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Duratec Australia

Inflatable forms prove indispensable in a mining remedial project.

Inflatable forms have many advantages over traditional forms and shuttering systems, especially considering weight, flexibility and storage.
Inflatable forms prove indispensable in a mining remedial project.

Back Ground

COMPANY:
Duratec Australia
LOCATION:
Australia

Duratec Australia is a leading industrial contractor specializing in protective coatings, remediation, and maintenance services. The company focuses on delivering innovative solutions for asset protection and durability across various industries, including mining, oil and gas, water, and infrastructure. Duratec excels in providing corrosion prevention, concrete repair, and industrial painting services. With a commitment to safety and quality, they leverage their expertise to enhance the longevity and performance of critical assets.

Challenge

Duratec Australia called on Giant Inflatables Australia to produce inflatable forms so they could install grout between the steel skid and a concrete slab. The challenge was to get the forms into the difficult areas and create an integral seal around the perimeter of the pour.

Inflatable Forms

Inflatable forms are the solution

Inflatable forms have many advantages over traditional forms and shuttering systems and were the perfect fit for this mining remedial project.

Inflatable forms are lightweight and easier transport set up and store when not in use, compared to traditional forms and shuttering.

The flexible nature of inflatable forms makes it easy to install in inconvenient or awkward spaces.

The porous, malleable nature of the rubber surface of the inflatable form creates a perfect seal against other surfaces. This is especially true when the surface is uneven.

Inflatable forms can be created in virtually any form and the drop stitch matrix web construction.

Results

Inflatable form
Inflatable Form

A closer look

Deflated forms are considerably less voluminous than traditional concrete forms making them easier to transport and store.
The drop stitch / Matrix web fabrication allows for a small corner radius.
Drop Stitch/matrix web products are robust and rigid. This 1.8-meter beam is holding 385kgs.

Background

COMPANY:
Duratec Australia
LOCATION:
Australia

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

A custom high-velocity fan was engineered and fabricated to meet the unique demands of the 50-metre inflatable tube man.
Several tests were conducted in Melbourne’s backcountry to determine how the giant inflatable would function under different wind conditions.
The custom-fabricated fan produces a controlled air current that keeps the tube man fully upright in Melbourne’s variable wind conditions.
Giant Inflatables Industrial

Australia’s leader in providing inflatable technology and expertise to the industrial sector.

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Giant inflatables Industrial PTY

27 Woodlands Drive,
Braeside, Melbourne
Vic 3195

Tel: (03) 9588 2626
Email Us

ACN:097 302 344 / ABN:30 097 302 344

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