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Fabrication | UGL 1

From strategically placed sites across Australasia, UGL provides a full range of fabrication, field welding qualification and quality control services. These are supported by established systems and expertise, allowing us to offer clients a full end-to-end solution, inclusive of design, detailing, fabrication, machining, site installation, and field services.Facilities in Henderson (WA), Bassendean (WA), Ballarat (VIC), Newcastle (NSW), Gladstone, Mackay and Townsville (QLD) and Kolkata, India (as a partner in the UGL Texmaco joint venture), offer fabricated structural steelwork, piping, pipe spooling, pressure vessels, heat exchangers, tankage, mechanical equipment and general industrial products in all materials.

Our facilities can fabricate structural steelwork, piping, pressure vessels, tanks, mechanical equipment and general industrial products in all materials. For the rail sector, we provide structural and complex heavy engineering assemblies to diesel locomotives and haulage bogies. The workshops’ lifting requirements are serviced by overhead cranage and supported by a fleet of mobile cranes. The facilities supply both on-site and off-site end to end service.

The facilities provide clients with total flexibility to undertake a variety of manufacturing activities. UGL has the skills, expertise and equipment to cater for client’s manufacturing needs.

KEY BENEFITS & DIFFERENTIATORS• An end-to-end solution from design to fabrication

and site installation

• Knowledgeable, safety-aware and experienced resources can be accessed and available for deployment to client project locations in the shortest possible time

• Optimised fabrication delivery, utilising our own in-house capability (workshops) and/or partnering with external facilities

• Shorter lead times and higher quality output through the use of local fabrication sites

• We have an established offshore supply chain network which can be utilised to minimise cost

OUR CAPABILITIESTo enable the delivery of our fabrication services, we have advanced capabilities in:

• Design engineering

• Electrical engineering

• Machining

• Mechanical engineering

• Pressing

• Welding

SECTORS & INDUSTRIESPowerPower DistributionPower GenerationPower TransmissionSubstations

WaterIndustrial Water & Wastewater Irrigation & ReticulationMunicipal Water & Wastewater

ResourcesChemicalsIndustrial ProcessingMinerals & MetalsOil & Gas

Transport & Technology SystemsRail SystemsIntelligent Transport Systems

Fabrication

UGL is ideally placed for fabrication delivery utilising in-house workshop capabilities and partnering with external facilities to provide the optimal solution for any situation. We can make use of our established international supply chain network to minimise both costs and delivery time.

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Current capacity

Our workshops have in-house capacity for fabricated product; production rates are dependent on complexity, project requirements and workshop capability.

MACHINING• Automatic undercutter

• CNC vertical boring

• Horizontal boring to 15t on table

• Lathes from 1.5m centres and 0.3m to 6.0m centres and 1.0m swing

• Line borer

• Milling machine

• Pedestal drills and grinders

• Radial arm drill

• Surface grinder

• Vertical boring to 7.0m diameter

PRESSES• 100t vertical

• 150t vertical

• 600t horizontal

STRESS RELIEVING FURNACES• 25t capacity

• Calibrated control system

• High velocity gas burners

• Internal dimensions 5 x 5 x 2m

• Programmable temperature cycles with chart recorder

• Trolley hearth

• Uniform thermal profile

WELDING• Boom welders to 6m high

• Flux cored arc welding

• Fully automatic robotic welding

• Gas Metal Arc Welding – GMAW

• Gas Tungsten Arc Welding – GTAW

• Manual Metal Arc Welding – MMAW

• MIG, TIG and gas welding

• Submerged arc welding

• Thermal cutting

• Welding positioners 5t to 15t

Our end-to-end delivery model

FABRICATEFabricate is a value-added process employing various raw materials supporting both manufacturing and construction activities.

With sites strategically placed around Australasia, UGL provides a full range of fabrication, field welding qualification and quality control services.

Established systems and expertise allow us to offer clients a full end-to-end solution, inclusive of design, detailing, fabrication, machining, site installation and field services.

UGL has an established international supply chain network which can be utilised to minimise costs.

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Materials UGL weld a wide range of materials for high quality structural and pressure vessel requirements including:

• Cast iron

• Engineering steels, such as 4140, 4130, 1040

• Ferritic, austenitic, super austenitic (6Mo), duplex and super-duplex (2507 and Zeron 100) stainless steels

• Nickel alloys such as Monel, Inconel and Incoloy

• Non-ferrous materials such as copper-nickel, aluminium and titanium

• Proprietary materials such as Maggoteaux, Sandvik SX, 3CR12, HA

ProductsHEAT EXCHANGERSUGL has the capability to manufacture, refurbish and repair a range of heat exchangers used in mineral processing, oil and gas refineries and chemical process plants.

MECHANICAL EQUIPMENTOur range of mechanical equipment includes stackers, reclaimers, conveyor modules, chutes and transfer stations, dragline and shovel components, car dumpers and pre-assembled modules for offshore platforms.

We specialise in equipment modularisation for construction and upgrade projects.

PIPE SPOOLINGPipe spooling in carbon and stainless steel is regularly produced at our facilities. Production rates have exceeded 175t a week but are dependent on contract work complexity and specifications.

PRESSURE VESSELSWe have produced more than 300 pressure vessels, many in excess of 80t. All are built to comply with AS1210 standards as well as relevant government regulations.

STRUCTURAL STEELComputer controlled equipment, including beam line, angle drilling and punching and cutting machines can produce more than 400t of structural steel per week.

TANKAGEUGL has the capability to design and fabricate many classes of tanks, including floating roof tanks. The largest tank built to date has a diameter of 90m. UGL has also built alumina precipitators and storage silos 45m high with a diameter of 24m.

National facilities

HENDERSON, WESTERN AUSTRALIALocated within the heart of the Australian Marine Complex (AMC) this facility is strategically positioned within 1km of the supply wharf enhancing UGL’s ability to deliver offsite modular assembly units for Oil & Gas, Mining & Mineral Processing, Chemicals and Industrial Processing clients.

UGL’s Henderson facility is certified to ISO3834 and provides reactive maintenance support.

Workshop facilities• 2 bay warehouse, stores and workshop facility 2,724m2

• Laydown/assembly hardstand area 6,500m2

• Mechanical and electrical facilities

• Office facilities 800m2

• Overhead cranage to 30t

• Stores receival and despatch

• Welder testing and training

Fabrication capabilities• Bins • Pipe spooling

• Chutes • Pressure vessels

• Conveyors • Structural steel

• Launders • Tanks

Welding capabilities • Carbon steels • Stainless steels

• Exotics supported by international qualified welding engineers

UGL has alliances with a reliable network of subcontractors offering the following disciplines but not limited to:

• Design • Machining

• Detailing • Mechanical fitting

• Hydro testing • Stress relieving

• Insulation • Surface treatments

• Cladding and fire protection covering all aspects for any project requirements

BASSENDEAN – PERTH, WESTERN AUSTRALIAThis facility undertakes locomotive refurbishments and major overhaul repairs on locomotive engines, compressors, power assemblies and wheel sets. Field support services are also available for day-today support and for the project management of major maintenance events such as component change outs on rail operator sites.

Key capabilities include wagon manufacture, locomotive rebuild and maintenance, locomotive component rotable repair and remote field support services. The site offers an extensive range of support for materials handling and processing and maintenance services for railway bogies. UGL also outsources the repair of locomotive components such as traction motors to certified sub-contractors within the Perth region.

• Blast, paint and coatings

• Distributor of GE locomotive products

• Field service and technical support

• Project Management for supply of complete Barber freight bogies

• Repair, overhaul and unit exchange of major freight vehicle components

• Supply chain and logistics management services

Welder testing and trainingThe workshops offer permanent welder testing and training facilities as well as dedicated apprenticeship training programmes.

The company has conducted and documented over 600 weld procedure qualification tests to cover a variety of welding situations, materials and client and code requirements. In addition, our experienced team of welding technologists and supervisors can develop a wide range of weld procedure specifications for low temperature and high temperature applications, for construction and repair and for workshop and site, in accordance to relevant manufacturing codes, including:

• ASME B31.3 - Chemical Plant and Petroleum Refinery Piping

• AWS D1.1 - Structural Welding Code

• AS1210 - Unfired Pressure Vessels Code

• AS4458 - Pressure Equipment Manufacture

• AS4041 - Pressure Piping

• AS2885 - Piping - Gas and Liquid Petroleum

• AS1554 - Structural Steel Welding

All personnel employed in a welding capacity are subject to pre-employment qualification testing in accordance with the prescribed requirements of the governing codes and client specifications. Each qualified welder also undergoes UGL’s welder training course ‘Weld Procedure Specification Induction’. Each welder is registered and allocated a welder identification number that is used to trace their work and maintain a record of performance and qualification status.

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BALLARAT, VICTORIAUGL’s Ballarat workshop is a heavy engineering workshop focused on the overhaul of mechanical and electrical components for rail Rollingstock, with capacity and necessary skills to complete component manufacture and overhaul for alternative industry.

The workshop provides an expansive range of services including maintenance, overhaul, refurbishment and manufacture of passenger and freight rolling stock. The site also handles the overhaul of rolling stock components, including mechanical and traction equipment for the Victorian and interstate rail industry.

Ballarat has proven technical capabilities in the building, overhaul and modification of both train and tram rotable components.

The site has 12,000m2 under roof with heavy lifting equipment capabilities for both rail and general heavy engineering. The site is located approximately 1.5 hours from Melbourne.

Metal Fabrication• Heavy fabrication and welding

• Heavy metal pressing

• Light metal fabrication

• Metal rolling

• Profile cutting

Additional capability• Brake equipment overhaul and testing

• Bogie overhaul

• Component overhaul

• Compressor overhaul

• Electrical component overhaul

• Machining

• Mechanical overhaul

• Passenger and freight rolling stock manufacture

• Rail vehicle maintenance

• Rolling stock repair and modification

• Traction equipment overhaul

• Wheel axle set overhaul

Management Systems Certification• Environmental Standard AS/NZ ISO 14001

• Occupational Health & Safety AS/NZ 4801

• Quality Standard AS/NZ ISO 9001

NEWCASTLE, NEW SOUTH WALESUGL’S Newcastle workshop provides a one-stop-shop for the overhaul of electrical motor and mining equipment to clients throughout Newcastle, the Hunter Valley and greater New South Wales.

Accredited to AS/NZS3800.2005 and ISO9001:2008, our workshop is approved by the Department of Primary Industries (DPI).

• 10 hectare site

• Assembly clean room

• Internal paint booths

• Stress relieving furnaces – calibrated control

• Overhead cranage to 40t

• Water blasting to environmental standards

• Workshop 4,900m2

TOWNSVILLE, QUEENSLANDUGL’s Townsville (Bohle) service centre, located on a 5.1 hectare site has excellent rail and road access.

The facility provides manufacturing and range of metal cutting, forming and welding equipment to fabricate components in mild steel and stainless steel.

Additionally, component overhauls are carried out on minor engine components, gearboxes, pneumatic and hydraulic components.

• 5.1 hectare site

• 90t overhead crane

• 7,700m2 main workshop

• 1,500m2 other buildings

• Brake press

• Farley plasma cutter (19m bed)

• Guillotine

• Hand held plasma cutters

• Locomotive weigh bridge

• Mechanical punches and croppers

• MIG, TIG & sub arc welding machines

• Radial drills

• Shunting tractors

Facilities and capability• Abrasive blasting capabilities

• Flammable goods storage shed

• Manufacturing / maintenance facility with heavy lift capabilities to 90t

• Paint drying booth (27m x 9.6m)

• Pressure vessel welding

• Pressurised paint booth (25m x 9.6m)

• Specialised paint lining and curing capabilities for commodity rail cars (GATX TankTrain)

• TIG, MIG, Pulse MIG and sub arc welding

• Quality Assured supplier to Queensland Government agencies

National facilities

KOLKATA, INDIAThe UGL Texmaco Joint Venture fabricates components for equipment required for oil and gas, minerals and metals, aviation, shipping, construction, materials handling, defence, water and power sector applications.

This fully integrated, high quality, low cost manufacturing base is spread over a 20,000m2 area, including a state of the art production facility located in Kolkata, employing approximately 400 dedicated staff and has the capabilities to meet any fabrication requirement where quality, precision, reliability, and repeatability are paramount.

The facility boasts the latest in steel manufacturing technology including:

• A variety of heavy lift facility cranes

• All-weather enclosed production line, blasting and painting facility

• Bridge mill machining centre

• CNC cutting machines including laser, plasma and oxy

• IGM robotic welders

• Koiki high tolerance plasma machine with second head and bevelling capability

• Laser guided CNC presses – 105t and 500t

• Plate blasting and straightening facilities

• Semi-automatic, water-cooled MIG welders with routine calibration

• Stress relieving furnace

International facilities

GLADSTONE, QUEENSLANDUGL’s 2,600m2 fabrication workshop in Gladstone is situated on 2.8 hectares in the South Trees industrial state and provides a variety of fabrication services to mining and oil and gas clients in Gladstone and the central QLD region. The facility boasts a modern workshop and a strong reputation for quality and safety.

UGL caters for all mechanical fabrication repairs, and provides a single point of contact for client by engaging with a network of trusted subcontractors for additional services when required.

• 2.8 hectare site

• 11m door opening with capability to accept loads 23m wide

• 3000m2 compacted laydown area

• Compacted hardstand area to allow module assembly

• Height under hook 9.6m

• Hydrotesting of vessels ad piping

• Mechanical facilities

• Overhead cranage to 10t (designed for 50t)

• Weldtesting and weld procedure development

• Workshop 2,600m2

MACKAY, QUEENSLANDLocated only a few hours’ drive from the Bowen Basin, our electrical and mechanical workshops in Mackay provide overhaul and repair services to industrial client in this region.

Situated on 3.2 hectares with excellent road access, our operations are supported by a workforce of approximately 800 people (shared with the Gladstone workshop) and various field services teams.

• 2 assembly clean rooms

• 2 workshops to 7,800m2 (mechanical and electrical)

• 11 overhead cranes to 40t capacity

• Height under hook 6.9m

• Internal paint booth 8 x 4.5 x 4m

• Mechanical and electrical facilities

• Stress relieving furnaces – calibrated control

• Water blasting to environmental standards

India

China

Australia

Malaysia

New Zealand

Kolkata

Mackay

Townsville

Gladstone

Newcastle

Ballarat

PerthHenderson

8 UGL | Fabrication

KOLKATA, INDIAUGL’s industry leading JV with India-based Texmaco provides cost effective, high quality, high precision, steel fabricated components for industrial and equipment manufacturers. For the rail sector, product lines include bogie frames, cabs, platforms and headstocks for passenger and freight rolling stock (diesel electric locomotives, electric locomotives, electric multiple units, coaches and wagons), and flat packed container and other specialist rail wagons for both Indian and international markets.

UGL also fabricates components for equipment required for oil and gas, minerals and metals, aviation, shipping, construction, materials handling, defence, water and power sector applications.

BASSENDEAN, PERTHUGL’s facility is a major locomotive supplier to Pilbara iron ore companies for both new and rebuilt locomotives, with capability to deliver railway products, dump-trucks, general engineering, fabrication and machining.

This facility also provides an extensive range of refurbishment and overhaul services, support for materials handling and processing, oil and gas production equipment as well as maritime repairs and maintenance of railway bogies.

HENDERSON, WESTERN AUSTRALIAThe Australian Marine Complex (AMC) facility is strategically positioned within 1km of the supply wharf enhancing UGL’s ability to deliver offsite modular assembly units for mining and oil & gas clients.

MACKAY Through our Mackay site, UGL offers comprehensive asset management, outage management and execution, and industrial maintenance services. Facilities include mechanical and electrical workshops and warehousing, set over 3.2 hectares; 8,000m2 workshops with overhead cranage to 40t.

TOWNSVILLEUGL’s Townsville service centre, located on a 5.1 hectare site in Bohle provides manufacturing and range of metal cutting, forming and welding equipment to fabricate components in mild steel and stainless steel.

GLADSTONEUGL’s operations are managed from its Gladstone Operational Centre providing fabrication services for oil & gas and alumina clients. UGL also provides comprehensive asset management, outage management and execution and industrial maintenance services to local clients.

HUNTER VALLEY MAINTENANCE CENTRE, NEWCASTLEUGL’s Hunter Valley Maintenance Centre (HVMC) is a fully dedicated service centre of excellence for maintenance that provides a complete through life support network for freight rolling stock operators across the Hunter Valley region.

BALLARATThe newly established Ballarat Service Centre provides an extensive range of services including fabrication, maintenance, overhaul, refurbishment and manufacture of passenger and freight rolling stock. The site also handles the overhaul of rolling stock components, including mechanical and traction equipment for the Victorian rail industry. Ballarat also has proven technical capabilities in the building and overhaul of both train and tram rotable components.

Fabrication facilities