COMPANY:
All Flow Systems and Solutions

Inflatable Weir Plugs isolate weirs during remediation projects 

Inflatable Weir Plugs isolate weirs and provide a dry environment for maintenance and remediation projects.

Back Ground

COMPANY:
All Flow Systems and Solutions
LOCATION:
Lithgow, New South Wales

Drop-stitched matrix web-constructed inflatables are ideal for industrial applications requiring precise shapes. These inflatables maintain their form when inflated, can be configured into squares, circles, and other shapes, and can be glued or welded together. They effectively seal and fill voids in complex environments, such as inflatable weir plugs.

A weir is a barrier built across a river or stream to regulate water flow. It controls water levels, ensures consistent flow rates, and helps manage flood risks. Weirs also divert water for irrigation and maintain navigation levels for locks.

Challenge

For this project, two inflatable weir plugs were constructed using Inflatable drop-stitched matrix web constructions, which are the ideal choice for industrial applications that require precise shapes. These inflatables maintain their form when inflated, can be configured into squares, circles, and other shapes, and can be glued or welded together for maximum effectiveness. They are perfect for sealing and filling voids in complex environments, such as inflatable weir plugs.

A weir is a highly effective barrier constructed across a river or stream to regulate water flow. It ensures consistent flow rates, controls water levels, and helps manage flood risks. Weirs also divert water for irrigation and maintain navigation levels for locks.

During periodic maintenance and repairs, such as valve replacements, grouting, and painting, the weir must be temporarily isolated, stopping water flow and leaving the affected weir dry for remediation.

In this case, two Matrix web cushions were bonded like Siamese twins to supplement the inherent weakness at each surface. The filler plug placed in the opening was supplemented by a lid plate. The lid plate was designed to seal against the outside face of the weir, and the filler plug was used to assist in securing it in place. An inflatable weir plug was placed on each side of the weir, which was undergoing maintenance in a double block and bleed configuration.

A closer look

Background

COMPANY:
All Flow Systems and Solutions
LOCATION:
Lithgow, New South Wales

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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