online, August AS 1796 is the Australian Standard related to the qualification of welders, welding supervisors and welding inspectors for pressure equipment. Last published in 2001, the Standard needed to be revised to align with current trends and international best practice. This online presentation

provided an overview of the 2022 edition focusing on alignment of welder requirements to AS/NZS ISO 9606.1, updating the welding supervisor requirements consistent with AS/NZS 2214 and the transition process for inspectors to Certificate 11. Winning Business: The Glencore GCAA Welder Qualification Scheme Case Study Online, August Presented by Garry Horner, who worked in the coal industry for his entire career, this event delved into the Glencore GCAA Welder Qualification Scheme. It provided insights into the types of welder qualifications required, why Glencore implemented the scheme, and the factors that led to its success. With the assistance of MC Quality and

AS/NZS ISO 3834: An Overview Online, September Weld Australia hosted a webinar that provided an overview of AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials. The presentation detailed what AS/NZS ISO 3834 is, how it is structured, why you need it, the requirements outlined in the standard, the benefits of undergoing the certification process, as well as the steps involved in the certification process. The webinar was presented by Weld Australia team members Victor Blain and Bruce Cannon. ASME Section IX Three Day Courses Perth and Brisbane, November Facilitated by Walter J. Sperko (President of Sperko Engineering Services), this three-day course was held in both Perth and Sydney. The American Society of Mechanical Engineers (ASME) standard regulates the design, development and construction of boilers and pressure vessels. ASME Section IX specifies the requirements for the qualification of welders and the welding procedure specifications. This three day course gave participants a working knowledge of ASME Section IX, including how to comply with its requirements.

Welding Technology Showcase in Mackay.

Further Information For further information about Weld Australia’s events, or to register for an upcoming event, visit our website: weldaustralia.com.au

2022 | Year in Review

EVENTS

INDUSTRY EVENTS IN 2022 With COVID-19 restrictions easing, industry conferences, exhibitions and expos were back in full force. From expos and career fairs, through to INDO PACIFIC and National Manufacturing Week, Weld Australia was on hand to answer questions and represent the Australian Welding industry. INDO PACIFIC 2022 Sydney, May The INDO PACIFIC 2022 International Maritime Exposition featured the largest exhibitor turnout in the event’s 20-year history. It is believed to be the largest defence industry event ever held in Australia, after a record number of participating exhibitor companies presented at the event. Weld Australia’s stand proved popular with attendees, with people keen to try out the Soldamatic augmented reality welding simulators. It was a great opportunity to talk to members and other industry experts about shipbuilding opportunities. Aboriginal Career Exploration Expo Adelaide, May Weld Australia was invited by South Australia’s Department for Education to attend the Aboriginal Career Exploration (ACE) Expo. The aim of the Expo was to help promote career pathways in the fabrication, manufacturing and steel industry. Held in Adelaide, the event attracted approximately 500 students. With several Soldamatic augmented reality welding simulators available, the students enjoyed getting hands-on with virtual welding. Weld Australia also had several students sign up for our free Student Membership. Careers Day Out Expo Shepparton, May Weld Australia’s interactive stand at the Careers Day Out Expo in Shepparton proved extremely popular with students. Now in its 24th year, Careers Day Out is the largest education, training and employment expo in Northern Victoria. Over 1,800 students from years 9 to 12 visit the Expo each year. The event included a range of workshops, demonstrations

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and talks to provide students with the opportunity to engage and interact with local businesses and trades to see what the workplace is all about. Australian Manufacturing Week Sydney, June Owned and operated by AMTIL, the inaugural Australian Manufacturing Week (AMW) took place in June at the International Convention Centre Sydney. The theme for 2022 was Where technology meets innovation. AMW exhibited some of the very latest manufacturing technologies, processes and support services with more than 170 organisations taking stands. Weld Australia also exhibited, with our Soldamatic augmented reality welding simulator on-hand.

CSIRO Generation STEM #WithSTEMYouCan Careers Expo Sydney, June Weld Australia had the pleasure of attending and presenting at the CSIRO Generation STEM #WithSTEMYouCan Careers Expo alongside S&L Steel. Generation STEM will deliver programs that attract more diverse, high-potential high school students into NSWbased STEM educational pathways. Many enthusiastic students tried their hand at welding using our Sodamatic augmented reality welding simulator at our stand. It was safe to say that there was a healthy amount of competition amongst students.

Engineering, Manufacturing and Technology Expo Perth, June Hosted by EMICoL and Innovation Central Perth, Weld Australia had the pleasure of attending the Engineering Manufacturing and Technology Expo at Curtin University in Perth. Attended by industry, academics and students, the event proved to be a great opportunity to engage with EMICoL members and partners. Weld Australia had its Soldamatic augmented reality welding simulator on-hand for attendees and students to try. As always, it proved very popular with the crowd. Queensland Mining and Engineering Exhibition (QME) Mackay, July For almost 30 years, the Queensland Mining and Engineering Exhibition (QME) has been at the heart of the mining sector in Mackay. Weld Australia shared a booth with Outsource Institute at QME 2022. This year, QME featured over 250 suppliers and attracted over 5,000 visitors across three days. Weld Australia

shared its knowledge around how to upskill workforces and individuals in trade and technical skills to help more businesses in the region enhance both their own and Australia’s sovereign manufacturing capability. IBSA Group’s Manufacturing Skills Forum Melbourne, August Weld Australia CEO Geoff Crittenden was invited to attend the IBSA Group’s Manufacturing Skills Forum in Melbourne. IBSA Group brought together manufacturers, union leaders, peak bodies and training providers to share opinions and insights into the strategies needed to address the skills needs of the manufacturing sector. Expertly hosted by ABC journalist Ellen Fanning with many Australian industry experts speaking, it was an interesting, thought-provoking day. Climate and Energy Mini Jobs Summit Canberra, August Following the IBSA Group’s Forum, CEO Geoff Crittenden attended the

Climate and Energy Mini Jobs Summit at Parliament house, hosted by the Federal Minister for Climate Change and Energy, the Hon Chris Bowen MP. The summit brought together key stakeholders to help discuss energy industry jobs now and in the future. The event examined the investments and pipelines required to upskill workers in preparation for the opportunities in renewables across the country. Canberra CareersXpo Canberra, August Weld Australia exhibited at the Canberra CareersXpo at Exhibition Park. An annual event, the Canberra CareersXpo is conducted in conjunction with ACT Education. It seeks to provide valuable career guidance and advice on career opportunities available to secondary students throughout the ACT and surrounding NSW schools network. This CareersXpo is the largest event of its type in the region with over 100 local and national exhibitors. The feedback from attendees was overwhelmingly positive.

Australian Manufacturing Week.

INDO PACIFIC 2022.

Careers Day Out Expo.

Aboriginal Career Exploration Expo

2022 | Year in Review

WELDER TRAINING

PREMIER WELDER TRAINING Weld Australia is Australia’s premier welder training organisation. We understand the value of ongoing professional development and are committed to upskilling the next generation of welders. This year, we progressed with the MEM 2.0 Welder Learning Resources project, launched the new Welding Fundamentals course, made a range of improvements to our online exam system, and facilitated several tailored in-house training courses. All this and more was achieved while delivering our usual high quality calendar of training courses. New Welding Fundamentals Course Launched Weld Australia facilitated its first Welding Fundamentals courses early in the year. The course gives technical personnel working in the metal and manufacturing industry an overview of welding processes, defects, testing and qualification as required by Australian and International Standards. Weld Australia taught two intakes of the brand new course. The first session was open to the general public, and facilitated via six sessions over Zoom. The second session was run for BHP employees in Western Australia. The format was tailored specifically for

103 IWI-B Students

135

IWE Modules Taught

IWS Modules Taught 18

Weld Australia

BHP, with lessons taught over the course of three consecutive days. The feedback from students was overwhelmingly positive. Over 92% of attendees found the module on Weld Procedures and Documentation relevant, while over 82% of attendees found the module on Standards highly relevant. MEM 2.0 Learning Resources Weld Australia is making significant progress with the national Metals and Engineering online learning resources project. Weld Australia is working with TAFEs across the country through the National TAFE Consortium to create excellent online resources. According to Michael Pitt, (National

605 Modules Taught in Total

Manager Education and Training, Weld Australia), “We are creating a set of national resources mapped to the national MEM training package, so that learning resources for trade students are consistent across the country.” “This will help ensure consistent training, regardless of where in the country students undertake that training. The new resources are completely online and accessible via phone, mobile device or computer. This will allow students to access learning at the time, place and pace that suits them best. We are very excited about the project and are already seeing some great results.”

Weld Australia circulated the new learning resources to members of the National TAFE Consortium. The feedback was extremely positive. As a result, South Metropolitan TAFE in Fremantle, Western Australia is running an official pilot using the new units of competency and online resources. Once again, the feedback received from students and lecturers alike has been extremely positive. Weld Australia will continue working closely with TAFEs nationally on further development and uptake of the resources. In-House Training and Testing Weld Australia facilitated in-house training and welder testing for a whole host of companies in 2021. Joseph Sandor (Welding Technology Trainer, Weld Australia) lent a hand to TAFE NSW’s Deniliquin campus in February. TAFE NSW was having difficulty sourcing a Welding Inspector to test the students in their training course for AS 1796 Certification of welders and welding supervisors. Given Sandor’s extensive experience within the TAFE system, he was only too happy to oversee the exam.

242

Welding Fundamentals Students

Over two days in May, Weld Australia facilitated a Welding Fundamentals course for Schenck Process Australia. The course was tailored specifically for Schenck with a focus on critical clearance, heat affected zone and distortion. There were 20 students in attendance, all of whom were engineers. We delivered ISO 9606 ‘Train the Trainer’ training to teachers from both Federation TAFE and Corrections Victoria in Ballarat in June. The training encompassed multiple welding processes, as well as multiple Welding Procedure Specification (WPS). In September, Weld Australia facilitated in-house Welder Supervisor training for ASC in Perth, in line with AS 1796 Certificate 10 and AS 2214.

Improvements to the WeldQ Online Exam System Earlier this year, Weld Australia rolled out a major new feature for WeldQ, the online exam system. Students are now able to complete online written exams using a single platform.

Welding Supervisor Modules Taught

In February and March, Weld Australia delivered training for Monadelphous across their Gladstone and Singleton sites, covering both the IIW International Welding Inspector - Basic (IWI-B) qualification and the Welding Supervisor AS 2214 qualification.

The process has been streamlined as much as possible to ensure that students can focus on the task at hand— achieving the best possible exam result. With the new process, students will use the robust WeldQ platform, along with interactive QR Codes to complete their exams.

19 Courses

Weld Australia also launched a brand new phone app version of the WeldQ platform. The app is available for download via both the Android and iOS platforms. The app has made accessing the WeldQ platform—and all the vital information stored within the platform—even easier for welders and employers alike. It will be particularly handy for use on-site or in a workshop when a computer is not readily available.

2022 | Year in Review

Advanced Welder Training Centres

AN UPDATE FROM THE AWTCs Weld Australia has worked with partners around the country to secure State and Federal Government funding for the establishment of Advanced Welder Training Centres (AWTCs). Using the state-of-the-art Soldamatic augmented reality welding simulators, the training delivered at the AWTCs quickly qualifies welders to the only industry Standard in the world that is accepted in both Europe and America: ISO 9606-1 Qualification testing of welders – Fusion welding. This Standard is the minimum requirement for working on rolling stock, defence and infrastructure projects, which are crucial to onshore Australian manufacturing and a stronger national economy.

Advanced Manufacturing School Outreach Program In June 2020 NSW Department of Education and Training (DET) ordered 32 Augmented Reality Welding Simulators (ARWS) to be deployed on a pilot program in 16 schools. The schools ranged from the Wagga Wagga, Lake Illawarra and Dapto high schools in southern New South Wales, to the Gorokan and Kurri Kurri High Schools in the Lower Hunter region. During October and November 2020, Weld Australia commissioned the machines and conducted training for teaching staff. The first pilot commenced at the beginning of Term 1 in 2021. The simulators have been used to teach high school students studying subjects like Manufacturing and Engineering; and Industrial Technology (Metal).

Based on the success of the first pilot program, the NSW Department of Education ordered a further 22 simulators in late 2021 for another 12 high schools in regional areas including Cobar, Bourke, Broken Hill, Bathurst, Temora, West Wyalong, Shepherds Park and Junee.

QMI’s Women Who Weld Program Throughout the year, Weld Australia participated in the Queensland Manufacturing Institute’s (QMI) Women Who Weld Program. The program aims to increase gender diversity and participation in manufacturing careers.

In 2022, a further 28 simulators were ordered and commissioned, with Weld Australia delivering teacher training for 14 high schools in Bateman’s Bay, Camden Haven, Dubbo, Evans, Great Lakes College, Gunnedah, Heathcote, Nowra, Macksville, Morisett, Mount View, Muswellbrook, Vincentia and Whitebridge.

It provides the opportunities for female high school students in years 10, 11 and 12 to gain insight into trade skills and career pathways, including local employment opportunities. The program was facilitated at several high schools across Queensland.

To date, 82 welding simulators are installed at 40 high schools across New South Wales.

Training for Students at Central Queensland (CQ) University Weld Australia facilitated a training session for first year apprentices studying welding at Central

Queensland (CQ) University. During the session, students reviewed an ISO 9606-1 qualified procedure, looked for essential welding parameters, and then practiced welding within those parameters using a Soldamatic augmented reality welding simulator. Training at TAFE Queensland’s Nambour and Maryborough Campuses In January, Weld Australia helped with the training programs being facilitated by TAFE Queensland’s Maryborough and Nambour campuses for working apprentices. The training days included training to ISO 9606-1 using the Soldamatic augmented reality simulators as well as additional information on quality and safety when welding. Augmented and virtual reality training is enabling future welders to acquire the skills and the self-confidence they need before moving into real-world workshops. Augmented Reality Welder Training at Queensland Schools Throughout the year, Weld Australia facilitated augmented reality welding training in high schools across Queensland, including in Caboolture, Brisbane, and Yeppoon. Students had the opportunity to undertake augmented reality welding training in line with ISO 9606.1 Qualification testing of welders. After just a few hours of practice, students were achieving results required to achieve qualified welder status. Murrumbidgee High School STEM Program The Murrumbidgee Academy of STEM Excellence (MASE) was treated to a demonstration of their new Soldamatic augmented reality welding simulators from Joseph Sandor (Welding Technology Trainer, Weld Australia). Joe walked staff, students and even industry professionals Heath and Craig from A&G Engineering through the new technology. The group got to pitch their abilities against one another using the augmented reality welders’ scoring feature. The Queensland Minerals and Energy Academy’s Tradies for a Day Program During 2022, the Queensland Minerals and Energy Academy (QMEA), the education arm of the Queensland Resources Council (QRC), delivered its Tradies for a Day program. The program is a day of exciting, resources-related activities with a focus on science, technology, engineering and maths (STEM) as well as trade roles. Weld Australia assisted with several of the programs throughout the year, providing Soldamatic augmented reality welding simulators with pre-loaded exercises, all ready for students to try their hand at welding.

Teachers try their hand at the Soldamatics at Temora High School.

Weld Australia

Further Information For further information about Weld Australia’s training, contact training@weldaustralia.com.au

2022 AUGMENTED REALITY WELDING TO INDUSTRY STANDARDS PROGRAM Weld Australia facilitated the 2022 Augmented Reality Welding to Industry Standards Program at the Outsource Institute. International Advanced Diploma of Engineering students had the opportunity to upskill and add to their professional portfolios by undertaking augmented reality welding training in line with ISO 9606.1 Qualification testing of welders. The students were given an opportunity to learn about welding, including quality control, safety aspects and following welding procedures. After just a few hours of practice, the students were achieving results required to achieve qualified welder status. This demonstrates just how much augmented reality can accelerate the learning process for students.

2022 | Year in Review

INDUSTRY GROUPS

LINKING MEMBERS: WELD AUSTRALIA’S INDUSTRY GROUPS IN 2022 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 Meetings of the Power Generation Industry Group were held in the offices of CS Energy (Brisbane) over 22 and 23 June 2022. A huge vote of thanks to CS Energy who provided excellent facilities, catering and support for the IT systems required to manage the meetings and online attendees. The Power Generation Industry Group comprises: 1. Boiler Industry Group 2. PG9 Project 3. Process Safety Industry Group 4. Asset Integrity Board There were four meetings held over two days. The meetings covered a wide range of subject material with many highly detailed presentations. A summary of each of the meetings is outlined below.

Boiler Industry Group With 35 people in attendance, the meeting was opened by Geoff Crittenden (CEO, Weld Australia). Geoff provided an industry update, touching on the nation-wide shortage of skilled welders and the MEM2.0 Learning Resources that Weld Australia is developing in conjunction with TAFEs. Geoff also detailed the issues related to wind tower manufacture and the import of towers considered to be non-compliant with Australian Standards. Weld Australia is calling for local manufacture and compliance with Australian Standards. CS Energy gave a presentation on the boiler dry out and preservation procedures following the major turbine incident at the Callide C4 unit which occurred on 25 May 2021. This process was subjected to a wide range of conditions, issues and constraints arising from the turbine incident which required actions well beyond normal operating conditions and requirements.

Photo: Power Generation Industry Group meeting attendees.

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CS Energy also provided an overview of a failure in a reheater cross over tube at Kogan Creek Power Station. The root cause was found to be excessive weld root concavity on one of the connecting welds. These welds were undertaken at the time of manufacture through a robotic welding process. The implication was that all welds would have the same fault. Energy Australia gave a presentation on layup practices for wet and dry storage of boilers. These practices had been developed at the Mt Piper Power Station covering a number of plant requirements, scenarios and layup durations. Les Sabo (Managing Director, Uneek Bending) provided an overview of Uneek Bending, which specialises in the bending of tubes and other types of steel. Les also discussed the Acoustic Gas Temperature Measurement System (AGAM) which has been developed by Germanbased Bonnenberg & Drescher. This system uses an array of acoustic transmitters and microphones to measure time differences between sending and receiving and so accurately determine the temperature of flue gases. This is particularly applicable to boiler flue gas exit ducts. Wayne Hill (Principal Engineer Boilers and Pressure Parts, EnergyAustralia) spoke about an investigation into post outage boiler tube leaks after major unit outages. One possible scenario was debris which can accumulate in boiler tubes and orifice plates leading to flow starvation and tube failure. This led to a discussion on the use of rice paper during boiler tube weld repairs and the need to

use the correct type of paper for draft reduction during weld repairs. HRL is currently working on a project to review flexible operations for Power Generation Industry Group member power stations. This mode of operation is extremely important, particularly as the industry is transitioning towards net zero carbon by 2050 and phasing out coal fired power stations. HRL’s presentation focused on how a process for flexible operations may be implemented. The meeting concluded with a discussion of current issues and future directions over the next five to 10 years. The discussion focused on the current market and transition towards the closure of coal fired power stations. PG9 Project The Power Generation Number 9 Project (PG-9) is being conducted within the Boiler Industry Group. The objective of the project is to develop a database of certified weld procedures which will then be accessible by the project members. The project is funded and managed by the members. The database is currently well developed and populated. The logistics for access and procedures for future qualifications and certifications are issues being addressed. PG-9 project members conducted a progress meeting. Weld Australia has engaged a specialist welding engineer Louise Petrick to work on the PG9 project. Louise brings a depth of knowledge and experience to the PG9 project which is most welcome. Louise will now focus on reviewing progress to date and carrying out weld procedure testing, certifications and qualifications and bring the project to completion. Process Safety Industry Group With over 30 people in attendance, Geoff Crittenden opened the meeting. This was followed by an open discussion around baseline audits. A number of issues were raised, from skills shortages, process safety, welder

certifications, chartered engineers, and the need for process safety to be accompanied by cultural change. Wade Underhill (CS Energy) gave an update on the progress of implementing process safety at CS Energy. A rigorous program of training is being undertaken across the entire CS Energy organisation, including a separate training package aimed at company leaders. While establishing the systems is easy, the implementation of training and cultural change is hard. Ryan James (Director, OXT Group) spoke on the topic of risk assessment, focused on improved performance monitoring, and risk control within a commercial environment. Ryan emphasised that process safety cannot succeed without leadership, or cultural change. Ian Rawlings (Chief Mechanical Engineer, CS Energy) gave a presentation on a near miss incident that occurred on the Callide B2 precipitator inlet duct. Operational conditions caused the dust loading in the duct to accumulate and overload one of the duct supports. The duct did not suffer a failure of the support but was considered to be a near miss. There were many learnings from this incident, including: • Gas velocities in ducts • Throttling of outlet dampers • Maintenance of precipitators • Process safety risks to be fully assessed in conjunction with health and safety risks Industry Group members then discussed general safety incidents and learnings. The first incident was an issue with a vertical 9m duct that ran from the top of a boiler to an air heater. A crack had developed in the duct, and an expansion joint was found to be locked up due to a build up of ash. In addition, constant load hangers were found to be out of adjustment. A major failure could have occurred if the crack had developed. The next incident raised was the discovery of asbestos-looking material around some thermocouples during

2022 | Year in Review

INDUSTRY GROUPS boiler maintenance. The asbestos register indicated that asbestos had been removed in the area, but did not detail the particular level and location of where the asbestos had been removed. The key takeaway from this incident was that staff need to be trained to be aware of asbestos. An issue which occurred with the controls on some newly installed tanks was then reviewed. There was a mismatch on the valve identification on the vessels. Testing was carried out on components only and the mismatch was not identified. This underscored the importance of thorough testing of all aspects of tanks. The TransGrid Tallawarra switchyard transformer failure and resultant fire was raised as a prime example of a catastrophic failure.

DEFENCE INDUSTRY NETWORK During the COVID the Weld Australia Defence Industry Network experienced a hiatus. Weld Australia is now in the process of restoring and reinvigorating the Defence Industry Network.

Monorails, cranes and lifting equipment are often over looked, but need ongoing maintenance and certification. A near miss was discussed which emphasised the need for ongoing maintenance and certification.

operations. The transition from coal fired plants to renewable energy is a massive issue and will not happen overnight. It will also require massive resources to complete and specialist knowledge in areas like BESS, pumped storage, wind and hydrogen.

Finally, the Process Safety Good Practice Guide is nearing completion but requires final editing. This is to be undertaken by a smaller committee and presented at the next meeting.

All members agreed that mentoring and skills development were of the utmost importance. A range of other issues was discussed, from skills shortages, aging plant, failure modes, and the use of non-destructive testing.

Asset Integrity Board The role of the Asset Integrity Board is to discuss the high-level strategic directions for the Power Generation Industry Group. Members discussed high level issues affecting each of the companies, with a focus on flexible and low load

• •

Standards, and certification and accreditation to Australian Standards. Australian local manufacture and equal opportunity. Advocacy to Government.

The Defence Industry Network will focus on companies who are either already operating in the defence industry, or have ambitions of joining. Our aim is to ensure that contractual commitments to Australian Industry Content and Indigenous Participation are honoured.

Earlier this year, Weld Australia announced that it signed a Memorandum of Understanding (MoU) with the Australian Industry and Defence Network (AIDN). Weld Australia and AIDN will cooperate and collaborate on matters related to their members and will engage in joint events.

The Defence will also focus on: • Contracting issues and the supply chain issues. • Compliance with Australian

Membership of the Weld Australia Defence Industry Network will be free of charge for all Weld Australia Premium Corporate Members.

Weld Australia

The next meeting of the Asset Integrity Board will be held on 23 November online. The next meetings of the Boiler Industry Group and Process Safety Industry Group will be held on 30 November and 1 December 2022 in Melbourne.

Just some of the benefits include: networking with others in the defence industry, addressing technical and welding issues, discussing supply chain issues and solutions and accessing Weld Australia training, resources and specialist personnel. Weld Australia will organise and facilitate all meetings, with agendas and areas of interest driven by members. Areas of Proprietary or Confidential Information will be recognised and appropriately managed by all participants. Further Information For details, contact: Andrew Davies (Manager Technical Industry Networks) on 0438 428 966 or a.davies@weldaustralia.com.au

WELDING SAFETY COUNCIL The Welding Safety Council (WSC) met on 4 May 2022. Membership of the WSC includes safety regulators from around Australia, suppliers to the welding industry and the Australian Institute of Occupational Hygienists (AIOH). Bruce Cannon (Principal Welding Engineer, Weld Australia) provided an update from the International Institute of Welding. In particular there was some concern regarding the importation of a new form of handheld laser welding machine. These are potentially available to the public and may pose significant safety issues to untrained users. Weld Australia will review further and will also review standards and regulations in relation to the use of such lasers. Bruce also provided a presentation on some of the dangers associated with voltage controls on some DC welding machines. There are some machines where the DC output has fluctuating ripple in the voltage which may act as alternating current and give rise to a safety issue with users. Bruce will prepare a briefing paper on this issue.

WELD AUSTRALIA WELCOMES NEW INDUSTRY GROUPS MANAGER Andrew Davies joined Weld Australia in February 2022 as Manager, Technical Industry Networks. Andrew boasts over 40 years of in-depth engineering and asset management experience across a number of power stations in New South Wales, including coal fired, gas turbines and hydro plant. Andrew will manage our Industry Groups, facilitating meetings and networking. This role was previously carried out by Alistair Forbes who has now retired. We wish Alistair all the best in retirement and thank him for all his work with the Industry Groups.

An update was also provided on the AIOH conference held in March 2022. In particular the issue of the health effects of welding fumes was discussed.

electrical work. The study did identify some actions (vibration and extended work rotations) which appear to be potentially modifiable factors of some importance.

A paper on women’s health in the welding and electrical trades was presented. The study revealed no marked difference between the welding and electrical trades. There was no significant increase in fetal loss in welding trades compared to

A report of an electrical shock during welding was discussed. While the nature of the electric shock was low level, it had the potential to be higher and more serious. The next meeting of the WSC will be held in late 2022.

THE BENEFITS OF INDUSTRY GROUP MEMBERSHIP • • • • • • • • • • •

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

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2022 | Year in Review

AUSTRALIAN STANDARDS

UPDATES TO AUSTRALIAN STANDARDS IN 2022

requirements of the standard with the latest revision of AS 4100 Steel structures and the New Zealand steel structures design standard NZS 3404.1. The revision will resolve known conflicts and anomalies via an amendment.

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

ISO Update ISO TC44/SC10 has commenced the revision of ISO 3834 Quality requirements for fusion welding of metallic materials series of standards primarily to take cognisance of changes to ISO 9001 Quality management systems — Requirements and the 2019 edition of ISO 14731 Welding coordination — Tasks and responsibilities. Parts 1 to 5 inclusive have been published and a project request has been submitted to Standards Australia to adopt the latest revisions.

Pressure Equipment Committee ME-001 completed a revision of AS 1796 Certification of welders and welding supervisors, and it was published on 24 June 2022. As previously reported, users have reported a number of issues with the revised AS 3992 Pressure equipment—Welding and brazing qualification (published in June 2020), and amendments have been prepared to address the issues raised. Public comment has been resolved and the amendment is being prepared for ballot.

ISO-based welding consumable standards. Projects have been initiated to revise the GMAW and FCAW suite of standards, including a proposal to supersede AS 4882 Shielding gases for welding with ISO 14175 Welding consumables — Gases and gas mixtures for fusion welding and allied processes.

The revision of AS/NZS 3788 Pressure equipment—In-service inspection is progressing. The initial draft has been completed and submitted for preparation for public review. Public review is likely to commence in the first quarter of 2023.

A project was also initiated to adopt the GTAW consumable standard ISO 636 Welding consumables — Rods, wires and deposits for tungsten inert gas welding of non-alloy and fine-grain steels — Classification to complete the GTAW suite of standards. The intention is to supplement and retain the existing AS/NZS 1167.2 Welding and brazing — Filler metals Part 2: Filler metals for welding. Public comment on all adoptions and revisions is complete and they were published in October.

Welding Consumables Committee WD-002 met in March 2022 to review Australia’s suite of

Welding Safety A proposal has been submitted and accepted by Standards Australia to

revise AS1674.1 Safety in Welding and allied processes—Part 1 Fire precautions. The standard is used extensively in industry to establish fire preventative measures whilst welding in locations not necessarily designed for hot work. The project is intended to clarify what is meant by the term ‘hot work’ and include provisions to assist small business and sole traders. A drafting committee is currently being constituted by Standards Australia and kick-off is anticipated in January. Associated with this project is a proposal to update AS 2812 Welding, brazing and cutting of metals — Glossary of terms. Kick-off meetings for both projects are currently in the early planning stage. This project will commence in December. Bridges The revision of AS/NZS 5100.6 Bridge design — Part 6: Steels and composite construction is well advanced. The revision will align the

Weld Australia Releases Updated Technical and Guidance Notes in 2022 Several of Weld Australia’s Technical Notes and Technical Guidance Notes were updated this year, as noted below. All our Guidance Notes are available via the website, free of charge for Weld Australia members. TGN-SG09: Inspection and Test Plans Published in 2022, this Technical Guidance Note is a guide to the writing and use of Inspection and Test Plans (ITP’s) typically utilised throughout the welding and construction industry. Originally developed for use with AS/NZS ISO 9001 quality management systems, these documents are also specified for use in AS/NZS 5131, and may be useful in the production planning and application of inspection and testing requirements of AS/NZS ISO 3834.

These ISO Standards are currently open for public review for adoption as AS/NZS ISO Standards. Part 6 of ISO 3834 is being revised by ISO to become an ISO Standard in lieu of a technical report and it is currently at the DIS ballot stage. Consideration for adoption in Australia will commence after finalisation by ISO.

TGN-SW04: Welding Safety - Audit Checklist Published in 2022, this Technical Guidance Note assists users to identify hazards associated with welding and its allied processes. It draws upon the recommendations of a range of Weld Australia’s Technical Notes and Technical Guidance Notes and is presented in the format of a selfaudit form. It may be particularly useful when identifying hazards associated with welding and related activities, and where additional control measures may be required.

TC44/SC10 has also been revising ISO 17660 Welding—Welding of reinforcing steel. This edition is planned to combine the two existing parts into a single document. A DIS ballot has been held and comments are currently under review. Due to the large number of technical changes within, a second DIS review and ballot will need to be held.

TGN-PG03: Control of Distortion in Welded Structures This Technical Guidance Note is a revision of Weld Australia’s Technical Guidance Notes on distortion control, originally published by the Welding Technology Institute of Australia (WTIA). It is designed to assist the fabricator in the production of welded structures with minimal distortion, and where distortion occurs, provides guidance on distortion correction techniques.

Similarly, ISO TC44/SC11 has been revising ISO 9606-1 Qualification testing of welders— Fusion welding— Part 1: Steels to combine all 5 parts into the one standard. This will simplify the ongoing maintenance and review requirements for the standards currently published as parts 2 to 5 of ISO 9606-1.

TGN-PG02: Minimisation of Fatigue in Welds Published in 2022, this Technical Guidance Note is a revision of Weld Australia’s various Technical Guidance Notes on fatigue improvements of welds including the dressing of welds to minimise fatigue, originally published by the WTIA. This guide is designed to assist the fabricator in the enhancement of weld bead shape when conformance with AS/NZS 1554’s Category FP and fatigue improvement methods have been specified. TN-18: Welding of Castings This Technical Note is a revision of the 1987 edition, with changes made primarily to updated health and safety requirements and references to standards. Importantly, references to welding consumables have been updated consistent with current recommendations and designations. This Technical Note is designed to give practical guidance together with some background information on the welding of various castings. It is intended to assist all involved in the welding repair and fabrication of castings in the foundry, maintenance and fabrication shop.

Weld Australia

2022 | Year in Review

COMPANY CERTIFICATIONS

COMPANY CERTIFICATIONS IN 2022 Weld Australia would like to congratulate all the companies that were awarded certification in 2022, including: • 12 new companies certified to AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials, bringing the total to 75 companies • 6 new companies certified to EN 15085 Railway applications – Welding of railway vehicles, bringing the total up to 13 companies • 6 new companies certified to DIN 2303 Welding and allied processes - Quality requirements to be met by production and maintenance companies for military products, bringing the total up to 8 companies

Photos Left: Members of the All Industries Group team. Image courtesy of All Industries Group. Right: Members of the JRS Manufacturing team. Image courtesy of JRS Manufacturing Group

Certification demonstrates a company’s ability to deliver a compliantly welded product, on time and on budget. Certification increases your potential to enter international markets with a competitive edge and improves the likelihood of repeat business.

All Industries Group All Industries Group is an innovative, multi-disciplinary design, engineering and fabrication specialist. Based in Yeppoon, Queensland, the company delivers turnkey solutions for local, national and international clients. All Industries Group is focused on delivering the best quality, price and speed for all their clients. Their team has extensive tooling capabilities to produce full in house manufacturing for specialised products across a range of sectors: underground, open cut, construction, and mobile plant and rollover and falling object protective systems. For further information, visit: allindustries.com.au Australian General Engineering A market leader in metal fabrication services, Australian General Engineering (AGE) provides full product and development services from concept to final product. With facilities in both Melbourne and Vietnam, AGE offers CNC laser cutting, CNC turret punching, CNC brake pressing and folding, other cutting services, height access equipment, and mechanical and electrical enclosures for applications in heavy vehicles, automotive, shop-fittings, rail infrastructure and agricultural and farming. For further information, visit: austgen.com.au

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DVR Engineering DVR Engineering provides manufacturing solutions for a range of clients across the defence, telecommunications, rail, aerospace, mining and marine sectors. The company operates in 30,000m2 over two manufacturing facilities, with more than 95 staff operating advanced manufacturing equipment for end-to-end solutions. With over 33 years of precision metal engineering experience, DVR boasts the latest CNC machining, laser and plasma cutting and machining technology. For further information, visit: dvrengineering.com.au Hofman Engineering (Bassendean) Established in 1969, Hofman Engineering has long been an industry leader in specialist engineering. With a dedicated research and development team, Hofman promises an innovative approach to meeting their customers’ needs and continued improvement of their technology. Hofman services industries such as mining, defence, transport, manufacturing and agriculture on a global scale with facilities in Australia, Chile, Peru, North America, India and China. For further information, visit: hofmannengineering.com

JRS Manufacturing Group JRS Manufacturing Group is a Toowoomba-based steel fabrication and welding company that specialises in fabrication consultation and construction of plate, pipe and structural steel products for clients in the civil, energy, mining, agricultural, oil and gas industries. Established in 2014 with a small team of five people, JRS rapidly expanded to workforce of over 50 people offering pressure pipe fabrication and welding, abrasive blasting and coating, medium to heavy plate fabrication, specialised surface treatments, CNC and general machining and assembly. For further information, visit: jrsmanufacturinggroup.com.au

Knox Engineering Founded in 1948, Knox Engineering specialises in metal forming, welding and general engineering. Based in Ingleburn in Western Sydney, but serving all regions of Australia, the Knox Engineering team and factory are equipped to handle both large and small projects. They provide expertise in steel and aluminium fabrication, repair welding and straightening, sheet metal fabrication, pulsed and pressure welding, metal piercing and cutting and general engineering. With a reputation for quality and reliability built over more than 60 years, Knox Engineering is one of Sydney’s premier metal fabricators. For further information, visit: knoxeng.com

K&S Metal Fabrication A family operated business, K&S Metal Fabrication boasts over 20 years of experience in metal fabrication across the industrial, commercial and residential sectors. Based in Smithfield, New South Wales, the company assists architects, builders and interior decorators in bringing their ideas to life with bespoke and custom work. Their services include welding, cutting, drilling, turning, hole punching and CNC plasma cutting. For further information, visit: kandsmetalfabrication.com.au

Marand Founded in Melbourne in 1969, Marand is a global supplier of precision engineered solutions to a range of industries, including aerospace, defence, rail, automotive, mining and energy. Offering total manufacturing solutions to their clients, Marand’s services include project management, design, manufacture, installation, commissioning, maintenance and support for all of their supplied precision machinery and products. Marand boasts facilities in Victoria, South Australia, Western Australia and the UK. For further information, visit: marand.com.au

Milspec Manufacturing For over 40 years Milspec has worked hard to become the premier designer and manufacturer of brushless alternators and portable power systems for defence forces across the world. Operating in a global market that demands precision, reliability, and low costs, Milspec has established themselves as the contract manufacturer of choice for defence and industry. Today, Milspec has grown into a successful privately owned Australian business, designing, integrating and manufacturing products and subsystems for multiple industries. For further information, visit: milspecmanufacturing.com

Rockpress Rockpress has been in business since 1972. In the 50 years since then, the company has grown to become one of Brisbane’s most highly-regarded steel fabrication suppliers. While Rockpress can supply ‘off the shelf’ materials in steel and other metals, their real expertise is in manufacturing and fabricating custom-made work, either for one-off projects or in quantities for high volume demand. Rockpress boasts more than 12,000m2 under roof floor space. All of these capabilities mean Rockpress is more than capable of handling work of any size or volume. For further information, visit: rockpress.com.au

Precision Metal Group Established in 2000 in Western Sydney, Precision Metal Group (PMG) specialises in mechanical engineering services and welding. As the business has evolved, PMG has developed its capabilities and achieved significant certifications, including AS/NZS ISO 3834, DIN 2303, and EN 15085. Working across sectors such as defence, infrastructure, construction, oil and gas, rail, mining and manufacturing, PMG is involved in high-profile projects like Rheinmetall’s Boxer Land 400 parts and seats for major rail supplier Probatec. For further information, visit: precisionmetalgroup.com

RUD Australia RUD Australia manufactures and supplies high-quality round steel link chain solutions and lifting technologies. They work with clients in the defence, infrastructure, mining, quarry, power station and engineering industries plus many more. Their collaborative approach makes RUD a partner of choice for organisations who value quality. All of their products are rigorously tested and assessed against strict quality-control measures. RUD complements these high quality products with dedicated technical support and training services. For further information, visit: rud.com.au 2022 | Year in Review

FEATURE STORY Shadbolt Group Since 1981, Shadbolt Group has provided cost-effective engineering solutions throughout Australia. They are involved in pipework projects, tank manufacturing, structural works, machine building, site work and more. Shadbolt Group is committed to delivering a high level of expertise and delivering genuine value for money on every project. They provide fabrication services for mild steel, stainless steel, copper-nickel and aluminium to various industries including defence, mining, transport, construction, energy and more. For further information, visit: shadbolt.com.au SP McLean Based in Bayswater, Melbourne, SP McLean manufactures high-quality stainless steel and carbon steel filtration solutions. They service a variety of industries across Australia, including fuel and aviation filtration, pressure vessels, architectural and general metal fabrication, and rolling stock components. SP McLean also designs and manufactures bespoke components to support their filter equipment. Established in 1999 as a

small family business, the company now has an impressive team of design engineers, project managers, welderboilermakers and more. For further information, visit: spmclean.com.au Thales Australia Thales Australia is a trusted partner of the Australian Defence Force and is also present in commercial sectors ranging from air traffic management and ground transport systems to security systems and services. With 35 sites across the country, Thales Australia employs around 3,800 people directly and supports over 2,000 jobs along its Australian supply chain. Thales Australia has a history of patient investment to build advanced in-country capability across manufacturing, critical systems and services. For further information, visit: thalesgroup.com TWK Steel Steel fabrication specialists, TWK Steel services large scale civil and infrastructure projects across the country. TWK Steel specialises in architectural steel, specialised formwork systems, temporary and

structural steelwork, aluminium, Corten weathered steel, and civil, marine and rail construction. Combining innovation with exceptional quality products, TWK Steel has over a decade of experience and a capacity of over 10,000 tons per annum. TWK Steel is also a stockist of Nippon Steel sheet pile, manufactured in Japan. For further information, visit: twksteel.com.au Uneek Bending Co Based in Dandenong, Melbourne, Uneek provides state of the art engineering solutions in the design, manufacture and application of complex metal bending, rolling and welding throughout Australia. Through extensive research and development, Uneek’s team of engineers, designers and researchers have built impressive structures that push the limits of engineering to incredible lengths. Since 1964, Uneek has established themselves as Australia’s leading bending, rolling and welding engineering company. For further information, visit: uneek.com.au

Weld Australia’s Certification Services Weld Australia is Australia’s premier welding certification body. We understand the value of ongoing professional and business development and are committed to upskilling the next generation of welders and safeguarding the future of local welding businesses. Our comprehensive range of certification services are designed to help Australian welders, fabrication and manufacturing companies and the industrial sector at large achieve and maintain a competitive advantage. As the International Institute of Welding (IIW) Authorised National Body (ANB) and the Authorised Training Body (ATB), we are able to provide internationally recognised qualifications and certifications, to the following Standards: • AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials • EN 15085 Railway applications – Welding of railway vehicles • DIN 2303 Welding and allied processes - Quality requirements to be met by production and maintenance companies for military products A RUD Australia team member hard at work.

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Contact engineering@weldaustralia.com.au for details.

2022 | Year in Review

MEMBER TESTIMONIALS

WHAT WELD AUSTRALIA MEMBERS AND PARTNERS HAVE TO SAY Weld Australia’s members and partners are made up of individual welding professionals, as well as companies of all sizes. In fact, Weld Australia members are involved in almost every facet of Australian industry and make a significant contribution to the nation’s economy. We recently spoke with a number of our members and partners, eliciting their feedback on our activities, services and membership benefits.

Chris Ross (Asset Integrity Specialist, CS Energy) “CS Energy has been corporate members of Weld Australia for some time now—already being a member when I started in my current role as Asset Integrity Specialist two years ago. The company was already a part of Weld Australia’s Power Generation Group, which is made up of power station operators and maintainers from around Australia. This includes sub-groups for different focuses such as Process Safety, Asset Integrity and PG9 (welding).” “These Groups bring everyone together from similar areas of the industry and provide a really good learning and sharing platform for the industry, and are one of the main reasons for CS Energy’s membership. The networking opportunities are great and allow us to reach out for advice or connect with engineering services that may be presenting during the meetings. For example, the PG9 group specifically is great for developing, qualifying and sharing weld procedures amongst the members.” “Weld Australia is also a great body to bounce questions off—they have a team of experts on-hand who are easily contactable and very helpful.” “Personally, I am finding the career

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development services that Weld Australia offer to be great and provide a clear pathway. There are a lot of courses available that I’m interested in, particularly in the welding coordination and inspection space.” “Weld Australia has been really positive and accommodating throughout all the study I’ve done with them so far. Recently, I’ve completed the International Welding Inspector - Basic course through Weld Australia. I found it a really positive, flexible experience. I was able to do most of the study online from home, with just the practical and exam done on-site. All the course content was very relevant, and the lecturer Cornelis was very knowledgeable.” “Australia is transitioning into the renewable energy era. With that comes a lot of new projects, which require a highly skilled workforce. I think Weld Australia is leading the way in terms of upskilling the next generation in the welding industry. Their programs with the welding simulators, and partnerships with the TAFEs and schools are playing a big role in securing the skills needed for Australia’s renewable energy transition. This will go a long way to having a quality workforce and keeping jobs in Australia.”

Mathew Billman (Quality Manager, UNEEK) “Uneek joined Weld Australia because they are the peak industry body—they are the number one go to for welding.” “We recently undertook a range of certifications with Weld Australia, including AS/NZS ISO 3834 Quality requirements for fusion welding of metallic materials, EN 15085 Railway applications — Welding of railway vehicles and components, and DIN 2303 Welding and allied processes - Quality requirements to be met by production and maintenance companies for military products.” “I had actually worked with Weld Australia in my previous role for certification to AS/NZS ISO 3834. The whole experience was trouble free. I had such a good experience with the certification process the first time, I enlisted the help of Weld Australia again.” “The auditor, Victor Blain, was very professional, easy to work with, and had great knowledge on the subject. He was able to provide meaningful feedback on improvements in the business. The whole auditing process was a pleasure, right from the beginning. The entire team is very responsive and always happy to help.” “Weld Australia also benefits the welding industry as a whole. Weld Australia, and their CEO Geoff Crittenden, are pushing the importance of Australian content and skills in welding. We are operating in an industry where the go to is always offshoring, from places like India and China. It is impossible to compete on price with product from these countries. What Geoff is doing— making it known how important local content is for major projects—is good for all Australian businesses.”

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

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2022 | Year in Review

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Year in Review 2022

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