1. Non-conforming Building Materials
7th November 2016

2. Examples of Non-conforming Product
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3. Examples of Non-conforming Product
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4. Examples of Non-conforming Product
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5. Examples of Non-conforming Product
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6. Introduction
Engineers rely on AS4100 when designing steel structures in Australia.
AS4100 was released in 1998, and at the time was based on testing Australian manufactured steel whereby the material composition was clearly defined.
Ancient???
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7. Introduction
Today structures within Australia are designed using AS4100, however globalisation has since resulted in the use of steel from international manufacturers.
In order to comply with the BCA, designers and erectors must ensure steel meets the strict minimum material requirements specified in AS4100.
However, there is growing concern that much of the supply of imported steel and bolts do not meet the requirements of AS4100 and the BCA.
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8. Introduction
The BCA specifies minimum standards for design and construction to ensure the safety of the general public.
The BCA categorises structures into different classes depending on their occupancy and risk levels.
Most occupied structures fall into a class covered by the BCA.
Structures within the BCA scope, must be designed in accordance with AS4100 & other Australian Standards.
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9. Discussion Heavy industry structures are outside of the BCA.
Discussion: What is the governing document for the design of heavy industry machines in Australia?
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10. Strict material requirements
AS4100
Strict material requirements
Amendment in 2012
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11. AS1163-2016 Cold-formed Structural Steel Hollow Sections
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12. AS4100
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13. Why Don’t We Update AS4100?????
The assemblance and updating of Australian Standards rely on industry support.
But limited steel is currently manufactured in Australia.
Therefore, AS4100 will not be updated in the foreseeable future.
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14. Why Don’t We Update AS4100????? Where to from here?
Australia is a small percentage of the worlds steel market.
Can we rely on international manufacturers to meet Australian Standards?
Our standards specify different steel grades and minimum requirements to other regions.
Consistency in International Standards – Adopt Eurocode 3: Design of Steel Structures???
Where to from here?
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15. Australian Steel Institute (ASI)
Supports senate inquiry into non-conforming product.
Undoubtedly a major issue of non-conforming product in Australia.
The link between the WH&S Act between safety and compliance needs to be explicitly stated and enforced under the duty of care obligations.
In past years it was commonplace that the builder’s engineer was responsible for ensuring all products used in the project were compliant with original design specifications.
Engineers are being put under pressure to sign off on substituted foreign materials.
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16. Australian Steel Institute (ASI)
Recommendations:
All Government contracts stipulate the use of industry backed third party compliance schemes.
WH&S Act be strengthened to support enforcement of penalties for unsafe supply of non-conforming product.
The National Construction Code & Australian Standards are good documents, but lack effective conformity assessment support mechanisms.
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17. Australian Steel Institute (ASI)
Recommendations:
There needs to be strict enforcement of the compliance to building code processes & penalties for knowingly signing off on NCP.
That Government building contracts seek to have transparency of non-conformance reporting.
That Government support industry to set up a confidential reporting scheme for non-conforming product.
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18. PKCT – New Yard Machines
PKCT have on order, 3 stackers and 1 reclaimer from ThyssenKrupp
Aspec were engaged as the clients third party auditor.
Chris is the Lead Structural Engineer for the Project Team
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19. PKCT Project Specifications
Structural Design Specification states that AS4100 & the various material standards shall be used for the machine design.
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20. Material Substitution
Became evident early on in the fabrication stage there was an apparent issue with sourcing materials manufactured in accordance with Australia Standards.
A long list of items was sent through requesting the approval for use of an alternative section due to unavailability of Australian sections.
What does all this mean?
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21. Material Substitution
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22. TK’s Material Tests Originally specified by designer as a 351 x 22 CHS
C350LO
TK proposed a
355.6 x 25 CHS
EN10210 S355J2H
TK’s Material certificates seem ok………
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23. PKCT’s Independent Testing Testing found a yield strength of 314 MPA
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24. Discussion TK requested approval for the use of substitute sections.
TK provided material certificates.
Allowed PKCT to be aware of a potential problem.
Even though the substitute material was under strength, at least it didn’t end up in the structure unnoticed.
A third party material certifier would have saved a lot of time and money.
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25. Additional Analysis
The under strength CHS had already been used in the construction of the reclaimer boom.
PKCT engaged Aspec to investigate the impact of reducing the yield stress of this section.
Sections in question
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26. Additional Analysis Non-conforming Building Materials
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27. Additional Analysis Non-conforming Building Materials
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28. Non-linear analysis to check residual strain
Additional Analysis
Set at
0.9 x 314MPa
Non-linear analysis to check residual strain
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29. Conclusions & Recommendations
AS4100 is nearly 20 years old and will not be updated any time soon
There is an issue with non-conforming building products being supplied to Australia from international manufacturers.
There is a grey area around the WH&S Act, Australian Standards and the legal requirements of design engineers.
It can be difficult to source sections manufactured in accordance with AS4100.
Use a third party certifier.
Non-conforming Building Materials
7th November 2016