Submarine Independent Certification

The scope involved the engineering certification of lifting lugs and lifting systems for equipment exceeding 100 kg, including:

• Inbuilt, welded, and fixed lifting lugs
• Verification of lifting plans for each unit
• Re-certification for modified or updated equipment

Each item required individual certification based on engineering calculations, rather than physical testing, ensuring consistency across a large volume of equipment sourced globally .

Key project parameters included:

• Initial certification of 108 equipment units, with anticipated increase (~15%)
• Equipment sourced primarily from European manufacturers
• Long-term program delivery extending to 2032
• Mandatory retention of engineering documentation until 2040

The certification process followed strict compliance frameworks, including:

• Australian Standards (AS4991)
• Defence Australia requirements
• BAE Systems and Aerius Marine specifications

• Certification needed to align with multiple overlapping standards, including defence-specific protocols and international supplier requirements.
• Each lifting lug required customised engineering verification, with no standardised design across units.
• Sensitive defence information required de-identified engineering templates, limiting access to full design details while still ensuring accurate certification.
• Certification relied entirely on:
• Analytical calculations
• Finite Element Analysis (FEA) rather than load testing
• All engineering calculations and certification records needed to be securely maintained until 2040.

Incon implemented a structured and scalable certification framework:

• Detailed structural calculations for each lifting lug
• Use of Finite Element Analysis (e.g., Strand7 software) to validate stress distribution and load capacity
• Verification against AS4991 lifting device standards
• Development of a uniform data template for all equipment
• Captured:
• Load capacity and geometry
• Material specifications
• Lifting configurations and constraints
• Independent review and certification of lifting methodologies
• Assessment of:
• Crane configurations
• Load paths and lifting angles
• Safety factors and operational constraints
• Modular approach enabling:
• Batch processing of multiple units
• Rapid re-certification for design changes
• Two-week turnaround per submission (subject to data availability)
• Alignment with:
• ISO-certified management systems (WHS, Environmental, Quality)
• Robust documentation, audit trails, and certification records maintained

The project enabled:

• Safe and compliant handling of critical equipment across the submarine build program
• Consistent certification across a large and diverse equipment portfolio
• Reduced risk in lifting operations through validated engineering design
• Efficient processing of certifications aligned with project timelines
• Full traceability and audit-ready documentation for defence compliance

• Independent, defensible certification aligned with defence standards
• Advanced analytical validation (FEA-driven design verification)
• Scalable certification workflow for high-volume engineering assets
• Risk mitigation in lifting operations without reliance on physical testing
• Long-term documentation strategy supporting lifecycle compliance