News for Xlerplate® steel customers ISSUE 13 | SUMMER 2008

SPECIAL FEATURE Fabrication: industry perspective

SPECIAL FEATURES Case Studies Regular Features In this issue Understanding steel plate - part two Abbot Point Coal Terminal Sales team contacts Fabrication - state of the industry perspective United Group Resources delivers for BP Quiz Latest news around the country Well, things have certainly The extremely high demand has now customers. We especially pride ourselves changed since we brought eased and we are back to a position in the expertise we put into products you the last edition of where our delivery performance is at the like XLERPLATE® steel and the technical XLERPLATE® Steel in Touch. high levels our customers are familiar service we deliver to our customers. It just goes to show that there with. As you can see, we have put extra effort is rarely a dull moment in Whilst many of us in the industry will into this bumper edition of Steel in Touch, this industry be feeling the effects of dynamic global which is packed with useful information of ours. economic conditions, it pays to remember and insight. Looking to the future, Only a couple that the economy, like the steel industry the new XLERPLATE® website will be of months ago itself, is cyclical. BlueScope Steel aims to launched early next year and we hope you we were in a be competitive and responsive to changes also find that to be a useful business tool. situation where in market conditions throughout the From all of us at BlueScope, we wish you unprecedented business cycle. a safe and happy festive season. demand for We’re up to the challenge, as I am sure XLERPLATE® you are too. steel was putting pressure on our The tough economic environment really supply capabilities, reminds us of what is at the heart of Bernie Landy notwithstanding BlueScope’s value proposition: our General Manager Industrial Markets we were producing at quality, Australian-made product and BlueScope Steel record levels. the high level of service we offer our [email protected] Worldwide governments respond to financial crisis

BlueScope economist Nick Scavarelli scheme totalling up to US$700bn has been Emerging economies provides an overview of the current announced which aims to stabilise the global The emerging world economies are also global financial situation and actions banking system. Another direct action has taking actions to limit the fall out of the global being taken to cushion negative impacts. seen America’s Federal Reserve cut its policy financial crisis. Russia is spending US$220bn interest rate by a further half point to 1%, Governments and central banks around the to shore up its financial system. South Korea on 29 October. world are searching for solutions to the has guaranteed US$100bn of its banks’ debt. global financial crisis, as it is now translating The expectation that the EU economy could The IMF has unveiled a new emergency into significantly slower economic activity maintain growth in times when the US lending programme that will get money to across most regions. Falling equity markets, economy was slowing has proven optimistic, well-run countries quickly and with almost no tighter credit and declining confidence have as the EU economy is now in recession. conditions attached if they are hit by financial left companies and consumers either unable Several Eurozone economies suffered volatility. The new liquidity facility is the or unwilling to spend and invest. As a result, contraction in the third quarter, with culmination of a decade of attempts at the there has been a combined global effort from Germany and Italy entering recession. IMF, after the Asian financial crisis of 1997/98, policy makers to simulate their economies to Governments in this region are taking to come up with a way of protecting emerging prevent a long period of recession. Australia’s measures to minimise the downturn, with markets from financial problems. Federal Government is no exception. the Bank of England recently lowering interest rates by 150 basis points, which China intends to inject US$586bn to avert The US economy is most likely already in was three times greater than most economic a more serious slowdown in its economy. recession, or likely to fall into recession in commentators expected. In addition, on 26 November, the People’s the near future. The question is how long Bank of China (PBC) slashed interest rates and deep the recession will be. The US Further, on 24 November, the UK government to around 5.5 per cent and further lowered authorities have taken drastic measures to introduced a stimulus package which totals banks’ reserve requirements. The governor stabilise their financial markets following the around US$30bn, or one per cent of annual of the PBC has also indicated that the bank collapse of Lehman Brothers and subsequent GDP over the next 12 months. will “actively work” with the International freeze in financial assets. A massive bailout Monetary Fund to develop a plan to stabilise

2 Increased investment in infrastructure projects is one of the Australian Government’s preferred measures to achieve a boost in economic activity

IMAGE HERE

Nick Scavarelli volatile financial markets. The governor to stabilise the domestic financial system, findings by the end of December this year. expects the Chinese economy to expand the Federal Government has also agreed to The domestic steel industry is likely to between 8% and 9% in 2009. guarantee savings deposits up to A$1m, as experience positive spin-offs from the well as loans used by Australian banks to Government’s desire to speed up the public Australian fiscal action raise capital on wholesale funding markets. It investment drive, which is designed to assist in In recent weeks, the Australian Government has also followed the US lead and decided to both city and regional areas. and Reserve Bank of Australia have also acted allocate A$8bn to purchase mortgage-backed swiftly to avoid a significant downturn in the securities in a bid to boost liquidity. Article written November 2008 domestic economy. The emergency action The Reserve Bank of Australia has also acted includes lower interest rates and a boost in by slashing its benchmark interest rate by 75 Nick Scavarelli is a senior economist public sector investment. basis points to 5.25 per cent, the third cut since with BlueScope Steel. His economic The Federal Government has announced a September when the cash rate was 7.25 per analysis and advice is utilised by A$10.4bn stimulus package designed to boost cent. In making the cut, the Reserve Bank cited divisions such as BlueScope’s spending and confidence, including changes reduced Chinese growth and lower commodity Industrial Markets. This is the to the first Homeowners Grant, pension prices as key factors. division that produces XLERPLATE® reform and support payments for low and hot rolled plate steel, manufactured middle income families, bringing forward Infrastructure and steel to tolerances that conform to infrastructure projects and creating additional As part of the government’s plan to boost Australian Standards and ISO 9001 training places to support employment. It infrastructure projects, it is working closely International Quality Standards. has also indicated it will instigate a massive with the states to speed up the federal audit injection of A$6bn to the automotive industry of the country’s infrastructure requirements. to ensure its long-term survival. In an effort Infrastructure Australia will present its audit

FRONT COVER Global Benchmark Interest Rates - % 10 The seven metre high XLERPLATE® US (Federal Reserve) Australia (Reserve Bank of Australia) Steel ‘trees’ which are a feature 8 Europe (European Central Bank) of Dogwood Crossing at Miles, China (People's Bank of China) are a talking point for users of the unique regional centre which 6 serves as a library, art gallery, social history museum and IT centre for 4 Queensland’s Murilla Shire Council. ■■ The trees, fabricated by Allied 2 Welding in Toowoomba are an appropriate scene setter for the 0 regional design and craft exhibition Jan-00 Jan-01 Jan-02 Jan-03 Jan-04 Jan-05 Jan-06 Jan-07 Jan-08 the venue is currently hosting.

3 XLERPLATE® steel case study

Fabrication of the headstocks for the Abbot Point extension project required ongoing attention to quality control Port extension boosts Queensland’s coal export capability

Overview PCQ has commissioned a major expansion of management, co-ordinating a team of 300 Ports Corporation of Queensland (PCQ) is Abbot Point to ensure that Queensland’s $16 people on site over what will be an 18-month using over 8,000 tonnes of XLERPLATE® steel billion coal export industry can meet future construction period. The team will be building in a major expansion of its Abbot Point Coal demand. Global demand for coal is growing at on the existing jetty to create a new wharf Terminal. XLERPLATE® steel will be used in the a phenomenal rate. Predictions for growth in and a new ship loader. The construction will construction of a new wharf and ship loader, demand for Queensland coal range between amount to a duplication of the existing facility including piling, headstocks and rail track. 5% and 13% per annum through to 2009/10, and is expected to use between 8,000-11,000 ® The extension will enable the port to increase fed by industrial growth in China and India. tonnes of XLERPLATE steel. coal export capacity from 25 to 50 millions With miners contracting to export increasing RPG is responsible for fabrication of the tonnes per year. quantities of coal, PCQ is acting to ensure that piling, which will be used to support the new Abbot Point is able to cater for the demand. wharf. The piling varies in length between 49 Background Upgrading the port’s export infrastructure will and 57 metres, meaning that each one must Ports Corporation of Queensland is responsible boost export capacity by 50% from the current be created in three sections or ‘cans’. These for the development and management of sea 25 million tonnes per annum. cans are created using 16mm Grade 350 port facilities which are vital to the export XLERPLATE® steel which is cut to size, rolled performance of Queensland. One of the ports Project to a 1,200mm diameter and then moved onto it manages is Abbot Point, situated about 25 John Holland’s SMP business, RPG Australia rotators for welding. kilometres north of Bowen. Abbot Point is of and BlueScope Steel are working in alliance “The sections are welded by submerged arc significant strategic value as one of the few for the Abbot Point expansion. John Holland, process,” explains Matthew Stewart, General sites along Queensland’s seaboard where deep which specialises in the expansion of Manager – Pipe Division, RPG Australia. water is close in-shore. marine facilities, is responsible for project

4 ”This means they can be welded internally ships ‘bounce’ against when they dock.” Holland will face problems when constructing and externally, eliminating double handling. the piles on site. It is this commitment to When it comes to the welding process, We consider sub-arc to be the most efficient thinking through the project as a whole that has John Holland uses the same submerged arc technique for this type of job, bearing in mind fostered an effective working relationship.” approach as RPG. Unlike manual welding the structural purpose and the thickness of processes, this is an automated method which the steel.” Steel-specific focus offers a high deposition rate and a lot of weld “This project impacts the export capability of RPG also ensures at the end of the pile pool. Practically, this means that the team the whole state and, as such, it is fundamental there is a 25mm thick diving shoe welded can complete the weld in a single flow rather that construction runs to schedule,” said Alban on with a bevelled edge. The bevelled edge than going over it numerous times, making the Manning. “A key factor in using XLERPLATE® provides a cutting tool which allows the pile process far more efficient. steel was BlueScope’s inherent reliability. With to slice through marine rock more easily. The BlueScope supplying local steel, the product surface finish of the pilings is also critical – Working together arrived quickly. This has contributed to a they need to be painted to resist corrosion in One of the biggest challenges in a project of speedy construction process.” a salt-water environment. this scale, is making sure that there is open communication between all members of the “XLERPLATE® steel can be pressed heavily John Holland is responsible for the fabrication project team. Ongoing dialogue, as well as without cracking and is easy to weld given as of all other project components. There are an understanding of each other’s working it has no major flaws,” Alban emphasised. “We a number of different applications of steel practices, is critical to the smooth roll out of also find that when working with XLERPLATE® planned, with the team converting XLERPLATE® the expansion work. we do not encounter any lamination issues – steel into sections including modules, box there are no layers of separation in the steel so sections, chutes and headstocks. “It is important that the teams at RPG, John no potential cracks. Holland and BlueScope Steel are sharing “The John Holland team is responsible for information,” said Matthew Stewart. “If all driving the piles into the seabed and then Looking forward parties are aware of changes in scheduling and scalloping the top of the pile so the headstock PCQ is already planning two additional stages logistics we are able to adapt accordingly.” can sit on top of it to create the new wharf,” of development. The X80 expansion will said Alban Manning, Manager - Fabrication “It is also imperative that we understand what increase export capability to 80 million tonnes and Coatings, John Holland’s SMP business. is required at each stage of the construction per year, with the X110 expansion lifting process,” Matthew continued. “For example, capacity to 110 million tonnes per year. “The team is also working on the fabrication one of the biggest challenges for RPG has and construction of the rail girders and support been to adhere to very tight dimension and beams that the new ship loader will run along straightness tolerances when fabricating the when moving across the wharf. Finally, we piles. This is because we are aware that if the are also fabricating rail fenders for the wharf. diameters of the piling are too varied, John These are rubber-guarded buffers that the

Alban Manning, Manager – Fabrication and Coatings Each girder’s fabrication involved numerous internal stiffeners of John Holland’s SMP business

5 What makes plate: understanding steel plate supply conditions – part two ByIMAGE John Dryden, HERE National Technical Manager Uncoated, BlueScope Steel Understanding the conditions in which steel the final pass in the rolling mill is carried out), period of time. During this heating period the plate is supplied is critically important for all but generally the finish rolling temperature ferrite and pearlite structure transforms back those involved in the use, fabrication, ordering of an As Rolled plate will be above the A3 into austenite. Because the temperature is and distribution of steel. Using steel with temperature (the temperature where the held close to the A3, a uniform fine-grained appropriate mechanical properties – such austenite in steel starts to transform into austenite structure develops. as strength, toughness and hardness – for ferrite – see previous article). After heating, the plate is cooled in still air. specific jobs, each of which will have its own Examples of As Rolled plate are AS/NZS 3678- As the plate cools, the fine-grained austenite unique challenges and needs, means lower 250. This sort of plate is often used for general structure transforms again into a fine- costs and more effective outcomes. structural applications and hoppers, bins grained ferrite/pearlite mixture. The result In the previous article (Steel in Touch Ed. 12) and tanks. is a structure with improved strength and of this two-part series, the four plate supply toughness compared to As Rolled. Examples conditions were discussed. In this article we normalised of grades are AS 1548-7-460NL40 and AS go into further detail on each of those four With plate supplied in the Normalised 1548-5-490NL50. Normalised plate is often conditions: condition, the plate rolling process is similar used in pressure vessels operating at low to As Rolled plate. Following rolling, however, temperatures and heavy gauge plate requiring • As Rolled the plate is subjected to an additional heat good toughness. • Normalised treatment process: Normalising. • Thermo-mechanical Controlled Rolled thermo-mechanical • Normalised Rolled Normalising is usually specified where there controlled rolling is some high-temperature forming process Another common supply condition is Thermo- As ROLLED during fabrication. It may also be used where mechanical Controlled Rolling (TMCR). This With As Rolled plate there is only a moderate the mechanical properties specified are not may also be referred to as Thermo-mechanical strength requirement and usually no or only achievable by rolling alone. In Normalising, Controlled Processing (TMCP) in some moderate toughness requirements for the the plate is heated up to a temperature standards. Note the terminology of ‘Controlled steel. There is no stipulation on the ‘finish’ just above the A3 (approximately 900°C for Rolling’ to describe the TMCR process is not rolling temperature (the temperature at which most plate steel grades) and held there for a

A stack of XLERPLATE® steel awaiting despatch XLERPLATE® steel exiting the rolling mill at the Plate Mill

6 A heat exchanger showing the tube plate at the end of the vessel strictly true, as any process that controls the advantages to TMCR is that it generates Normalised Rolling is not effective in heavier temperature at which final deformation is equivalent strength and toughness to gauge plate as it is difficult to get the required carried out is ‘Controlled Rolled’. Hence, by normalised steels at lower carbon equivalents reduction through the thickness of the plate definition the ‘Normalised Rolled’ process without the extra cost of heat treatment. The at the correct temperature (similar to TMCR). described below is also a ‘Controlled Rolling’ disadvantage is that it cannot be fully utilised Hence to achieve the required properties in process. in thicker (usually greater than 50mm) plate. heavier gauge plate, it may be necessary to Examples of TMCR steels are AS/NZS 3678- carry out a normalising heat treatment process. In the TMCR process the final rolling passes 400 and AS1548-7-490TL50. TMCR plate is occur at, or just below, the A3 temperature. An example of Normalised Rolled plate is often used in making locomotives and As a consequence of the low(er) finish AS 1548-PT460NR from the 2008 revision of rolling stock. rolling temperatures, the recrystallisation of AS1548. Examples of international grades that the austenite structure is inhibited and the can be supplied are EN 10025-2-S355J2+N and normalised rolled subsequent transformation of austenite leads EN 10028-3-P355NL. Normalised Rolled plate to a fine-grained ferrite and pearlite structure. The final supply condition, Normalised Rolled, is often used in making pressure vessels. The fine-grained structure produces plate with is a rolling process whereby the finish rolling In summary, although the various supply good strength and toughness. passes of the plate are tightly controlled so that they occur in a narrow range of conditions of plate steel can seem confusing However, because rolling is completed at temperatures just above the A3. In doing so, at first, when specified correctly, each leads a temperature below the A3 there is some the mechanical properties of the plate are to steel with the mechanical properties best deformation (or cold work) of the ferrite equivalent to that obtained by carrying out a suited to the unique demands of each project formed as a result of the transformation from Normalising heat treatment. for the lowest cost. the austenite. As a result, if a TMCR steel is heated up to above the A3 (as in hot forming Furthermore, if the ‘Normalised Rolled’ plate John Dryden is the National Technical Manager Uncoated, of of dished – dome-like – ends) the cold worked was subsequently given a normalising heat BlueScope Steel. His technical ferrite will transform back into austenite and treatment, the specified properties of the expertise is applied to XLERPLATE® the plate will lose strength. plate would be met. Normalised Rolled plate, therefore, offers a less expensive option than hot rolled plate steel, manufactured Consequently, hot forming of TMCR grades is normalising as it eliminates the need for a to tolerances that conform to Australian Standards and ISO 9001 limited to ~620°C to prevent any significant subsequent heat treatment process. International Quality Standards. loss of strength or toughness. One of the

7 Touching the earth Touching the earth lightly...Touching the earth to the sustainability issue aimed at lifting lightly... lightly... understanding of steel’s environmental value in plain English.

“Every attempt has been made to include local examples and figures where practicable and pertinent,” said Don. “There’s a lot of conflicting information out there on evaluating ‘green’ materials, such as points schemes, embodied energy and other measures.

Australian steel’srole “We recognise that a life cycle analysis is Australian steel’srolein a sustainable world.

in a sustainable world. the only real way that steel’s recyclability Australian steel’s role gets properly accounted for and are in a sustainable world. currently working through the Building Products Innovation Council (representing major material suppliers) on this issue.”

The new publication also talks about a number of major programs here in Australia, many driven by BlueScope Steel involving Touching the Earth lightly recycling water and waste heat to reduce With issues like carbon trading and The other involves representing the industry the greenhouse gas and eco footprint of embedded energy at the forefront of public in forums and on bodies that are developing steelmaking. debate currently, there has been no better methodologies to measure environmental and Sustainability services time for Australian steel to mobilise an sustainability performance. Representation in industry-wide and far reaching response on these areas is critical if the emerging systems Andrew Marjoribanks explained some of sustainability issues. are to be fair and based on a level playing the approaches the ASI is taking. “Now field for all construction materials. that we have Touching the Earth Lightly on Enter the Australian Steel Institute’s (ASI) general release, our next task is to conduct Sustainability Group which was established The ASI Sustainability Group also provides sustainability seminars in each state in 2006 comprising environmental experts strategic direction and information on steel’s commencing in early 2009. from Australia’s two steel producers, as well environmental credentials to customers and as other recognised specialists from the field. others parties. Its membership is drawn “These will draw together the latest from wide experience and expertise in developments taking place and our members The group aims to positively differentiate environmental and sustainability affairs and and other participants will be able to learn steel in sustainable construction by comprises Ross Davies and Amy Luscombe how these and the issues they raise will influencing the construction industry’s from BlueScope Steel, Nick Fithall and affect them and their businesses. perceptions of steel and the treatment of Phil Ridgeway from OneSteel, Mick Clarke steel in various environmental rating systems. “This will be an important role for the from Fletcher Building, Nigel Howard from This will help ensure that the material’s group as sustainability in a steel context Edgeenvironment, an acknowledged world sustainability credentials are fully understood is emerging as a significant factor in many expert on sustainability matters, and the and applied. construction decisions,” continued Andrew. ASI’s National Marketing Manager, David “This trend is likely to continue and likely to Ryan. The group is chaired by Andrew The Sustainability evolve into regulation as it has done in many Group at work Marjoribanks, a former long-time BHP Steel overseas countries and our members need marketing executive and now a consultant in The group has chosen a two-pronged to be kept abreast of these matters. this field. approach. The first involves promoting “As with safety, good environmental steel’s role in improving the sustainability of The ‘green guide’ practice is everybody’s business and the buildings and other infrastructure by lifting The latest development from the group is Sustainability Group intends to underline awareness of its high strength-to-weight the first dedicated publication on Australian this by initiating a good sustainability ratio and what that means for minimising steel’s environmental credentials from an practice award on similar lines to the ASI foundation work, achieving wide column-free industry-wide perspective, a sixteen page National OHS Awards program. This is so spans and generally offering greater design brochure titled appropriately, Touching the that everyone who works in our industry can freedom to designers and architects. It also Earth Lightly. be involved in improving our use of energy entails highlighting steel’s unique reuse and and materials.” recyclable properties and its superb capacity ASI Chief Executive, Don McDonald said that Further details, visit Sustainability at to facilitate design for deconstruction the new publication is the first real attempt www.steel.org.au and reassembly. to provide a steel industry-wide response

8 United Group Resources delivers for BP United Group Resources has fabricated and chemical and industrial processing sectors. fabrication teams as the column required delivered a major process unit for the BP For the BP naphtha splitter column, it took temporary support saddles, lifting attachments refinery in Kwinana, WA. responsibility for design, detailing, fabrication and complicated transportation requirements. and delivery to site as well as providing much It also involved close liaison with balance- The naphtha splitter column was constructed of the labour to erect the process unit. of-plant design engineers Worley Parsons, in at the leading construction, engineering, asset numerous 3D design review sessions, to refine management and maintenance provider’s “There are a lot of advantages with this the interface with the associated civil, piping, Kwinana workshop. approach,” said Glenn. “With intelligent design electrical and instrumentation works. we’ve been able to use 16mm, 20mm and More than 200 tonnes of 460N Grade 25mm XLERPLATE® steel at various points All internal and external attachments for the (normalised) XLERPLATE® steel went into throughout the shell. naphtha splitter column were fabricated from fabrication of the unit’s cylindrical shell and 350 Grade XLERPLATE® steel. dished ends. “This has helped to contain costs for our customer, but still provides the performance Internally, the column has been fitted with Because of the size of the finished vessel the they require.” perforated process trays approximately every shell was constructed in 3m by 4.5m diameter 450mm. On the exterior, nearly 300 square sections which were welded together to form UGL Resources could have sourced the metres of platforms have been mounted in the column in the horizontal plane. 460N Grade XLERPLATE® steel directly from various segments. BlueScope Steel by mill enquiry, but elected to United Group Resources (UGL Resources) leave that role to OneSteel Steel & Tube. “Fabrication of the column was completed on project team leader Glenn LeMerle says the schedule by UGL Resources, with zero health fabrication phase involved 20 employees “BlueScope Steel and its distributor OneSteel and safety incidents and zero quality issues,” working two shifts since November 2007. The Steel & Tube have a thorough understanding of says UGL Resources Workshop Services installed naphtha splitter stands 64 metres tall, what we require when we order steel,” Manager Julian Bleddyn. weighs 308 tonnes and holds a total volume of said Glenn. 1,000 cubic metres. The splitter column is the largest vessel design and fabrication fabricated by UGL Resources to date. It was The smooth progress of the project has proven challenges delivered to the refinery in July using heavy-lift the value of UGL Resources’ integrated “Despite the grade requirements and non- specialised transporters. engineering, fabrication and construction standard sizes involved, everything was delivery model. The three kilometre trip involved the lifting and delivered as and when we needed it.” de-energising of power lines and civil works UGL Resources has wide experience in the The project provided significant challenges including the removal and replacement of mining and mineral processing, oil and gas, for the company’s combined design and traffic islands and traffic signals.

The splitter column was delivered to the BP refinery Beneath its shiny exterior more than 200 tonnes of XLERPLATE® steel went into the fabrication of the naphtha splitter using heavy-lift specialised transporters

9 George Petley, Business Development Manager PIC utilises the latest welding machinery and at Pacific Industrial Company techniques and trains its staff on an ongoing basis. The company is committed to exploring advances in welding technique and passing the benefits on to its customers.

Another challenging aspect of the fabrication process is the trend towards modularised components. Modularisation refers to breaking down very large projects to a multiple of lesser sized components, before delivering them to the construction site for assembly. Construction work can take place more quickly when there are fewer pieces to assemble, cutting down on site costs for clients. George believes that there is more emphasis on modularisation in today’s market. This is partly driven by the growth in fabricated steel imports. A lot of imported fabrications are now modularised and the Australian industry needs to rise to the challenge to remain competitive.

FabRication challenges The fabrication of steel is a complex process and clients often rely on the expertise of the fabricator when starting work on new projects. The fabricators’ Fabrication – state of the estimators are often called upon to work from architect’s plans, visualising how the industry perspective construction will work in order to estimate fabrication requirements and pricing. George Petley, Business Development facilities using leading edge Computer Manager at the Perth based Pacific Numerically Controlled (CNC) machinery. However, most of these ‘estimators’ are Industrial Company (PIC), is an industry “When I started in the business in the 1950s, now in their 50s and 60s with a skill gap veteran, having worked in the steel many fabrication shops were working in the developing lower in the ranks. This leads business for 55 years. He spent 25 years in kind of conditions that would have been usual George to worry that the current expertise construction before moving into fabrication, for the UK back in the 1920’s such as dirt held in Australia’s fabrication sector giving him a thorough understanding of floors and over-head belt drives to machinery,” will dwindle. the industry from both fabricator and client says George. “The UK sent their old machines “A lot of fabricated steel is imported and it perspective. out to Australia when they were upgrading, is starting to impact on the industry – we meaning that we were always working with George notes that a key issue for out-dated machinery.” fabricators and clients alike is ensuring that the right steel is used for each job. Talent pool “The things we look for are quality, timely Australian fabrication shops, however, have delivery and the capability to meet a client’s seen major advances in recent years and local specification for the job,” says George. operators are now highly geared in respect “One of the products we use is XLERPLATE® to modern equipment and facilities. There steel. With BlueScope supplying Australian is a huge amount of talent in the Australian made steel, the product arrives promptly industry, where expertise has been built in and is guaranteed to be of a high quality.” even the most demanding areas of the job. George has witnessed vast developments “Welding and modularisation are by far the during his time in the fabrication sector. most challenging aspects of fabrication,” He has seen the industry advance says George. “Welding is a very technical from “glorified blacksmith’s shops with process and it needs highly skilled people. If a rudimentary tools” to today’s sizable weld fails then the whole construction could collapse, so it has to be done correctly.”

10 are seeing fabrication shops closing up,” Blast Furnace reline says George. “We have seen a huge boom in demand for Australian steel but there is still In March 2009, BlueScope Steel will begin the not enough fabrication work to go around reline of its No. 5 Blast Furnace at Port Kembla because this is taking place in other countries. Steelworks. The reline is scheduled to take The less work we get, the fewer apprentices 105 days to complete. we can afford to employ, meaning that the next generation of fabricators are not being There will be sufficient capacity to satisfy this trained.” demand through the following measures: • No. 6 Blast Furnace will operate at full technology in FabRication capacity Another welcome development George has • Sales to deep sea export customers will be noted is the rising prevalence of technology reduced in the industry. One example of this is the • BlueScope offshore production facilities advent of 3D modelling by architects and have largely secured alternate feed sources. engineers, offering benefits from conceptual design right through to shop detail drawings No.5 Blast Furnace, a key asset in the and procurement. Construction plans can production of Australian steel, requires this now be modelled on a computer in 3D, rather essential maintenance to ensure the furnace than sketched. Dimensions and details are operates through its next campaign life of 15 added as the model is passed from architects to 20 years at peak condition, with customer to engineers. This model will then go to a needs being comprehensively met. ‘detailer’ who will size it down to each nut and During the reline, $372m will be committed bolt, proving that the final components will fit to overhaul and upgrade a number of together. major components. This includes replacing refractories and cooling elements inside the eliminating mistakes furnace, upgrading the gas cleaning system, “It wasn’t unusual to find beams out of changing to closed loop for a number of place half way through a job so the last the water cooling systems and replacing stage of construction was always correcting refractories inside the hot blast main. The the mistakes,” says George. “3D modelling work will involve over 1,000 people, many of eliminates this correction stage because the them local contractors. computer program picks up any mistakes before fabrication or construction begins.” George is a former West Australian chairman CMC Coil Steels win ASI Safety Award of the Australian Steel Institute and is immensely proud of what the Australian steel CMC Coil Steels won this year’s ASI Safety eliminating waste on site and running industry has to offer. He has seen it adapt Award to recognise their impeccable safety stock supply low (this helps CMC stay and grow with the times and looks forward to performance and improvements to their organised and decrease the risk of injury). seeing how it will continue to evolve to meet Erskine Park site. This award, which BlueScope Steel’s Port Kembla site won last year, rewards their today’s challenges. Ashley Smith, the national operations on-site dedication to safety. manager at CMC Coil Steels, attributes

George Petley inspects a platform assembly for the the award to keeping projects small, Woodside LNG Burrup Train 5 gas turbine emission stack. Pacific Industrial Company was awarded the contract to design, supply, fabricate, surface treat and refractory line three GTES emission stacks for the project.

11 XLERPLATE® steel National Sales team In the hotseat HEADOFFICE Peter Panteli – Customer Service Officer [email protected] with Matthew Stewart Mark Scott – National Sales Manager 1300 135 004 [email protected] 4275 3181 / 0417 271 525 QLD Todd Bryers – Market Manager Tony Fotea – Regional Sales Manager [email protected] [email protected] 4275 3896 / 0439 451 198 07 3845 9351 / 0407 751 653 Troy Gent – Market Manager Jamie Cooper – Account Manager [email protected] [email protected] 4275 4107 / 0418 297 874 07 3845 9394 / 0407 377 355 John Dryden – National Technical Manager Uncoated Rob Bauer – Account Manager [email protected] [email protected] 4275 4667 / 0409 321 898 07 3845 9382 / 0407 544 833 Job title: General Manager RPG-Australia Martin Frylink – Account Manager Pipe Division Warren Simpson – Technical Representative [email protected] [email protected] No. of years with RPG: One 4275 4668 0418 694 876 07 3845 9350 / 0427 160 895 My role and responsibilities involve: Graham Unicomb – Product Manager XLERPLATE® steel Keven May – Customer Service Officer Managing a core group of people committed to [email protected] [email protected] the growth of the Pipe Division and delivering 4275 3861 / 0448 834 330 1300 135 004 results that exceed the board’s expectations NSW/ACT SA/NT My greatest working challenge: Ensuring Matt Hennessy – Regional Sales Manager Mike Hesketh – Regional Sales Manager people enjoy coming to work and feel they [email protected] [email protected] contribute equally to the business’s success 02 4275 3314 / 0410 312 113 08 8243 7352 / 0419 588 131 The secret to success is: Always remember Phil Burke – Account Manager Dean Trenwith – Account Manager that you never stop learning [email protected] [email protected] 02 4275 3388 / 0411 561 855 08 8243 7355 / 0418 840 161 I like steel because: It is what I have always been involved with and there are some great Lube Dimovski – Account Manager Monica Maloney – Account Manager personalities you meet along the way [email protected] [email protected] 02 4275 3536 / 0418 297 874 08 8243 7357 / 0488 130 493 I start my working day by: Walking the dogs – Customer Service Officer to clear the head Tony Apps – Account Manager Nathan Squires [email protected] [email protected] My favourite pastime: Currently it is 02 4275 3536 / 0427 223 027 1300 135 004 learning to play the guitar Zoran Sterjovski – Customer Service Officer WA My favourite car: 1969 Ford Capri V6 GT [email protected] Elly Pilkadaris – Regional Sales Manager 1300 135 004 Last time I laughed out loud was: Every [email protected] day, I may only be here for a short time, so I VIC/TAS 08 9365 6665 / 0419 931 605 intend to get the best out of it Simon Fieldsend – Regional Sales Manager (Acting) Monica Macaskill – Account Manager [email protected] My favourite movie of all time: The Castle [email protected] 03 9586 2324 / 0418 325 836 08 9365 6676 / 0448 976 862 My favourite food is: A stubby on a hot day Greg Harbour – Account Manager . . . they do say there’s steak and eggs in every Adam Cheeseman – Account Manager [email protected] [email protected] stubby 03 9586 2282 / 0407 287 817 08 9365 6650 / 0400 204 893 My earliest childhood memory: Coming Maria Gounis – Account Manager Nathan Squires – Customer Service Officer from a family of nine kids, I still have [email protected] [email protected] nightmares remembering when my brothers 03 9586 2298 / 0418 386 972 1300 135 004 left me hanging off the Hill’s Hoist at full height Scott Sheedy – Account Manager [email protected] My secret talent is: Barry Gibb impersonation 03 9586 2273 / 0418 386 964 For technical enquiries call 1800 800 789

Test your Australian sports knowledge! 1. ‘Out of my comfort zone’ is the 3. Which Australian rugby player 5. In which sport did Steve Bradbury autobiography of which Australian has scored the most points in one win an Olympic Gold Medal at Salt sporting great? Rugby World Cup (1999)? Lake City in 2002:

Ian Thorpe 4. Which Australian swimmer is the Athletics Steve Waugh only athlete to hold every world Rowing Shane Warne freestyle record from 100m to Speed skating Greg Norman 1500m simultaneously? Swimming 2. Which Australian tennis star is 6. Which of the following Rugby

Kieren Perkins BIM0314 12/08

ranked third in the world for the League Legends was known as

Ian Thorpe

most Grand Slam singles titles? ‘The Old Fox’? 6

Shane Gould 3 0

John Newcombe Murray Rose Dally Messenger 8

Ian Thorpe 5 0

Rod laver Gorden Tallis

5 6. 5. 4. Harry Bath Harry Skating Speed

Roy Emerson Darren Lockyer Gould Shane 7

0

3. 2. 1. Matt Burke Burke Matt Emerson Roy Waugh Steve Ken Rosewall Harry Bath Answers: 0 2 3

9

The XLERPLATE® Steel in Touch newsletter has been prepared for information purposes only. BlueScope Steel makes no representation or warranty as to the completeness or accuracy of the information 12 contained in the Newsletter and you rely on it wholly at your own risk. Xlerplate® and BlueScope are Registered Trademarks of BlueScope Steel Limited ABN 16 000 011 058. © 2008 BlueScope Steel.