Latest News from Kador
February 2012
Simulated Rescue Provides Good Training for Workshop Personnel
Kador is currently fabricating eight 150KL water tanks to suit Cat789 trucks for a Hunter Valley (NSW) client.
These will be amongst the biggest installed on rigid dump trucks in Australia, and need an extensive array of internal baffles to prevent the unwanted kinetic energy effects of water ‘sloshing’ when the truck is turning a corner, or under heavy braking.
Unfortunately, the baffles create a significant confined space risk for welders working inside the tanks during the final stages of manufacture. To ensure that an incapacitated worker could be quickly and safely evacuated in the event of a problem, Kador workshop employees developed a rescue procedure, then trialled it in a training session for all those working on the project.
The exercise helped finesse the procedure and demonstrated that a rescue could he performed within an appropriate time, to ensure personnel safety.
January 2012
Kador - Treadcorp Agreement
Kador recently reached an agreement with leading manufacturer of bulk explosives handling equipment, TREAD Corporation, to support TREAD's growth in Queensland.
The agreement provides for Kador to install TREAD's Unibody components onto a locally sourced truck chassis, to provide a convertible bulk explosives truck that has the capability to be reconfigured to deliver the right mix of products for any particular job.
TREAD's focus is exclusively on servicing the explosives industry on a worldwide basis. Corporate offices and the manufacturing facilities are located in Virginia, USA, with service capabilities managed from Chile, Australia and South Africa.
Commenting on the relationship, TREAD's Australian Business Manager Andre Fouche said "We selected Kador as our partner because we wanted an organisation that could work with us to provide a higher level of customer service than we could provide on our own."
December 2011
The 2011 Billykart Challenge
Since 2008 the Billykart Challenge has been contested between state high schools in the western corridor of Brisbane to increase students’ awareness of manufacturing, giving them an insight into the industry through a hands-on approach, whilst also providing local manufacturers an opportunity to meet potential employees/apprentices. Over the past few years, Kador has assisted schools with their entries in the event.
Each school partners with a local manufacturing company to create their billykart. Over a two day period, teams of students visit their industry partner and, together with tradespeople from within the company, commence construction (working within a set of design rules and specifications). The students then invest many more hours in their school workshops finishing off their billykarts.
The project also enables students to build on their metal fabrication and career transition skills in a real manufacturing environment.
This year Corinda SHS partnered with Kador’s Sherwood Workshop. A group of students worked for a full day at Sherwood to cut the material and start the fabrication of the frame. Kador’s contribution included the supply of some of the material and “special” wheel bearings as well as the use of welding equipment, tools and safety equipment needed while on site. Under the supervision of Manual Arts teacher Andrew Newberry, by the end of the day the boys had the frame well on its way to completion.
Once the billykarts have been completed, the student teams and industry partners competed in the Billykart Challenge race day - an opportunity for the schools and industry to come together and celebrate the completion of the project, while helping to strengthen the relationship between the school and business communities. Of course there’s the small matter of who has the fastest Billykart! .To crown the Billykart Challenge Champion the teams participate in a series of heats, playoffs and then the finals.
Thanks to the hard work, dedication and good engineering of all involved, the Corinda SHS team won the event and thus the title of Billykart Challenge Champion 2011.
The winning team later brought their billykart to Kador’s Sherwood workshop to show our workforce and size it up against a 63 tonne capacity dump truck which we were working on at the time.
November 2011
UQ Students Gain Work Experience at Kador
Each year Kador takes on a student from either UQ or QUT over the university summer vacation. This employment not only provides the compulsory work experience that students require prior to being awarded their degree, but also enables the completion of useful engineering projects that present themselves during the year. This year, three UQ students are joining Kador to undertake separate projects over the summer months. These are:
- to design and implement a removable, temporary safety handrail system for use during the manufacture of large sized mining products in our workshops
- to undertake a lean manufacturing improvement project by developing formalised ‘standard work’ norms for the current state of manufacture, including time allocations to individual processes, and then review the ‘standard work’, identifying opportunities for improvement such as elimination of wastes (eg over processing, defects, over production, movement/double handling etc.)
- to design and implement a Microsoft Access database to automate current incident reporting processes that are managed manually through Excel spreadsheets
Kador is encouraged by the enthusiasm of all the UQ applicants for these positions and expects these projects to be of benefit to both the students and Kador.
October 2011
More Bottom Dump Trailers
Kador’s position as Queensland’s leading manufacturer of bottom dump trailers was reinforced by a recent order for five 195 tonne capacity bottom dump bauxite trailers for a FNQ mine. These bring to 22 the number of bauxite trailers supplied since 2004.
Since 1990 Kador has also provided twelve 160 tonne and twenty seven 220 tonne trailers (see photo) for the Qld coal industry.
With our design partner, we can provide bottom dump trailers and associated hitch post assemblies for a range of OEM tractor sizes and hauled products. Contact us at sales@kador.com.au to learn more.
September 2011
New Machining Facilities at Sumner Park
Kador has recently installed two state-of-the-art Okuma CNC machines at our Sumner Park facility, replacing older equipment that has now been retired.
The new machines are a Millac 852 Vertical Machine Centre, and a Genos L300–MX1000 lathe.
These have the capacity to process a wide variety of machined parts that were previously produced by external contractors.
The new machines have expanded the scope of work that can be produced in-house, and now allow us to undertake all machining required for the Terex Franna crane contract, and to produce high quality products for our mining and general engineering fabrication divisions.
We are now also able to undertake machining work for outside parties. Contact us to discuss your requirements
August 2011
Kador Continues WELL Literacy Program
Kador has been running a Workforce English Language and Literacy (WELL) program for our migrant workers since late last year (refer News item for July 2010).
The benefits achieved from this Ai Group sponsored pilot program encouraged Kador to embark on a business wide commitment to improve workplace language, literacy and communication skills across all levels in the Company.
Our workplace trainer, Julie Peries, has been working with employees at our three workshops, providing specific training to individuals and groups, to lift the level of literacy, comprehension and communication for all staff.
Philip Smith, Managing Director, was recently invited to speak at the Industry Skills Council meeting about Kador’s experience. Philip described the process and decisions that lead to Kador investing in the literacy program as well as some specific successful examples. There was a great deal of interest from the attendees as the literacy problem is experienced across all sectors.
Further information is available at www.isc.org.au or by contacting WELL-QLD@deewr.gov.au
July 2011
Cat Dump Body Assembly for HDAL and Mine Rite
Local Cat dealer Hastings Deering (Australia) Ltd has long been a major purchaser of Kador’s water spray rigs for its Australian and Pacific customers. The relationship was extended recently with an agreement for Kador to assemble dump bodies for Cat mining trucks from kits manufactured in Caterpillar’s overseas workshops.
The kits arrive in four prefabricated sub assemblies – floor and front wall, two sides and canopy. Kador’s scope is to assemble and weld out the sub assemblies and paint the completed bodies, prior to delivery to HDAL’s customer.
Since the work started in late 2010, Kador has assembled more than 20 bodies for Cat 789 and 793 trucks.
July also sees the delivery of the first of 14 Cat 785 dump bodies Kador is assembling for USA company Mine Rite. These bodies are prefabricated in kit form in Wyoming, and sent to Australia for final assembly and top coat painting, before despatch by sea to a gold mine north of Australia.
Commenting on the relationship, Mine Rite’s MD Mr Dennis Frank said “Kador’s reputation in the industry was a key factor in the success of our tender for this project.”
Kador has wide experience in the manufacture and assembly of dump bodies for off-road mining trucks, using either our own designs or those of OEMs or others. See here for more details.
June 2011
Kador Participates in Post-Flood Cleanup Research
Kador’s Sherwood workshop recently participated in research conducted by the International Laboratory for air Quality and Health in the wake of the January Brisbane flooding (see News item for Feb).
The International Laboratory for Air Quality and Health (ILAQH) is based in Brisbane and operates within the Queensland University of Technology (QUT).
It undertakes research, postgraduate training and consultancy in the complex interdisciplinary field of air quality and its impact on human health, with a specific focus on fine, ultrafine and nano particles.
The three main aspects of ILAQH research activities are:
- Comprehensive characterisation of indoor and outdoor air, including emission sources;
- Integrated health and environmental risk assessments;
- Strategies for controlling and managing air pollutants;
The research is being conducted on properties which were inundated and looks at the air quality post cleanup. Samples of the indoor air were collected in several parts of the Sherwood site and the volume of moulds registered was visually displayed in a 3D model. Samples were also taken to grow the various moulds which were present.
As part of the survey the actual post-flood cleanup process was also reviewed.
We hope that we have contributed in a small way to lessons learnt, for use in future clean up processes.
May 2011
Increased Lifting Capacity For Carole Park Workshop
Kador recently expanded the lifting capacity in the Carole Park workshop. This was done to better enable the facility to build the larger sizes of water tanks, service modules, haulers and other components required by our clients, like this headframe column section being built for a North Qld underground mine.
An aging 10T overhead crane was replaced with a new 25T overhead crane.
The new 25T crane will work with the existing 20T crane and significantly increases the manufacturing flexibility in the workshop. The benefits of greater lifting capacity are already being seen.
April 2011
Bespoke Mine Service Vehicle Modules
Kador has long been a leader in the supply of spray rigs used for watering mine haul roads, but until recently, had not had such a significant part of the market for the modules which carry fuels, lubricants, coolant and greases to service in-pit mining equipment. This has changed over recent months.
In March we delivered a service module to suit a Cat 773 truck for a coal mine west of Brisbane.
In Jan we commenced manufacture of two large fuel tanks to suit Cat 777 trucks, for a Hunter Valley (NSW) client. The tankers will each carry around 68,000 litres of diesel fuel and 1,000 litres each of coolant and lubricating oil, This order continues Kador’s push into the Hunter Valley market.
Later in 2011 we will deliver a service module for a Komatsu HD785 truck, and another, to suit a Komatsu HD605 truck, both for Bowen Basin clients.
In each case the module is purpose built to meet the end user’s specific requirements for fuel, oil, grease, coolant and water tank capacity and configuration, and controls and accessories
Details of Kador’s range of service vehicle modules are available here.
March 2011
Kador Supports Downer on CHPP Upgrade Project
Over the past few months Kador has been working with Downer EDI Engineering to provide tanks, chutes, collectors and underpans, pipe spools and welded beams for a major coal handling and preparation plant upgrade in Central Qld.
The work is being fast tracked through our Sherwood and Carole Park workshops, with the Downer EDI Engineering quality inspector and expeditor working closely with Kador’s Project Manager to ensure the work is scheduled to meet site erection requirements.
Kador’s three workshops provide the flexibility to run multiple production lines in parallel to achieve rapid completions for tight project deadlines.
February 2011
Brisbane Floods
Like many Brisbane businesses, Kador’s Sherwood workshop was impacted by the floods of 10 and 11 January.
Kador shares an industrial estate in Sherwood Rd, beside Oxley Creek which (normally) drains into the Brisbane River. During the flood however, the three workshop bays had 2.5 metres of water through them, as flood waters backed up the creek and onto the site.
Kador’s workforce did an outstanding job during the following weeks, cleaning the buildings and offices, and drying out welding machines and other equipment to get the site back to full production.
We also had great support from our clients and business partners who provided labour and equipment to help us during this period.
Fortunately, our two other workshops, at Sumner Park, and Carole Park, were unaffected by the floods.
January 2011
Apprentice of the Year
Each December, Kador Manufacturing Director Don Vogel gives an award to the Kador Apprentice of the Year.
This year, the award went to Luke Alvea, who won a jacket from Kador, a welding helmet from Aitken Welding Supplies and a $100 voucher from Kargo Industrial Supplies.
In making the award, Don thanked Aitken and Kargo for their support, and congratulated Luke for his hard work and dedication during 2010. He commended Luke for setting a high standard for his peers and Kador’s future apprentices.
Luke commenced with Kador in January 2010, joining us through our industry partnership with Nyanda State High School. He is looking forward to jet skiing and motor racing over the Christmas break and spending time with family and friends.
Kador currently has seven apprentices and will take a further four in Jan 2011.
December 2010
Tailgates for Hitachi EH4500 Dump Bodies
Kador recently delivered a tailgate for an Hitachi EH4500 dump body, to be trialed on a Hunter Valley Coal Mine. Designed by CMP Engineers, the tailgate is expected to be the first of many.
The mine operates a fleet of Hitachi EH4500 trucks with dump bodies previously built by Kador, and the tailgates will extend the versatility of these bodies, enabling them to carry a wider range of materials.
Kador and CMP Engineering have good experience in enhancing the performance of existing dump bodies, and can provide tailgates, ducktails and spill containment boards for all sizes of dump trucks.
November 2010
Kador Partners with United Industries
Kador recently reached an agreement with United Industries of Perth WA, for United to market and manufacture under licence, Kador’s range of mine water tankers, rear dump bodies and service modules in Western Australia.
The relationship with United will now give mine operators and OEMs the ability to purchase the same high quality Kador equipment for their operations in all the major mining regions across Australia.
United will manufacture and provide full after sales service and spare parts support for these products, which will be branded ‘United – Kador’, from their facility at Henderson, just south of Perth.
United Industries is a privately owned company founded in 1973, originally specializing in industrial and commercial insulation. Since then, it has grown and diversified its ability to manufacture, supply and install a wide range of products for the mining, oil and gas, industrial and commercial sectors.
For further information contact Mark Hipgrave at Kador on 0418 556 048, or Angelo Raguseo of United Industries on 0418 921 898.
October 2010
Qld Mines Inspectorate Comments on Problems Caused by Haul Road Overwatering
Twice this year, the Qld Chief Inspector of Coal Mines has commented on safety problems caused by excessive watering of mine haul roads.
In Safety Bulletin No 94 (22 Jan), he wrote that ‘the number of incidents on haul-roads relating to over-watering is increasing. Most occur on ramps, and result in vehicle collisions with safety berms (bund walls)’. He recommended that ‘water trucks should be fitted with pulsed infusion systems that can be effectively controlled by the operator to manage the water output.’
In Safety Bulletin No 99 (23 Aug) he pointed out that high potential uncontrolled movement incidents on mine roads are currently averaging 7-10 per month, with watering or excessive watering identified as the primary cause of such incidents in 46% of cases.
The bulletin goes on to say that it is ‘imperative that more engineering controls replace administrative controls, to reduce or eliminate the probability of judgemental errors by water truck operators’.
Kador’s water tankers, fitted with the EnviroSpray road speed dependent continuous and pulsed water spray system can help operators satisfy inspectorate guidelines and recommendations in this area. Contact us to learn how.
October 2010
InterSafe Helps Kador Improve Safety
Earlier this year safety consultant InterSafe conducted a number of interactive workshops with our workforce, and carried out high level risk assessments of all of our sites. Looking at the damaging energies that relate to manufacturing industries, talking to staff and evaluating the taxonomy of injury data, InterSafe were able to provide a comprehensive report for Kador to use as a blueprint for corrective action.
After rating the risks of the action points, teams have been rolling out the improvements across all sites. Our competitive manufacturing teams have also looked at some of the manual handling issues highlighted in the report, and have revised some work practises to eliminate hazards. For example at the Sherwood workshop, we have repositioned a jib crane so that a piece weighting over 70kg is more easily moved by crane instead of pushed on a trolley, thus eliminating several hazards and improving the flow of work.
We still have more challenges to address as we roll out our two year action plan, however, the participation of all sites in addressing the shared issues has resulted a synergy that has already produced excellent improvements.
September 2010
Mission River Bridge Splint Piles
In early September, Kador delivered the last of sixty pile splints being manufactured to strengthen a rail bridge over the Mission River near Weipa on Cape York in FNQ.
The pile splint sections are fabricated in two halves from 12mm plate, and are designed to be bolted around the existing bridge piles, with the interstitial gap being filled with a special grout after installation. Particular attention was needed to the mating faces of the pile halves, with trial assembly undertaken in the workshop to verify a gap-free joint.
Accurate fabrication helps ensure the efficient and safe installation of the splints. This work is carried out by divers operating with few tools, while coping with poor visibility, tides, and the ever present ‘salties’ adding to the occupational hazards.
The application of lean manufacturing techniques enabled Kador’s Carole Park workshop to complete the work five weeks inside the allocated twenty week contract period while still achieving tight manufacturing tolerances for camber, twist, out of round and overall dimensions.
August 2010
Hamilton Island Ferry Jetty Pontoons
Patrons using the high speed ferries that service Hamilton Island probably don’t think at all about the jetty they are walking on as they arrive or leave the resort.
But if they inquired, they would learn that Kador, working with partner organisations Steelpro and Brisbane Abrasive Blasting provided the pontoons for a new floating passenger jetty for the ferries servicing the tourist destination in North Queensland. The jetty is 40 metres long, made up of two rows of 1.4m dia pontoon sections, bolted together and joined by three cross-sections.
The Kador team worked closely with Hamilton Island staff to provide the best available paint system for the pontoons, to ensure a long service life. The pontoons were also fully trial assembled in the Kador Sherwood workshop to ensure easy erection on site, to minimise disruptions to passenger services.
July 2010
Kador Participates in National Workforce Literacy Project
Like many in our industry, Kador has a significant number of employees from a non English speaking background.
To assist them in both their working and home environments, Kador is participating in a National Workforce Literacy Project being sponsored by the Australian Industry Group and funded by the Department of Education, Employment and Workplace Relations. Kador is one of two sites in Queensland involved in this pilot program which commenced in early 2010 and aims to improve the literacy and numeracy skills of workers. Julie Peries from Monica Mitchell Consulting is conducting weekly training with a small sample of our employees: some migrant workers, their leading hands and relevant managers in a holistic approach to improve communication in the workplace.
Training is customised to Kador specific identified issues, for example:
- improving English speaking skills;
- understanding written and spoken English;
- communicating effectively with migrant workers;
- documenting workplace procedures; and
- working together to improve productivity and safety.
The project is expected to conclude in October this year.
June 2010
Container ConVerter®
Kador recently helped Bulk Connections Australia Pty Ltd commission and make ready for local use a rotating container ConVerter® which they have imported from overseas.
The ConVerter® can be installed at ports and stockpile facilities that don’t have conveyor type shiploaders.
The ConVerter® works with standard open top shipping containers (with removable lids) which are brought to port either by road or rail and positioned within reach of the crane. The ConVerter® is then lowered onto the open top container, and twist-locks and side wall supports are engaged and the container is lifted into position above the vessel cargo hold. The container is then rotated 180º degrees and the material discharged into the ship’s hold. Once discharge is complete, the container is returned to the wharf, and the process repeated with the next container.
Bulk Connections plans to build future ConVerter® in Australia, and expects the concept to be popular at ports where cost and volumes don’t justify the construction of more conventional shiploading facilities.
May 2010
Competitive Manufacturing
In October 2009 Kador embarked on a 15 month Lean Manufacturing program in partnership with TAKT Australia and the Sunshine Coast Tafe. The program is a long term commitment by Kador to further the implementation of lean manufacturing into the business, and involves approximately forty employees across all three manufacturing sites.
The program is being delivered to four groups, each comprising a cross section of team members, including Directors, Administration, Leading Hands and Workshop Personnel. It takes a practical, hands on approach to the implementation of lean principles to achieve specific goals, while continuing to foster an environment of continual improvement.
Over the last six months, the program has introduced key fundamentals of lean to the team members including Waste Identification and Elimination, SMART goal setting, and 5S. In addition, the introduction of regular, structured lean activities through the Team Improvement Boards has facilitated obvious improvements in key areas, with the Plan-Do-Check-Act cycle ensuring that the improvements are sustained.
As the program continues into areas of Mistake Proofing, Value Stream Mapping and Problem Solving, Kador looks forward to the continuation of the benefits already gained through the program, in terms of both process and cultural improvement.
April 2010
Carbon Energy Bloodwood Creek Power Station
Over recent months, Kador has played a key role in the development of Carbon Energy’s 5MW Underground Coal Gasification (UCG) power station project at Bloodwood Creek (approximately 50 kilometres west of Dalby) in South West Queensland.
Commencing in Oct 2009, Kador has delivered spooled pipework, a metering skid, a pressure letdown skid and a knockout pot skid which all form part of the gas supply stream to what is understood to be Australia’s first UCG syngas power station.
In order to meet the project’s timetable, Kador’s Project Manager, Hector Martin worked closely with CE’s design consultant and the site construction crew, to ensure fabricated items were fast tracked through the workshop, to meet project deadlines.
Carbon Energy is an emerging listed energy company whose purpose is to produce clean energy and chemical feedstock from (UCG) syngas, using technologies developed in conjunction with the CSIRO.
April 2010
Dave Rogers – 30 Years Service With Kador
Kador recently celebrated 30 years of valued service by one of its tradesmen, Dave Rogers. Dave commenced with Kador in our Sumner Park workshop and has worked in all sections of our operations from crane bodies through to mobile mining equipment, including rear dump bodies and water truck units.
Dave has been at our Sherwood workshop for the past five years, the same location where he commenced as an apprentice with ANI Sargent in 1967, building draglines. He stayed at Sherwood through to 1980, prior to joining Kador at Sumner Park.
At a ceremony at the Sherwood workshop, Kador's Chairman Ron Strasser praised Dave’s commitment and the influence he had had throughout the Company.
Dave is seen here with a gift from the Company in recognition of his 30 years of service.
March 2010
Market Uptake of the Enviro-spray™ Water Control System for Mine Water Tankers Continues
Since the start of 2010 Kador has received orders for nine new water tankers, in sizes from 45KL to 75KL, to be fitted onto Cat trucks. Eight of the nine will be fitted with the Enviro-spray™ water flow control system, which puts water onto mine haul roads at a rate dependant on the vehicle’s speed.
Conventional water spray control systems have a fixed (or manually operated step variable) water control system which can result in over-watering of mine haul roads when the water truck is travelling slowly or stopped. Over-watering has long been identified as the cause of many high-potential safety incidents. The Enviro-spray™ system prevents over-watering and also enables substantial water savings for mine operators.
The Enviro-spray™ system was developed by Hyden Engineering, in the Hunter Valley NSW, and is distributed in Qld by Kador.
Kador’s MD Mr Philip Smith commented: “We are very pleased that of these nine new orders, five will be going to a major mining operation in the Hunter Valley, our first deliveries into this area. It is also great to see that the benefits of the Enviro-spray™ system are becoming widely recognised by both contractors and mine owners. We look forward to continued interest in Kador water tankers and the Enviro-spray™ system from clients throughout eastern Australia.”
February 2010
Qld Dept of Main Roads Approval
Over the years, Kador has fabricated many structures for Queensland’s road contractors, including this pedestrian bridge over the Gold Coast Highway.
After a recent audit by the Qld Department of Main Roads, Kador has now been formally included on MR’s own list of fabricators approved to supply steelwork for bridge and other infrastructure projects in the following categories:
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Fabricated Steelwork:
- Road side mounted fabricated sign gantries
- Bridge Restraint Angles
- Bearing Attachment Plates
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Bus Stations:
- Bus Station Structures
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Road Lighting:
- Traffic Mast Arms
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Noise Barriers:
- Fabricated noise Barrier Posts
Main Roads prime contractors wanting a quotation for these or other items on projects where MR approved fabricators are required, can contact us here.
January 2010
Coal Load-Out Bin
Kador recently completed fabrication of a 500T load out bin for new coal mine being constructed near Lithgow in NSW.
The 1.7 mtpa mine will supply coal for the export markets through the Port Kembla Coal Loader.
With an overall height of over 16 metres and diameter of 10 metres, the bin was fabricated in segments, and trial assembled and match marked in our Carole Park workshop to ensure easy erection (by others) when it arrived on site.
December 2009
Apprentice of the Year
Kador apprentice Matt Riddell was recently awarded the Kador 2009 Apprentice of the Year at a ceremony in the Sherwood workshop.
Matt who joined Kador in January 2009 received a jacket from Kador, a tool voucher from Kargo Industrial Supplies and a portable welder from Aitken Welding Supplies.
Speaking at the presentation, Kador Manufacturing Director Don Vogel thanked Kargo and Aitken for their support and congratulated Matt. He added “Matt has set a great example to all our apprentices by his hard work and dedication. We are taking on four new apprentices in 2010, which will bring our total to seven apprentices, and look forward to continuing our work in training tomorrow’s tradespersons.”
November 2009
New Overhead Cranes for Sherwood Workshop
November sees the installation of two new 35T overhead cranes in the heavy fabrication bay of Kador’s Sherwood workshop, replacing two old 25T cranes. This investment demonstrates Kador’s confidence in the future of heavy manufacturing in SE Qld.
With mining equipment getting larger (and heavier) there is an increasing requirement for manufacturers to be able to handle larger fabricated components. The new 70T lifting capacity will better enable us to handle the larger sized pressure vessels, haul truck dump bodies and dragline components that are being used in the mining and process industries.
Typical of these is this large subassembly despatched in late October - the last of nine pieces which make up the rear rotating frame for a new dragline being built in the Bowen Basin, in Central Qld.
October 2009
Kador’s relationship with Nyanda State High School Continues
Nyanda SHS Year 11 students with Kador’s Greg Birch
The following article appeared in the Sept/October issue of the Nyanda State High School Newsletter:
During the year our Year 11 students have been working with Greg (welder / fabricator from Kador) under the supervision of their teacher Mr. Hufschmid to manufacture components for Kador projects.
The Students are really enjoying the challenge of producing the components on a regular basis and meeting the quality assurance standards of industry. To reward the students for their efforts, and to broaden their knowledge of the metal fabrication industry we decided we would make a visit to Kador to check out where the parts we were producing fitted into the ‘Big Picture’.
On arrival we were greeted by the Worksite Manager, Mr M Robinson, who welcomed us and escorted us into the office for our workplace health and safety lecture by their on-site WPHS Officer. It was good for the students to experience the emphasis now placed on safety in the work environment as it added reality to many of the requirements we now impose upon them at school.
During our tour we saw some dragline components being manufactured that made our school buildings look very tiny. The students were surprised at the enormity of many of the components. We were shown the crane booms being put together, and the students were very proud to see the components they manufactured being welded into place, and still with their names on them.
After our tour the students have expressed an interest in furthering their studies in this area, hopefully gaining employment at Kador.
September 2009
Coal Dump Bodies for Clermont
Kador was recently awarded a contract for the design and manufacture of seven dump bodies for the Komatsu 830E trucks at the Clermont Mine in Central Qld. These bodies will each carry 220 cubic metres of SG1.0 coal, making them amongst the largest 830E bodies built in Australia. Deliveries will commence in the first quarter of 2010.
They will replace the seven overburden bodies originally provided by Kador (pictured) and which have been in service at the mine since early 2008.
(photo courtesy of RTCA)
July 2009
Dragline Tee Section Upgrade
Kador’s Carole Park workshop recently delivered a new Tee Section for a Bucyrus 8200 dragline upgrade.
The contract was to fabricate, trial assemble, weld, heat-treat and paint prior to loading out the 8 large 114mm plates to form four 21 tonne ring sections. When complete, these make up a 15 metre diameter assembly.
A combination of manual and semi automated welding processes were used to minimize distortion and ensure dimensional accuracy, for trouble free fitup when the quadrants are installed on the dragline.
After fabrication, the quadrants were stress relieved in a purpose built oven assembled in the work shop.
June 2009
Kador Implements 5S Housekeeping System
Kador, with the help of Brisbane based consultancy QMI Solutions, recently introduced the 5S Housekeeping System across its three workshops. The 5S system is a structured, systematized approach to housekeeping and a cornerstone of any successful manufacturing operation. It recognizes that good housekeeping is fundamental for an organization to deliver quality products on time.
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| Before | After | Before | After | |
There are five steps to the 5S system. They corresponded originally to five Japanese words starting with ‘s’ but now are most commonly known as follows:
- Sort - The first step in the 5S program is to get rid of excess materials and equipment
- Set in Order - The second step is to ensure that all materials, tools and equipment have a designated location and that all such locations are easy to find – ‘a place for everything and everything in its place’
- Shine - This third step is sometimes referred to as "sweep" or "scrub". It emphasises the removal of dirt, grime and dust from the factory, and its purpose includes improving morale and ensuring that when someone needs to use an item it is in good condition and ready for use
- Standardise - Step four is to establish standards to be regularly applied to the workplace that will help maintain the first three steps (3S)
- Sustain - The fifth step is to make a habit of maintaining the momentum of the previous four steps to assure sustainability of the system
The system aims to remove waste from the workplace, provide a reduction in non-value adding activities, provide an environment that fosters continuous improvement and improve safety and quality.
Even after only a short period, Kador is reaping the benefits the 5S system provides.
QMI Solutions is a not-for-profit organisation dedicated to helping industry on the journey to manufacturing excellence through research, education, and implementation of world class practices and technologies.
For further information on the work QMI has done with Kador, click here.
May 2009
Kador Helps Put a Lid on Municipal Landfill Problems
Kador is helping municipal landfill operators put a lid on both their costs and their environmental problems through the manufacture of WasteWell Environmental’s ‘Landfill Lid’.
WasteWell have designed a simple, affordable and adaptable landfill day cover system that controls birds, flies and windblown litter, and reduces fire risk, all at a lower cost than using virgin excavated natural material (VENM, or soil cover).
The Landfill Lids are placed over a compacted waste tip face at the end of every working day, using the machinery on site. Each lid comprises a portable, rigid, wind resistant 90m2 steel frame that weighs 1.5 tonne. A UV-rated PVC tarpaulin is attached to the frame and has no contact with the waste or ground. The lids are used in a series to cover the active working tip face, replacing the 150mm layer of VENM that would otherwise be required.
Easy to move with dozers, compactors, excavators or other machinery, the Landfill Lid can be positioned in minutes, making the end of the day easy for operators.
According to Wastewell, the Landfill Lid in use on a number of landfill sites and is gaining a growing share of the market.
April 2009
SEBBA Dump Bodies
Kador recently delivered the first of a quantity of dump bodies being manufactured for SEBBA International. SEBBA is the product design and development arm of Queensland based Swift Group Holdings.
SEBBA selected Kador as their Brisbane based partner for the manufacture of their innovative, lighter weight, larger volume OHT bodies to meet the ongoing demands for their products.
The first bodies are for CAT 793 & TEREX MT3700 trucks and will be used in the Central Qld coalfields and are built in accordance with SEBBA's quality assurance specifications.
Over the past nine years Kador has manufactured more than 120 dump bodies for both OEMs and the body replacement market.
March 2009
Salt Harvesters for Western Australia
Kador played a major role in the manufacture of two new salt harvesters for use at Shark Bay, and Onslow in Western Australia.
Kador’s experience in the manufacture of complex fabrications, and ability to ‘fast track’ the work while the design was being developed, prompted Brisbane based Loadquip to select Kador as a partner for this project.
The harvesters sit on crawler tracks, with a cutter head harvesting the dried salt and feeding it into two inclined conveyors, a cross conveyor, and then into a truck.
Kador’s scope of work included the fabrication and surface treatment of the main frame, the salt harvesting ‘cutter’ and the conveyor support structure.
The harsh operating environment for the harvesters on the salt pans in northern WA required extensive use of 3CR12 steel, and an onerous surface treatment specification.
February 2009
Kador’s Occupational Health and Safety - and Environmental Systems Accredited
Kador’s integrated management system was recently audited by SAI Global as complying with ISO 14001:2004 (Environmental management systems) and OHSAS 18001.2007 (Occupational health and safety management systems).
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ISO 14001:2004 is the international Standard that specifies requirements for a structured and systematic approach to environmental management. The Standard applies to those environmental aspects which the organisation can control and over which it can be expected to have an influence. As such is provides a sound basis for organisations to meet their environmental challenges. |
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OHSAS 18001.2007, the Occupational health and safety management systems standard, shares common management systems principles with ISO 14001. This Standard sets auditable criteria for an occupational health and safety management system and includes guidance on how those criteria may be achieved. It encompasses the requirements of AS/NZS 4801:2001, the Australian and New Zealand Standard for Safety Management. |
In recent years, Kador’s clients have placed greater emphasis on the safety and environmental management systems in place at their suppliers workshops, and in response, Kador commenced work to adopt these standards, in late 2006.
Kador’s Managing Director, Philip Smith said “The success of these audits is a reflection of the significant improvements in safety and environmental performance that our work crews have achieved in recent years. We look forward to further and continuous improvement in the future.”
January 2009
Dragline Boom Repairs
One of five draglines at a mine near Blackwater in Central Qld was undergoing routine maintenance in early December when a boom fell 30 metres from a crane.
Kador were asked to assist in getting the machine back into production by fabricating new boom sections, and were pleased to be able to respond by allocating workshop crews to work 24/7 to achieve the best possible turnaround.
Kador’s three workshops provide capacity and resource flexibility to handle urgent jobs such as this, to ensure the dragline is back in production as soon as possible.
December 2008
Rio Tinto Hydrocyclone Batteries
In December, Kador completed the first of three hydrocyclone batteries for Rio Tinto Aluminium’s US$1.8 billion Yarwun Stage 2 alumina refinery expansion project near Gladstone. The project will more than double annual production, increasing annual alumina output from 1.4 million tonnes to 3.4 million tonnes by 2011.
The hydrocyclone batteries are each 6m wide and 5m high and will be installed in the Hydrate Classification section of the refinery. They each contain 24 cyclones and take liquor slurry from the Precipitation Tanks through a central distributor and separate it into Product (Hydrate) Slurry and Fine Seed Slurry.
Kador’s scope of work included full shop trial assembly of the batteries, and hydrostatic testing of the internal piping systems.
Kador has good experience in the fabrication of the complex shapes used to make the hydrocyclone battery tanks and tundishes, having made the batteries for the initial stage of the Yarwun refinery, in 2003.
October 2008
Kador Sponsors Brisbane Mining Dump Trucks Conference
As Queensland’s leading manufacturer of dump bodies for mining dump trucks, Kador was pleased to accept an invitation to become a major sponsor of the Mining Dump Trucks conference to be held at the Brisbane Hilton Hotel on 9 & 10 Dec.
The conference organisers write:
Increasing the payload on mining trucks can deliver substantial returns and improved productivity. Lighter trays deliver greater payload, however durability must be maintained for the productivity to be realized. But lighter trays and increased payload cannot be at the detriment of tyres or maintenance.
The impact of tray design can flow through to reduced maintenance, servicing, fuels, lubricants, tyre wear and tear. Workplace safety is also a major consideration in the operation of dump trucks. All of these items are critical to the overall successful management of a mine. The savings these design and operational changes deliver can result in many millions of dollars of additional profit.
The Mining Dump Trucks conference will bring together experts to look at the most pressing issues associated with dump truck tray design and to examine how best to improve productivity through streamlined operations.
At a time of economic uncertainty and rising pressures at the operational level this practical and focused event offers delegates a unique opportunity to learn from experts and to network with peers.
Further information about the conference, and registration details, are available on the Informa Australia web site.
October 2008
Kador & Nyanda State High School Enter Into an Industry Cooperative Programme
Teachers at Nyanda State High School in Salisbury approached Kador in late 2007, looking for assistance to give their students real life skills that could lead to possible trade placements in the steel fabrication industry. Kador suggested that the students manufacture a quantity of the concrete mixer discharge chutes and support racks that Kador makes for a long standing customer.
After some months of set up, and with the assistance of a grant from the Queensland Department of Education, Training and the Arts, the students delivered their first batch of chutes in September.
The key focus areas for the program were to give the students an introduction into the engineering industry with real deadlines and simulated work conditions. With the help of Kador personnel and support from their teachers, the students have fabricated, welded and presented parts to industry quality standards. All students have enjoyed the challenge and are now looking forward to planning and producing further components.
Kador already has fifteen apprentices in its three workshops, and plans to take on further school based - and full time apprentices in the near future.
September 2008
TV Network visits Kador Workshops
During September, Kador hosted a visit from a writer and producer from one of the TV networks who are researching a planned six part television drama series. The series will be largely set in and around a fictional medium sized engineering workshop which produces equipment and components for the mining industry.
Their specific interest was life in the workplace in the twenty first century - how things have changed, the cultural mix, migrant and temporary guest workers, the impact of the mining boom, the "post Workchoices" world in terms of employer/employee relations, etc.
The proposed fiction drama series will be set in Townsville and feature ‘nuts and bolts’ detail of life in the engineering world - from the minutiae of work on the shop floor, to the experiences of both local and guest employees, and the increasingly competitive business environment faced by employers.
Through visits to our three workshops, Kador gave the network personnel a good overview of life in a busy steel fabrication facility making engineered products for the mining and other industries.
August 2008
Norwich Park Mine - Coal Hauler to Water Spray Rig Conversions
Kador is giving a new lease of life to two old 220T belly dump coal haulers by converting them into 190KL water spray rigs.
The haulers, which are each over 15 years old, and at the end of their useful life, are being sent from BMA’s Norwich Park Mine to Kador’s Carole Park workshop, where we cut off the gooseneck and tail section, and fit a new 190KL water tank in between.
Kador’s work scope includes the design (including FEA) of the new baffled monocoque tank, integration of the new tank with the old gooseneck and tail end, and all mechanical, hydraulic and electrical work to provide fully functional water spray rigs for BMA.
The first of the ‘new’ water spray rigs was returned to Norwich Park Mine in August, and married up with its Cat 784 prime mover where it will provide many more years’ service to the mine operations.
The second rig conversion commenced immediately after the completion of the first.
July 2008
Mobicon Container Handlers
Brisbane based Mobicon Systems Pty Ltd has appointed Kador to manufacture the steel structure of their Mobicon container handlers.
The Mobicon is a straddle carrier that provides an effective method for loading, unloading and maneuvering any 20 or 40 foot container without the use of expensive forklifts. It is especially effective in height and space restricted areas including warehouse environments.
Mobicon selected Kador because they wanted a partner who could deliver a quality product to support the production demands of their fast growing business.
June 2008
Ammonia Storage Vessel
Kador recently completed the delivery of a 100 tonne capacity ammonia storage vessel to be installed as part of an ammonium nitrate plant upgrade, in Central Qld.
Kador’s contract included the design of the vessel, to AS1210, Class 1.
The vessel is 26 metres long and 3.2 metres in diameter, with a total weight of 64 tonnes. These dimensions called for careful transport co-ordination to ensure its journey through the suburbs of Brisbane to the site was executed safely.
Perhaps the most pleasing feature of the whole project was the quality of the welding work carried out in Kador’s Sherwood workship. Welding was subject to 100% X-ray, and over the whole vessel, the Kador workforce achieved a weld repair rate of less than 0.1%.
May 2008
Kador's Steel is Now Green
Kador’s resource industry clients specify their steel in many different colours. But, underneath the paint system applied by our surface treatment partners, the steel is now a lovely shade of green.
This has come about through Kador signing up to the national GreenPower Program.
Kador’s three workshops consume over 1.5 GWh of electricity each year, producing a wide variety of fabricated steel items for our clients. Through our participation in our electricity retailer’s Green Energy program, our resource industry clients can be assured that the fabrication of their dump bodies, water spray rigs, haulers and other items is helping support their own environmental goals.
Established in 1997, GreenPower is a national accreditation program that sets stringent environmental and reporting standards for renewable electricity products offered by energy suppliers to businesses across Australia. GreenPower aims to increase Australia’s capacity to produce environmentally friendly renewable electricity by driving demand for alternative energy generation.
The program was developed in consultation with the energy industry, and various non-government organisations including the Australian Consumers Association, Greenpeace, the Australian Conservation Foundation and WWF.
April 2008
Enviro-spray™ Dust Suppression System
Kador has recently been appointed Queensland distributor for the Enviro-spray™ water control system, for use on mine water spray rigs.
Enviro-spray™ was specifically developed by Hunter Valley NSW based Hyden Engineering as a ‘plug-and-play’ system to optimise water usage on mine roads.
The basic system consists of a water pump module containing a hydraulic pressure sequence valve, a large variable speed hydraulic motor and water pump.
The Enviro-spray™ push button control system sets the water flow rate, road speed and spot spray distances while constantly measuring tank water level, filter condition and motor condition. The system can be preset to have default water flow rates, road speed settings and spot spray distances so that the operator simply selects road speed, spot spray or both and drives, while the Enviro-spray™ system takes control. It will stop and start the water flow at intersections and automatically adjusts the water flow rate as the machine speeds up and slows down while also stopping and starting to provide the set wet and dry distances.
Options such as Enviro-spray™ foam injection, spray head controls, water cannon controls and water level monitoring can all be added to realise the full potential of the Enviro-spray™ system and are simply fitted and plugged into the control system.
Kador will offer the Enviro-spray™ system on its own design water spray rigs, or as a retro-fit on existing rigs, and expects the system will be welcomed by both OEMs and mine owners as a step forward in the efficient use of scarce water supplies.
Further technical details are available from Hyden Engineering
March 2008
Bucyrus Dragline Components
Kador has played a major role in the delivery of a new Bucyrus 8750 dragline for the Lake Lindsay coal project in central Queensland. Commencing in early 2007, Kador converted over 755 tonnes of heavy platework and large tubular sections to the following key dragline components:
- Propel sections;
- Tristructure;
- Backlegs;
- Transformer supports;
- Centre Boom;
Components were fabricated and machined in accordance with Bucyrus’ strict quality requirements with the work scheduled to meet the site assembly and commissioning target of late 2008.
Bucyrus International is the world's leading manufacturer of walking draglines, electric rope shovels and rotary blasthole drills. It has manufactured 90 per cent of the draglines in use around the world.
February 2008
Komatsu Dump Bodies
In Feb 2008, Kador delivered the first of seven dump bodies being manufactured for Komatsu Australia, for installation on 830E model dump trucks at the new Clermont Mine. These bodies have a capacity of approximately 150 cubic metres, and will be used to carry overburden excavated as part of the mine’s development.
Kador has a long record of building dump bodies for even the largest haul trucks, and over the past nine years has delivered over 120 dump bodies for installation on haul trucks of all sizes. We can supply bodies to OEM’s standard designs, or provide mine specific designs where required.
November 2007
Water Spray Rigs
Over recent years, Kador has designed and constructed many water spray rigs, used for dust control on mine roads. With their large on-board water storage capacity, these rigs also have the ability to be used for fire fighting if required.
From Sept through November 2007, Kador was awarded contracts for eight more water spray rigs, ranging in size from truck mounted 70,000 litres units to a massive 190,000 litre articulated unit. By way of comparison, a good sized home swimming pool holds around 50,000 litres.
The rigs will be used on both new and existing mines, and are to be progressively delivered through to mid 2008.
October 2007
More Bauxite Trailers for Weipa
Kador recently commenced manufacture of four more 195t bottom dump bauxite trailers for Rio Tinto Aluminium (RTA). These will be delivered through to mid 2008, and will take the total number of Kador supplied trailers to seventeen.
Kador is responsible for the full fit-out of the trailers, including all electrics and hydraulics, and fitment of axles and wheels. They will be handed over to RTA in Brisbane as fully commissioned units ready to be put into service on arrival at site.
September 2007
Fuel & Service Trucks for Clermont Mine
In Sept 2007, Kador was awarded a contract to provide three Fuel and Service Trucks for the new Clermont coal mine in central Qld.
The trucks will carry fuel, lubricants and coolant to mining and ancillary equipment in the open cut, to enable this equipment to operate at maximum productivity.
One truck, to carry 30,000 litres of diesel fuel and a range of lubricating and hydraulic oils and coolant, will be based on a Cat 773E chassis. The others will carry smaller quantities of fuel but a similar range of oils and coolant, will be installed on Mack Metroliner bases.
Kador, with its partner Liquip Sales has wide experience in the design and manufacture of fully fitted out service vehicles, with large and small units currently operating in many mines throughout Queensland.
August 2007
1,000th Franna Crane
Kador has been fabricating booms and bodies for Franna cranes (now part of the Terex Group) since 1998, and we recently completed our 1,000th Franna crane set.
These workhorses of the Australian lifting industry were originally designed in Brisbane and are now to be found on construction sites and industrial locations across Australia and in some locations overseas.
Kador currently fabricates the full boom sections and bodies for the 15T, 20T and 25T cranes in its Sumner Park and Sherwood workshops, and delivers painted components to the Terex Eagle Farm facility where engines, drive train components, hydraulics, winches and electrics are added, and the completed cranes are assembled and commissioned, ready for dispatch. Current production is at a rate of around 30 crane sets per month.
With the increasing demand for Franna cranes, Kador has worked with Terex to implement ‘lean’ manufacturing techniques, so that Terex can meet ever increasing customer orders. This initiative was undertaken with the help of QMI Solutions, a Brisbane based not-for-profit organization which helps industry achieve manufacturing excellence through implementation of world class practices and technologies.
June 2007
Bucyrus 8750 Dragline Propel Sections
In Feb 2007, Bucyrus Australia awarded Kador a contract to fabricate the Propel Sections of the new 8750 Dragline for the Lake Lindsay Coal Mine. These consist of the left and right Intermediate Sections (approx 44 tonne each) and the left and right Bearing Sections (approx 70 tonne each).
Kador was able to meet the very strict quality requirements both in project management documentation/controls and in their application to fabrication and welding. The work was completed to schedule in June 2007.
Project Manager Neil Kerswell commented that “Kador has an open book policy with our customers and we work hard to be on time and meet client quality requirements. This journey with Bucyrus has been more like a partnership than a customer/supplier relationship and thus mutually beneficial to both companies. We hope this is the beginning of many more contracts with Bucyrus.”
September 2006
Rio Tinto Aluminium (Weipa)
In September 2006 Kador was awarded a contract by Rio Tinto Aluminium (RTA) for the supply of four 195t bauxite trailers. These will be progressively delivered through to July 2007, and will take the total number of trailers supplied by Kador to RTA over the past three years to thirteen.
Shortages of Bis-alloy plate in the early stages of the project were overcome by careful planning and pre purchasing which enabled the promised delivery schedule to be met.
To ensure the success of the project, prior to commencement Kador reviewed and updated the job safety, work procedures and quality plans for the work.
The trailers are fabricated at Kador’s Carole Park workshop, then fully painted and fitted with all hydraulic systems and electrics. When completed they are transported on a low loader to the port of Karumba and then barged to Weipa.