SPECIALISED TEXTILES ASSOCIATION INC. Vol 12 No 6November • December 2012 • January 2013

STA member newS | induSTry eVenTS | memberS in The SpoTlighT | rTos

All manner ofbaNNers

large market for geomembraNes

Tomorrow’s industry leaders

uNite today

Fabric structures committee sets the standard

www.hvgfabrics.com.au

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NOVEMBER • DECEMBER 2012 • JANUARY 2013 · 1

CONNECTIONS magazine is published on behalf of the Specialised Textiles Association Inc. by CommStrat Limited.

Publisher CommStrat

editor Nicola Cardnicola.card@commstrat.com.au

design & Production Annette Epifanidisannette@commstrat.com.au

national sales Manager Yuri MamistvalovPhone: 03 8534 5008yuri@commstrat.com.au

contributors Jamie Howard, Roger La Salle, Beatrice Moonen, Dhani Narejo and co, and Holly O’Dell.

coMMstrat ABN 31 008 434 802

Level 8, 574 St Kilda RdMelbourne Vic 3004www.commstrat.com.au

sPecialised textiles associationSuite 201, 22 St Kilda Road,St Kilda Vic 3182Phone: 03 9521 2114Local call: 1300 555 787Fax: 03 9521 2116www.specialisedtextiles.com.au

Disclaimer: Except where specifically stated, the opinions and material published in the magazine are not necessarily those of the publisher or the STA Council.

contents

A S S O C I A T I O N

association Matters2 Report by STA President 4 STA office update16 Young Leaders Conference Priming the next generation of industry

leaders 33 Fabric Structures Committee

report by Beatrice Moonen 42 STA welcomes new members

neWs corner8 Members' news

suPerb structures18 Novel and unique structures Showcasing member talent

sPecial Features12 Gargantuan geomembranes The size of the market continues to

expand

26 All manners of banners All that matters: the right ink, print and

timely delivery30 Using geosynthetics to

stabilise soils In a remote Pacific location34 Innovation Roger la Salle uncovers the ‘third eye’ 36 Truck cover and tarp markets

pick up speed Banners on the move

sPotlight on MeMbers44 Members’ products and services

training and eVents48 Industry events and RTOs subscriPtions

to subscribe to Connections for just $75 inc gst annually contact ruth spiegel ruth.spiegel@commstrat.com.au

16

1210

4226

2 · CONNECTIONS

a few words from the President

STAMATTERS

Thank you to

all who put up their hand to be involved in a committee and

thank you to those already working

hard in the already well established

Fabric Structures Committee.”

Another couple of months have flown past since my last

missive in this magazine. A lot has been happening in

STA land and much of it has already been mentioned in

various newsletters from the office or from me.

The most notable event of course was the recent

Young Leaders Conference held in Melbourne during

the middle weekend of October. Nineteen young

leaders attended the event, which was hailed by all who

attended as a great success. This event is fast becoming

a feature of our calendar, an envied one at that.

Recently I was travelling overseas on business and our

Young Leaders Conference and subsequent challenge

was known to my overseas contact (via our STA

e-newsletters) and very favourably commented upon to

me and all I was with.

One comment was along the lines: ‘I wish we had

something like this here.’ It is rare to find any industry

association that does what we do in this regard.

Congratulations and thank you to all who attended,

Young leaders, Legends and members of COM. None

of it would have been possible without all of the work

and organisation of our hardworking and long-suffering

association Manager Ana Drougas. Thank you Ana for

another winner.

Sell out successWhile we are talking of highs, the Super Expo 2013 on

the Gold Coast is selling out fast. Recently an additional

hall was hired to allow for additional exhibitors. We now

have four halls at the Gold Coast Exhibition Centre. At

the time of printing, I understand 85% of the booth space

has been sold. I also understand that all, or at least

all but the sponsorship on offer, has been taken up. It

certainly appears that the industry at large is very keen

on the idea of the combined expo.

Training agreementOther good work has been done (quietly and in the

background) by Kent Williamson in relation to the

agreement with NSW TAFE and their input and training

delivery of the Certificate 2, Installation of Blinds and

Awnings Course. STA has received NWDF funding.

The process took a little longer than expected but with

the agreement in the bag we should be in a position to

commence the first lot of training in February 2013.

Fabric structuresOur Fabric Structures Committee has also been working

busily and now the consumer checklist document has

been finalised it will soon be circulated to members,

along with the licensing document. In addition a letter

to the Queensland Coroner has been prepared and sent

offering technical and expert assistance for the coronial

inquiry into the recent tragic fatality at Lismore involving

a shade structure.

The Young Leaders’ Conference

Much of the work done by the STA is not as high profile

as the expo/convention or the Young Leaders Program

but it does not mean it is any less important or valuable.

We are very fortunate to have a very dedicated

Manager and COM, who work hard to make the

organisation something of value, something to be proud

to be involved with.

We are getting better all the time and much work is

continuing, such as the accreditation program, setting

up of various committees, for example the editorial

committee to give direction and ideas to the editor

who produces the association magazine; and also the

awards committee which is tasked to look at the awards,

categories, judging criterion etc.

Thank you to all who put their hand up to be

involved in a committee and thank you to those

already working hard in the already well established

Fabric Structures Committee.

Remember you only get out of any organisation what

you put into it. Get involved, have your say and reap the

rewards of membership of STA.

N AT I O N A L D I ST R I B U TO R S O F I N D U ST R I A L & CO M M E R C I A L T E X T I L E S

Ricky Richards (Sales) Pty Ltd 16 Park Road Homebush NSW 2140 Phone: 02 9735 3333 Fax: 02 9735 3311 www.rickyrichards.com.au

Contact our team today to find your fabric solution!

For 30 years Ricky Richards has assisted fabricators across Australia with solutions for a

multitude of fabric applications. Our extensive product portfolio, technical expertise and

friendly, efficient staff ensures that Ricky Richards offers the highest quality of service

available to customers today.

Tarpaulins

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Annexes

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Sports Equipment

TentsWindow Furnishing

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PolyethyleneGround Covers

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fabric solutions foraustralian applications

RR ACASPA ad 2012.indd 1 16/02/12 3:01 PM

4 · CONNECTIONS

Super Expo

The Super Expo has generated enormous

interest and support from sponsors and

exhibitors. Sponsorship was taken up so

enthusiastically that it had to be extended -

and still some may be disappointed. Most of

the exhibition booth space has been taken up,

so an additional (hence fourth) exhibition hall

will be used to cater for the huge demand.

This Expo is shaping up to be bigger than

Ben-Hur and clearly what our industry is

clamouring for.

GreeneFox has been appointed project

manager for SuperEXPO 2013 and will

handle much of the marketing, bookings

etc. In addition to Greenefox, Exponews

has been engaged to organise and manage

registrations, provision of ipad apps, scanners

for exhibitors etc. We are really moving into

the 21st century with some of the initiatives

for next year’s Expo.

A dedicated website for the SuperExpo will

soon be up and running. This is where you

will find all relative information on sponsors,

exhibitors, events, accommodation etc.

During our recent member sessions across the

country, a number of members expressed the

desire for the STA Awards night to continue as

an independent event at next year's combined

expo. This was discussed with the SuperEXPO

committee and all agreed. However, the

overall format may be a little different. We are

establishing an Awards Committee to review the

categories and other administrative details, but in

essence it will be similar to past practices.

The SuperEXPO 2013 program will probably

feature a welcome reception on the Tuesday

night, the awards night on Wednesday, a free

night on Thursday and the Gala Dinner on the

Friday night. A committee will organise the social

side of the expo.

specialised textiles association The STA diary

The Young Leaders’ Conference

The Young Leaders Conference is in its

second year and was an enormous success.

Our young leaders are an integral part of our

industry's future and as an association we are

committed to supporting them and guiding

them along the way.

This year, COM decided to charge a nominal

fee to attend the YLC, with the bulk of the costs

being met by the association. The YLC is an

expensive program to run and we will be

looking at opening the event to sponsorship or

a greater contribution by attendees (members)

in the future. Irrespective of the proportion

of costs met by the association it is a very

worthwhile project and one that deserves the

support of all employer members. It is so very

worthwhile for the young leaders who attend

and is a program that we all can be proud of.

Our two Young Leader groups have now

started working on their challenge which will

be presented at the SuperExpo 2013.

See pages 16-17 for a fuller report

STAMATTERS

Fabric Structures CommitteeThe Fabric Structures Committee is

committed to keeping our industry clean,

transparent and skilled. To this end the

committee is working on a consumer

checklist to facilitate the ‘right’ questions and

comparison of installers.

A properly installed fabric structure is an

investment in lifestyle. The committee is

interested in ensuring that consumers, both

domestic and commercial, who invest a lot

buying a fabric structure, are getting the best

product built by the best installer. After all a

happy customer is the best marketing tool a

fabric shade installer can have and this in turn

reflects well on our industry.

Presenting consumers the right questions

to ask is the critical first step, enabling

consumers to secure a contractor who can

operate and complete work according to

standards, regulations and best industry

practise. And deliver a shade product that will

exceed expectations.

If you would like to know more about the

work of the Fabric Structures Committee or

have any questions, please contact Beatrice

on email beatrice@shadesails.net

See Beatrice Moonen’s report on page 33.

Connections inaugural Editorial Committee

The Connections Editorial Committee is

now on board and was scheduled to meet in

late October.

The Committee will determine major

themes and supporting articles to appear in

each issue. The 'new look' Connections is to

become effective from issue 1, 2013 and will

set the tone for Connections for future years.

Our young leaders are an integral part of our industry's future and as an association we are committed to supporting them and

guiding them along the way.”

A recap on recent and upcoming association activities.

Sydney – (02) 9669 3333 • newcaStle – (02) 4957 7766 • Melbourne – (03) 9545 5588briSbane – (07) 3387 8500 • adelaide – (08) 8260 1055 • Perth – (08) 9376 2666

darwin – (08) 8981 1555 • www.NolanUDA.com.au

We’ve always got you covered!

• Blinds & Awnings • Covers & Tarpaulins • Marquee & Tenting • Banners & Billboards • Shade Sails & Structures

• Architectural Fabrics • Motor & Marine • Solar Protection • Sporting Equipment

• Fasteners, Fittings & Accessories

Looking for a supplier to solve your industrial fabrics requirements...

the answer is

6 · CONNECTIONS

STAMATTERS

Update on Accreditation ProgramWork continues on the STA's accreditation program.

The proposed approach and draft model was

presented at member information sessions at cities

across Australia in late July/early August and was well

received by members in attendance.

Although there was some initial wariness, members

on the whole understand the importance of

encouraging higher standards in our industry and feel

positively disposed to self-regulation.

Members at these sessions were also provided with

a copy of a draft accreditation application form and

asked to provide feedback on the proposed areas to

be accredited as well as standards and points to be

applied to each.

Feedback from these sessions is currently being

collated and used to define and shape further the

content of the detailed accreditation application form.

Once this process has been completed, we will

circulate the proposed approach and draft application

form to the wider membership base for comment.

Awards for Excellence committee

Three members have volunteered to start this

committee which is separate to our judging

committee, and will just be required to revise the

award categories, entry process and judging criteria.

For this committee to have a good cross section we

require two more members, preferably those with

experience in blind and folding arm awning, tent/

annexe/camping and or trimming product.

The expected commitment is a total of three

meetings of about one hour each between now

and the end of this year. This committee will then

'hibernate' until the time or need to resurrect it arises.

Meetings will take place via telephone, Skype

and email.

If you are interested in joining this committee, please

email me at ana@specialisedtextiles.com.au

Training committee updateWe have three volunteers so far, representing WA, Vic

and NSW. We are now looking for representatives who

are based in Qld, NT, SA and Tasmania.

The training committee will work with training

institutions across Australia to identify gaps and needs

in our industry training.

If you are passionate about training in our industry,

contact our office and join the training committee today.

Expected commitment: one hour each month with

meetings to take place via telephone, Skype and email.

If you are interested in joining this committee, please

email me at ana@specialisedtextiles.com.au

National Workforce Development Training

By now, you will all know that we were successful in our

submission for funding towards Certificate II in Blinds

and Awnings

Members who have registered interest to participate

in this training will be advised shortly on the

commencement dates and procedure to follow. We

are currently working with NSW TAFE on a plan that

will see the first group/s of trainees commence their

training early in the New Year.

If your workplace missed out on the first round of

expressions and you are now interested in taking up

the training, we are pleased to advise that training

positions have become available. Please contact our

office to place your name on the training list.

If your company has identified a training need in the

installation of blinds, awnings and shade structures,

wasn't part of this round of funding and you would like

to know more, please contact me on 1300 555 787

(local call) or email me for further information.

Bright Future campaign for NSW work placements

The Bright Future Campaign is a NSW Government

initiative established to promote the concept of

school-based apprenticeships, traineeships and

work placements to employers around NSW. School

Based Apprenticeships, School Based Traineeships

and Structured Work Placements are all excellent

opportunities for students to gain valuable

experience in workplaces while still at school.

These opportunities provide a platform for

students to explore an industry area and get a

head start in their career while still completing

their Higher School Certificate. They also give

employers a chance to start working towards the

future skills base of their business.

To find out more about the Bright Future

campaign or express your interest in gaining a

school-based apprentice/trainee student for 2013

visit www.sbatinnsw.info

STA COUNCIL OF MANAgEMENT

SPECIALISED TEXTILES ASSoCIATIoN INC.Suite 201, 22 St Kilda RdSt Kilda, Vic 3182 Ph: (03) 9521 2114Local Call: 1300 555 787Facsimile: (03) 9521 2116Email: ana@specialisedtextiles.com.au

Web: www.specialisedtextiles.com.au

ASSoCIATIoN MANAGERana drougas Email: ana@specialisedtextiles.com.au

PRESIDENT lance st hill Fabric Solutions Australia Pty Ltd PO Box 6283 Yatala DC Qld 4207 Mobile: 0400 103 534 Ph: (07) 3807 0200 Fax: (07) 3807 8217 Email: lances@fabricsolutions.com.au

CoUNCILLoRSKent WilliamsonRoyal Melbourne Institute of Technology (RMIT)25 Dawson Street Brunswick, Vic 3056Ph: (03) 9925 9182 Fax: (03) 9925 9129Email: kent.williamson@rmit.edu.au www.rmit.edu.au

gary smithCampbell & Heeps5/125 Highbury Rd, Burwood, Vic 3125 Mobile: 0419 311 899Ph: (03) 98086911Fax: (03) 9808 3148 Email: gsmith@campbellheeps.com.au

tom gastin Pattons—Textile Fabrication80 McDougall St, Kirribilli, NSW, 2061 Mobile: 0414 952 007 Ph: (02) 9955 2563 or 1300 799 980 Fax: (02) 9959 3158 Email: tom@pattons.com.au

david burtonRicky Richards16 Park Road, Homebush NSW 2140Ph: 02 9735 3333Fax: 02 9735 3311Email: David.burton@rickyrichards.com.au

Jamie howardTotal Shade Solutions4 Aldinga St, Brendale QldPh: 07 3889 7200 Fax: 07 3889 8865Email: Jamie@totalshadesolutions.com.au

ConneCtions MAGAzINEAdvertising submissions: yuri@commstrat.com.auPh: 03 8534 5008

Editorial: Nicola Cardnicola.card@commstrat.com.au

The committee is interested in ensuring that consumers, both domestic and commercial, who

invest a lot buying a fabric structure, are getting the best product built by the best installer. After all a

happy customer is the best marketing tool …”

Untitled-2 1 1/03/2012 2:31:14 PM

8 · CONNECTIONS

MeMber neWs

Halifax Vogel Group (HVG) has further

strengthened its NSW sales team with the

appointment of Steven Bell as Account

Manager – HVG Fabrics.

Steven brings more than 10 years of

experience in sales, having previously

worked in real estate and for the past

6 years in the industrial and decorative

fabrics markets in NSW.

Prior to joining HVG, he worked

as Business Development Manager at Nolans/UDA, where his

responsibilities included maintaining existing accounts and

developing new customer relationships.

This experience will prove invaluable in his new role as Account Manager

– HVG Fabrics, as he will be tasked with developing customer relationships

and encouraging sales growth of HVG’s extensive range of fabrics products

for the agricultural, domestic & commercial shade and transport industries.

“I am looking forward to building long-lasting relationships with

customers in NSW and demonstrating the solutions that can be

achieved with our cutting-edge range of fabrics products,” Steven said.

HVG’s Fabrics products portfolio includes Tarpee® Polyfabric a high

grade Japanese woven coated PE fabric for grain and cotton covers,

Flex PVC for transport covers including side curtains and roll tarps,

Duraskin® PVC for tension membrane structures, and Extrablock

Shadecloth ideal for both commercial and domestic shade sails.

Steve Simiana, National Sales Manager, HVG Fabrics said Steven’s

appointment would help ensure the company expanded its fabrics

products presence in NSW.

“Steven brings to us not only a strong background in customer

management and an enthusiasm for the fabrics products market, but

also a wealth of experience and knowledge of the fabrics industry in

NSW,” Steve Simiana said.

hVg appointment

Steven Bell of HVg

relocating from west to east

Greg Barnett from D&R Tarpaulins

recently managed to lure Fred

Tarbotton over from Western

Australia, where Fred worked for

Sail City.

Fred provided this snapshot of his

career to date, which commenced

when he was just 15 years old:

“I started in the Canvas/PVC

industry in southwest WA in

November 1978 and the company

was very diverse covering all

industry aspects including tarpaulins,

marquees, annexes, blinds, awnings

and general covers.

“At the end of 1981 I took three years out of the industry but on return

began learning cutting, sewing, welding etc of all the industry had to

offer, including liners tarpaulins and blinds etc. I spent four years in

Perth before returning to Bunbury where I was appointed leading hand,

responsible for up to eight staff and dealing with customers measuring

and quoting etc. From there I accepted a job in Perth as factory

manager in a small Tarpaulin General Canvas manufacturing company.

“Having moved to live near Fremantle, I decided to move closer to

my new home and for the next four years managed a department in a

large company manufacturing many textile products including awnings,

blinds, marquees and some specialised bedding and medical products.

“I convinced the company to become more involved in the industry

and its association, then called ACASPA, and I was nominated to join the

ACASPA Council – one of the best decisions I have ever made. My main

focus was training and helping the WA government to set up trainee/

apprenticeships in the light manufacturing industries. We achieved

our goals and now have a fully recognised training/ apprenticeship

available through the TAFE system in every state.

“During this period I launched my own general canvas manufacturing

business in Fremantle which I successfully ran for two decades.”

Fred recently crossed the continent to take up an exciting new role at

D&R Tarpaulins.

D&R Tarpaulins is located at Shed /84 Anton Road, Hemmant in

Queensland and Greg can be contacted on 07 3393 3477 or by

email greg@drtarps.com.au | www.drgroup.com.au

Fred Tarbotton

on the moveStructureflex recently packed its bags and is now in a new location.Details as follows:7/7 Lakewood Boulevard, Carrum Downs, Vic 3201Phone: 03 8796 5400Fax: 03 9708 2797www.structureflex.com.au Alan Stewart’s email remains unchanged at alan@structureflex.com.au

TexConnex/Hiraoka has also upped stumps and relocated to

2/37 Rimfire Drive, Hallam, Vic 3803

Phone: 8795 7322 or 9702 3778

Until recently the premises was occupied by Australian Solar manufacturers

– which promotes itself as the only manufacturer of solar panels. Bob

secured the site as it is bigger and better placed as a base for his expanding

operations (see Bob's insights in the Geomembranes feature).

5-7 June 2013 Gold Coast Convention & Exhibition CentreShowcase your business at Australia’s largest trade exhibition for the window furnishings and specialised textiles industries.

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Presented by

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HURRY

LIMITED SPACE!

Ensure your company is on show by booking your space today.contact Brett Greene on 07 3262 3114 or email info@superexpo2013.com.au

Window Furnishings Specialised Textiles Shade Produc ts Machiner y

Equipment Components Accessories Ser vices

10 · CONNECTIONS

southside Memorial PoolMakMax Australia proudly announced its contribution to the

redevelopment of Rockhampton’s landmark Southside Memorial Pool.

The $17 million Federal, State and Regional Council funded project

will feature a 4000 square metre tensile membrane roof over the main

50 metre pool manufactured and installed by Brisbane based MakMax.

Partnering with Brisbane’s Liquid Blu Architects and Rockhampton

builder JM Kelly (Project Builders) Pty Ltd, MakMax will manufacture

the Architectural Membrane roof in Serge Ferrari® PVC (Poly-Vinyl

Chloride) fabrics , providing both shade and rain protection over

the 50m pool and 650 seat grandstand. Fabrication of the membrane

is scheduled to take place at MakMax’s Brisbane facility later this

year with installation of steelwork scheduled for January 2013 and

membrane to follow.

The new state of the art facilities will service Central Queensland as

the only facility of its kind in the region equipped to handle State and

National swimming events. The Liquid Blu designed pool will comply

with the highest FINA rating “Olympic and Championship Standard”.

International swim teams are expected to be seen at the site during

the Commonwealth Games on the Gold Coast.

MakMax Australia’s Director of Sales Daniel Cook says “We are

extremely pleased and excited to be awarded this contract; it was very

much a team effort. The knowledge that our project team demonstrated

throughout the tender and post-tender process was second to none and

converted into a successful outcome. Now the real work begins”.

The project team is currently detailing workshop drawings for

manufacture of the steelwork, membrane and hardware. The structure is

scheduled for completion March 2013.

MakMax makes a splash …

MeMber neWs

new lambton bowls club gets sun smartEarly in November MakMax Australia started work at New Lambton

(Wests) Bowls Club in Newcastle, New South Wales. As part of a

complete redevelopment of the club house and facilities MakMax will

supply more than 2600 square meters of tensile membrane roofing in a

variety of applications.

Partnering with Graph Building and Altis Architecture, MakMax will

provide three separate structures on site. The key feature to this project

will be the main roof structure over green number one - a 1,600 square

metre leaning arch/bowstring arrangement.

NOVEMBER • DECEMBER 2012 • JANUARY 2013 · 11

In addition to the large PTFE membrane structure over green number

one, the site will feature an inverted, semi-conical, double cantilevered

PVC walkway structure surrounding green number two, additional

cantilevered PVC awnings which interface with the main roof structure,

and a custom designed PVC membrane structure to provide coverage

to the outdoor BBQ area adjacent to the clubhouse. It is anticipated that

the project will be complete by mid January 2013.

For more information visit www.makmax.com.au

Connections correction On page 42 of the September/October

issue of Connections we ran a piece about

MakMax’s creative installation at Cairns

airport car park.

It turns out that the fabric was supplied by

Serge Ferrari, not Mehler.

Ruwini Perera who is Marketing Services

Manager with Innova International said MakMax

has acknowledged and apologised for the mix-up.

Wire balustrade regulations stay putMiami Stainless has advised that the Australian Building Codes Board

(ABCB) recently announced it will no longer be supporting proposed

changes to wire balustrade provisions in the National Construction

Code (NCC) for 2013. This means the wire balustrade regulations will

again remain unchanged.

The proposed changes detailed in NCC 2013 draft included

provisions that would see the implementation of an offset rail design

for horizontal wire balustrades between two to four metres above the

surface beneath.

The ABCB has acknowledged there were significant stakeholder

concerns with the new regulations including deficiencies in injury data,

assumptions used in the RIS, the potential negative impact on industry,

lack of targeted consultation, underestimation of the cost impacts, and

problems associated with the proposed balustrade solutions.

The ABCB has indicated there is a need for further analysis and

careful review of the concerns raised in the public consultation process

before any changes can be introduced.

“Although this is great news for the industry there will still be the

need for further involvement in the consultation process … and Miami

Stainless has and will continue to work closely with the ABCB through

future consultation and decision-making processes,” Matt Gisler said.

Mark of Miami Stainless would like to receive any feedback or

opinions as well as hear from anyone who may be interested in the

ABCB’s public consultation process. He can be contacted on 1800 022

122 or by email at info@miamistainless.com.au.

12 · CONNECTIONS

SPECIALFEATURE

Spurred by increasingly stringent environment regulations in mining, agriculture and landfill, the market for geomembranes is enjoying a stellar trajectory. By all accounts the market looks set to remain healthy, and some savvy businesses are reaping the rewards of moving into the sector.

By Nicola Card

Life in the fast lane

The shape of the world has shifted considerably during the past four

years. A black man was sworn in as US president, waves of recession

reverberated across the globe, a nuclear plant was uprooted in Japan,

Greece went bankrupt, several dictators were toppled, and the world

population hit seven billion.

And in that same time frame, the geomembrane market has moved

apace. In the words of Dr John Scheirs, Principal Consultant of

ExcelPlas “The geomembrane market is very much the hot topic …

things have moved swiftly due to the mining boom, coal seam gas and

landfill … for example the Victorian EPA mandated double linings for

landfill following the Cranbourne disaster.”

Remember that debacle? Built decades ago, the large landfill was

devoid of any form of polymer lining. “They just used sand and as

the weight decomposed the methane generated migrated through

the sand and accumulated in underfloor cavities of new houses in the

nearby community,” Scheirs explained. “It was a costly process – the

fire brigade took gas samples and found that lower explosive limits

were exceeded which meant houses were at risk of blowing up if there

was an ignition source, so residents had to be evacuated.”

The EPA which lacked data bases relating to older landfills then had

to establish a register and double liners for landfills was mandated;

predominantly high density polymeric material separated by a leak

detection system. This has increased demand for quality membranes.

Soon after, Best Practice Environment Management was published,

setting rigorous standards and higher reliance on conformance

(pre-installation testing). Also Construction QA placed demands on

welds, leak testing, holes and tears. Other states have taken note of the

tightening of controls.

Testing times

That snapshot helps illustrate why the ExcelPlas Laboratory is

constantly conformance testing plastics, polymer and geomembranes

(HDPE, LLDPE, fPP, PVC, EIA-R, EPDM) for properties such as tensile

strength, weld strength, tear strength, puncture resistance, stress

cracking resistance, oxidative induction time (OIT), UV ageing

resistance, multiaxial burst strength, truncated cone puncture, carbon

black content and carbon black dispersion.

Why the need? Given that many materials are manufactured in hot,

humid non air-conditioned plants in the tropics (including Thailand

and Malaysia) it is not always possible to maintain consistencies and

that affects the properties of the material which invariably come with a

design life of 50-100 years.

“There’s a saying by engineers that ‘It is always the two dollar

component that lets down the million dollar project’. Not unlike the ‘o’

ring on the space shuttle,” Scheirs said.

Much is at stake, given the magnitude and function of geomembrane

applications: water management/irrigation, coal seam gas and

associated water/containment ponds; acid leaching of base and precious

metals and other mining applications, as well as landfill plus energy or

biogas capture from landfill and sewerage treatment plants. While each

sector is booming, coal seam gas is steaming ahead.

Streaming gases During the past four years Queensland has seen “unprecedented

levels of activity” in coal seam gas (CSG), with Max Brady of Darling

Downs Tarpaulins stating the geomembrane industry is “still very

much driven by the coal seam gas sector.”

captivating business

NOVEMBER • DECEMBER 2012 • JANUARY 2013 · 13

Along with extraction of gas from wells comes salty sub-terranean

water from aquifers. The toxic hypersodic or hypersaline water

destroys matter in contact, hence enactment of legislation for water

containment and treatment via large container dams and brine ponds,

with desalinated and potable water then pumped back into the aquifer.

Thus the strong demand for polyethylene liners.

The tally of Australian CSG wells is believed to be around 2000

but within 15 years the number is likely to swell to 20,000, creating

enormous demand for water management – and subsequently, a strong

flow of orders for geomembranes.

Scheirs explained the processes surrounding leachate collection

process for iron ore enrichment which involves containing and

separating acids from the environment through a series of processing

ponds. Suffice to say huge areas – hectares – are involved, spawning

enormous demand for leach pads.

Lisa Doolan of Tex Connex stated that the mining industry, from base

metals to nickel, copper, gold and all in between, has to be particularly

careful to avoid negative publicity in a world far more conscious of

environmental damage.

“Mining companies are increasing their demands; these days two

or three layers of geomembrane systems are being installed, instead

of one or two,” said the trained civil engineer. “They may have a leak

protection layer such as a geonet and another liner to detect damage

with methods of picking up leaks in a liner.”

Wet or dry, a flood of work Strong demand also stems from the shift in weather patterns from

drought to floods, with Scheirs saying “In the past irrigation channels

were collecting precious water, but in times of excess rain they manage

the flow of water as well as erosion.”

Whatever the weather, it’s a win-win for the lining industry with a

flurry of activity surrounding channel upgrades or remediation of

existing infrastructure involving millions of square metres of liners.

Reflections on a watershed The past four years have been a watershed with many activities

underpinning the use of geomembranes, hence pressing demand for

ExcelPlas services in Construction QA and testing fusion welding, load

testing and more.

Keeping a keen eye on all local and global developments, John

captures and collates notable events through his monthly newsletter

GSN geosynthetic news (visit www.excelplas.com). One avid reader is

newcomer Graham Brown of Garden City Geotech.

Very proudly Australian made Australian family business Garden City Plastics invested millions developing

Garden City Geotech manufacturing facilities in Heatherton, Victoria.

Business Development Manager Graham Brown explained the

business was reviewing avenues for diversification and up popped

geomembranes on the radar; a market surveyed on behalf of the think-

tank Industry Capability Network (ICN) Victoria.

“We considered which types of membranes would be best for the

market, and settled on the flat T-die dual extrusion calendared process

…only two places in the world make the calendared sheet lines; the

machinery is massive, each of our three rollers weighs 25 tonnes, is

nine metres wide and one meter in diameter enabling widths of up to

eight metres,” Brown explained.

“There’s a saying by engineers. ‘It is always the two dollar component that lets down the … million dollar project.’ Not unlike the ‘o’ ring on the space shuttle.”

Dr John Scheirs of ExcelPlas

“There is lots of competition but the risk of low-cost producing countries is short-cuts taken with raw ingredients … it is important to use high grade resins in the design of geomembrane applications otherwise product will not last long enough to give satisfactory performance in the field.”

Bob Cahill of Tex Connex

14 · CONNECTIONS

Equipped with a Honeywell gauge control system and Zumbach

pinhole detector, materials are mixed in Moretti gravimetric

weigh scale blenders to ensure even dispersion of stabilisers and

carbon black. The advantages of flat sheet extrusion process for

geomembrane is gauge control to within +/- 3% compared to the

blown film process thickness variations of up to 10%.

Tech specs: Garden City Geotech sources Chevron Phillips K307

natural resin for the GRI GM13 HDPE geomembrane, due to its

“excellent stabiliser package and outstanding stress crack resistance”

and the company claims the broad fusion range results in more

consistent welds than with most other materials.

“The standard is the Geosynthetic Research Institute’s GM 13 and we

easily exceed that benchmark which is used in mining and by landfill

and authorities for water channel lining and other applications,” Brown

told Connections.

Australian made carbon black masterbatch (M248) – with its very fine

milled particle size which provides long term UV resistance – is used in

the black geomembrane.

“This is quite thick material; it is flexible to a degree but basically strong

material … previously this type of material was all imported,” he said.

Heavy transport Shipping containers or contract carriers criss-cross the continent

transporting Geotech rolls, each weighing one and a half tonnes.

Representing around 60% of business, traditional mining and coal seam

gas form the bulk of Geotech’s three markets.

“Landfill is significant too, with municipal tips requiring a double

lining to help prevent toxins seeping out; also dams are big business

… but our first break was in the northern Victoria irrigation program in

the sandy channels from rivers to the Murray Darling food bowls area,”

Brown, a chemical engineer, explained. “They were losing lots of water

as the river flats are sandy and we won the tender to line the channels.”

The family company has invested several million dollars in machinery

and upgrades. “Had we bought via the United States we may have secured

slightly higher quality equipment but timing was a consideration, it would

have taken two years to arrive and we wanted to move more quickly to

secure our position as the first in Australia to produce this line.”

It did not take long for Garden City Geotech to gain a foothold in the

geomembrane market whose import statistics clock in at 60,000 tonnes

annually. The company has the capacity to produce 20,000 tonnes a

year and their operations “Have the benefit of removing dependence

on imported material which reduces uncertainty associated with

imported supply and shipping delays,” Brown said

Few would disagree that in a nation whose manufacturing base is fast

shrinking it is refreshing learning about a quality, home-grown start-up

that has quickly forged a significant presence.

on a rollAbout the time Geotech first flicked the switch on its giant rollers,

newcomer Tex Connex was rolling up its sleeves for business, with

Bob Cahill appointed agent for world renowned geomembrane

manufacturer Layfield Environmental in mid 2011.

SPECIALFEATURE

“The geomembrane industry is still very much driven by the coal seam gas sector and mining generally.”

Max Brady of Darling Downs Tarpaulins

NOVEMBER • DECEMBER 2012 • JANUARY 2013 · 15

With his qualifications in Agricultural Science, experience with a

polypropylene company and years spent dealing with fabricators,

Cahill was a natural for the role and in common with Geotech found a

ready market helped by the three-decade strong reputation built by

Layfield which is regarded as a leader in the field, supplying top quality

products from superior grades of parent resins.

“The risk of low-cost producing countries is short-cuts taken with raw

ingredients, it is important to use high grade resins in the design of

geomembrane applications otherwise product will not last long enough

to give satisfactory performance in the field,” Cahill told Connections.

“Ours is a mix of HDPE and LLDP which has slightly different

properties so it can be moulded and prefabricated. That is our market

niche, we can supply material that can be fabricated in the workshop

which gives the fabricator greater control of the welding conditions,

but realistically some work has to be done on site. Our materials just

provide more flexibility,” said the man who until last year had limited

involvement in geomembranes.

“It’s not too far a stretch from tank liners to dam liners,” quipped Cahill

who is now immersed in effluent and waste control at piggeries and

dairies, dam liners and floating covers for water storage/reservoirs

(which reduce evaporation and maintain water quality and keep blue

green algae at bay through reduced sunlight) and in mining and

coal seam gas applications for salt water containment. Also liners for

molasses and other crops.

CSG Advisory Committee An Independent Scientific Committee on Coal Seam Gas and Large Coal Mining Developments was recently developed to equip governments with “the best scientific advice available” when making decisions about coal seam gas and coal mining projects, and to scope and advise on bio-regional assessments with sci-entific analysis of the ecology, hydrology and geology to assess the potential risks to water resources as a result of the direct and indirect impacts of coal seam gas development

For more information visit www.environment.gov.au/coal-seam-gas-mining

Cahill notes a bank’s recent upbeat advisory on agribusiness, with

demand for farm commodities anticipated to bolster the economy for

several years, and good long-term opportunities stemming from healthy

crops after years of drought. The welcome term “bumper harvest” is

being bandied around.

The crew at Tex Connex have certainly jumped on the bandwagon at

a timely moment and are set to enjoy the journey.

“It’s a diverse market and there is lots of competition. But whether it’s

mining or molasses each project is treated on an individual basis and

we carry out a detailed assessment of what the material is trying to

contain, for example certain chemicals may be aggressive toward the

liners and shorten their life, otherwise a normal lifespan would be up to

25 years.”

> CONTINUES PAgE 23

Left: Lights flash when a silo runs empty, alerting operators to change the pipe-work to a full silo.

Top: geomembrane stock ready to be exported.

NOVEMBER • DECEMBER 2012 • JANUARY 2013 · 23

SPECIALFEATURE

Tex Connex Colleague Lisa Doolan who boasts years of experience

in geomembranes and geosynthetics added that when solvents or

oil based products are involved great care needs to be applied in

matching lining to product and that “When anything is questionable

we get testing done before getting approval. Either Layfield or

independent testing lab such as ExcelPlas, who are gurus in testing.”

The years aheadWhat sort of a future awaits? Cahill believes the tighter regulatory

controls in livestock management coupled with a strong agribusiness

sector and need to tighten up waste collection practices paint a relatively

rosy picture.

“With our 15 years of drought followed by two good years of rain it has

looked like a boom, but that will drop off with drier weather [anticipated]

over the next two years. However lots of momentum is being generated

around Australia becoming a major food supplier to the Asia Pacific

region, hence the strong signs of agricultural investment.”

For his part, Graham Brown of Geotech “Cannot foresee a stalling

in the mining market and China is still growing at an enormous rate,

growth may be steadier rather than frantic, but lots of orders are still

coming through the pipeline.”

Max Brady of DDT says “Despite the negativity that assails us through

the mainstream media these days I’m a little surprised and impressed

by the apparent resilience and strength of the mining and energy

sector.” He reckons there is still “plenty of ongoing investment by

the mining and energy sector – which includes coal, CSG, and base

metals,” and observes only a minor downturn in mining margins.

Dr Scheirs concurs, saying “There is now a little softening of demand

in base metals but not in the area of CSG with gas exported to India,

China and elsewhere for use in domestic heating or cooking rather

than manufacturing. And environmental safeguards for bio-gas are very

strong so it is still a good time for membranes.

“It is like a perfect storm – and that puts demand on supply. Hence

the development of new manufacturing plants here and overseas. More

plants will continue to be built, until we reach oversupply.”

For more information:

www.gardencityplastics.com

www.gseworld.com

www.layfieldenvironmental.com

www.excelplas.com

www.ddt.com.au

< CONTINUED FROM PAgE 15

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