COMPANY:
Hall Earth Moving

Inflatable Safety Barrier

Hall Earth Moving required an inflatable aquatic safety barrier to protect men deploying and welding the liner against entry into the tailings water during construction.
Hall Earth Moving required an inflatable aquatic safety barrier to protect men deploying and welding the liner against entry into the tailings water during construction.

Background

COMPANY:
Hall Earth Moving
LOCATION:
Tasmania

Hall Earth Moving (HEM) is a privately owned and Tasmanian-based company, operating in the construction industry for over 30 years.

They have a diverse spectrum of works from minor to bulk earthworks, civil road construction, and hardstand works, with a specialised emphasis on embankment dam construction. The company maintains a longstanding commitment to safety by engendering a culture of safe work practices and strong occupational health and safety systems for every project.

Challenge

Hall Earth Moving was constructing the Hellyer Gold Mine Tailings Storage Facility, located approximately 1 km west of the Hellyer mill, as part of Nq Minerals’ environmental clean-up initiative and site rehabilitation.

The project involved 500,000m3 of fill placement for a nine-metre dam raising, plus the face liner works. The face liner is a bituminous membrane. The liner material arrived in four and five and a half metre-wide rolls and was deployed from the dam’s crest, and subsequently, the seams were welded together.

Five metre-wide rolls were deployed from the dam's crest, and the seams were welded together.
Five metre-wide rolls were deployed from the dam's crest, and the seams were welded together.

The Project

Hall Earth Moving (HEM) contacted Giant Inflatables Industrial (GII) to manufacture an inflatable aquatic safety barrier to protect men deploying and welding the liner against entry into the tailings water during construction.

HEM required fifty linear metres of the barrier, enabling the deployment of five or six roll widths of the liner membrane before welding with a ten-metre extension on either side of the work area for additional safety.

GII manufactured the inflatable aquatic man safety barrier in the form of a cylindrical tube 1.2m in diameter made in nominal five-metre lengths to create segments to suit the width of the liner rolls. Each component was tethered at the ends through a set of eyelets and contained water for ballast and maintained a low inflation pressure, and was anchored in the water for stability.

To compensate for the PH levels of the tailing water, which fluctuates between six and eleven, GII paid particular attention to the fabrics used in the manufacturing process to mitigate the danger of premature deterioration of the barrier.

Results

The Aquatic Man Safety Barrier was delivered in mid-December and deployed in January 2023 for the duration of the three-month project.

Inflatable Fall protection for a dam project
Each component contained water ballast maintained a low inflation pressure, and was anchored in the water for stability.
HEM required fifty linear metres of the barrier with a ten-metre extension on either side of the work area for additional safety.
HEM required fifty linear metres of the barrier with a ten-metre extension on either side of the work area for additional safety.
Inflatable Aquatic Safety Barrier

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Background

COMPANY:
Hall Earth Moving
LOCATION:
Tasmania

Giant Inflatables Industrial, known for its expertise in the mining, power generation, construction, and defence sectors, temporarily shifted focus to assist its sister division, Giant Inflatables, with an unprecedented challenge: building the world’s tallest inflatable airdancer. Leveraging its engineering capabilities, the team designed and fabricated a 50-metre inflatable tube man, overcoming complex technical and environmental hurdles. This collaboration demonstrated Giant Inflatables Industrial’s adaptability and commitment to delivering innovative solutions beyond its traditional industrial focus.

Unique Challenge

Giant Inflatables Industrial provided technical advisory and fabrication expertise to its sister division, Giant Inflatables, to engineer a 50-metre inflatable tube man for Amber Energy’s marketing initiative in Melbourne’s CBD. The project required precision engineering and innovative materials to overcome unique challenges.

Fabric Technology from a Different Sector

The team utilised spinnaker cloth, a material renowned in professional sailing for its exceptional strength-to-weight ratio to achieve the ideal balance of strength, flexibility, and lightweight properties. It was designed to endure high wind pressures and provided the durability needed to withstand continuous airflow stresses while maintaining the tube man’s dynamic motion. Its flexibility and resilience ensured stable performance and safety in Melbourne’s variable weather, showcasing the team’s ability to adapt advanced materials for innovative engineering solutions.

Custom Engineered Fan

A custom high-velocity fan was engineered and fabricated to meet the unique demands of the 50-metre inflatable tube man. Where standard fans lacked the power and precision required to maintain consistent airflow over such a large structure, engineers at Giant Inflatables Industrial designed a solution capable of generating a powerful, controlled air current that could keep the tube man fully upright, even in Melbourne’s variable wind conditions.

The fan incorporated high-strength materials to endure continuous operation and was equipped with advanced airflow stabilisation technology to prevent fluctuations that could cause instability. Its design also reduced noise, ensuring minimal disruption in the busy CBD environment. By balancing power, efficiency, and durability, the fan became a critical component of the project, ensuring the tube man performed reliably throughout the week-long campaign.

Testing occurred in Melbourne’s backcountry, where engineers assessed inflation safety, fan efficiency, and wind response. A smaller, 30-metre version was also developed for unfavourable weather scenarios.

Results

The Amberman debuted in Melbourne’s CBD, operated by Giant Inflatables’ team to ensure safe assembly and compliance with municipal regulations. The inflatable was activated during optimal renewable energy availability, symbolising Amber Energy’s commitment to sustainable practices. The week-long event, live-streamed and shared on social media, achieved widespread visibility and reinforced Amber Energy’s eco-friendly message.

Worlds tallest air dancer
The team used spinnaker cloth, a material highly regarded in professional sailing for its outstanding strength-to-weight ratio, to attain an optimal blend of strength, flexibility, and lightweight characteristics.
Worlds tallest air dancer
Giant Inflatables Industrial created a high-velocity fan that produces a strong, controlled airflow, ensuring the tube man remains fully upright, even amid Melbourne’s unpredictable wind conditions.
Worlds tallest air dancer
Testing occurred in Melbourne’s backcountry, where engineers assessed inflation safety, fan efficiency, and wind response.
Worlds tallest air dancer

A closer look

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