The vessel has been returned to service, with repairs expected to be addressed as part of upcoming maintenance.
The fleet had been plagued with problems over the past 18 months since the Herald first revealed its River-class ferries could not pass under specific bridges if passengers were seated on the top deck.
Asbestos was also found in those ferries, which are unable to operate at night due to a glare issue in the cabin and experienced stalling issues when braking under emergency conditions during early testing.
A source with knowledge of the matter described the welding defects as “cracks in the welds” and added the problem had not been identified with previously locally acquired Emerald ferries.
Opposition transport spokeswoman Jo Haylen called on the government to release the full findings of the independent report into the Balmoral.
“Passengers across Sydney are paying the price for the government’s failed transport procurement policies. Whether it’s cracked Manly ferries or cracked inner west trams,” she said.
“The government cannot hide behind the private operator. They should release the independent maritime surveyor’s report into the Balmoral immediately. The people of NSW deserve to know the truth about the government’s failed Manly ferry purchase.”
Doubt has lingered over the ability of the new ferries to operate in bigger swells on Sydney Harbour, particularly near the Heads, which the larger Freshwaters can handle.
The government last year announced its intention to retire all four Freshwater ferries, but backed down on the decision and kept two of the ferries for weekend and public holiday services amid public pressure.
The Emeralds had not been able to operate in larger swells recently because they had not yet been tested and certified for the conditions.
Delays to the arrival of the Emerald-class ferries were due to flooding in Port Macquarie earlier this year, where work was being carried out on the vessels.
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Cracks found in brand new Sydney Harbour ferry
Source: Philippines Alive