Connection - Composites Australia Aust Connection - Dec 07.pdf · Connection 4 Gerard, in...

From the Desk of the Office of Education and Employment by Gerard Murphy

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Composites AustraliaReport on the US Mission

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Letter from the President

New Member Profiles6

Composite Engineer’s Viewpoint by Rik Heslehurst

Designing with Composite Materials Part 9 – Design Optimization11

www.compositesaustralia.com.auCompAust081 RMC

Gold Sponsor

Silver Sponsor

Bronze Sponsors

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Composites Australia Level 15, 10 Queens Rd Melbourne 3004 Tel 03 9866 5586 Toll Free 1300 654 254 Fax 03 9866 6434

www.compositesaustralia.com.au

Composites Australia Level 15, 10 Queens Rd Melbourne 3004 Tel 03 9866 5586 Toll Free 1300 654 254 Fax 03 9866 6434

The official magazine of Composites Australia Inc. Issue 15 December 2007

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Victoria – industry briefing, Christmas partyand inaugural poker tournament

StateNews

12 Conference & Exhibition 2008Formula for the Future

My first year asPresident of CA hasbeen a very busyone, with many newinitiatives and eventsfor CompositesAustralia. I’d like tothank the Board ofDirectors, four of

whom were new to the Board as at thestart of the year, for their involvement,enthusiasm, and hard work. Thanks alsogo to Kerryn Caulfield and her staff atApical, who have continued to improvethe value of membership for members in 2007.

Our continued growth as an associationwould also not have been possible withoutthe commitment of our corporatesponsors, namely FGI, Valspar, Colan,DIAB, Robinson, Pacific Resins and ournewest sponsor, Nupol Composites. Ourthanks to those sponsors, and also to theQueensland Government Dept of StateDevelopment, which has supported ourbriefings and other events in Queensland.In addition, we continue to work closelywith Composites CRC and they are ourpartners in organising our annualconference and exhibition.

Significant activities in 2007 included theannual conference & exhibition, whichtook place in April on the Gold Coast, ahub for the marine industry. With 438attendees, representing a 48% increaseon last year, this was by far the bestattended conference & exhibition to date.We also had 34 trade display booths, 8live practical demonstrations, a site visit toRiviera Marine and 35 well attendedtechnical and business sessions, as well asround-table discussions on OH&S Issues,Education & Employment, and Research& Development. The Welcome Drinks onthe Wednesday night proved extremelypopular for all to meet and mingle, andthe poolside “Queensland BBQ” dinnerattracted 229.

The delegates who were rewarded with awealth of information and insight providedby our excellent local and internationalspeakers.

2008’s Exhibition & Conference inMelbourne at the Flemington RaceCourse will take place on 13-14 March theThursday and Friday which lead into theFormula One Grand Prix, so be sure to

book now - and make a long weekend of it! It will again feature an exhibition, this time with the practical demonstrationstaking place amongst the trade displays.Our dinner will again have a relaxed andcasual atmosphere, but with aspectacular city lights view that willimpress. Early-bird registration forms, as well as applications for trade displaybooths, are now online on our new,dedicated website –www.compositesconference.com.

This past year we held members’ briefingsthroughout the eastern seaboard states, in South Australia and in Western Australia.With a variety of topics and the chance to network, these events are increasinglypopular. You can read all the details in the Events Committee Report.

One new and very successful initiative we undertook was a mission to the USA, to attend the American CompositesManufacturers Association (ACMA)“PolyCon” Conference & Exhibition, and to tour a number of US compositesfabricators’ factories. This is discussed in fullin a separate report, but suffice to say thatthe conference, trade show, and manynetworking functions provided a wealth ofinformation and contacts, and that thetours of US factories offered an incredibleand unique opportunity to look at thebiggest market in the world and learnwhat there is to learn. We were surprisedand gratified to discover how open andforthcoming the venues we visited were intalking about how they do business.

We have also enjoyed regular andprofessionally prepared editions of thismagazine, and we thank our regularcontributors as well as all who haveadvertised in it.

We have improved our website evenmore this year(www.compositesaustralia.com), adding15 pages of occupational health & safetyinformation, among other enhancements.

Our joint initiative with Composites CRClast December to appoint a Training andEducation Officer, Gerard Murphy, hasproduced a substantial program oftraining and a number of excellent resultsthat address both the labour and skillsshortages you reported to us. Many thanksto Composites CRC for their contributionto this position.

Some of these initiatives and results which

Letter from the PresidentThe 2007/08 Board of Composites Australia

NORM WATT – PRESIDENTBUCHANAN ADVANCEDCOMPOSITESEmail: [email protected]

MARK STERBICDIAB AUSTRALIA Email: [email protected]

TREVOR PANOZZA AMPELITE AUSTRALIAEmail: [email protected]

ALEXANDER KRYGER APTEC COMPOSITESEmail: [email protected]

FLOREANA COMANENGINEERED MATERIALS AUSTRALIAEmail: [email protected]

GENELLE COGHLANCOLAN PRODUCTSEmail: [email protected]

IAN CROUCHCOMPOSITES CRCEmail: [email protected]

GRANT PEARCEEXEL COMPOSITESEmail: [email protected]

MICHAEL DI STASIFIBER GLASS INTERNATIONALEmail: [email protected]

MALCOLM WESENER GLAS-CRAFT AUSTRALIAEmail: [email protected]

BILL REESKANGAN BATMAN TAFEEmail: [email protected]

SHARON SWANLSM ADVANCED COMPOSITESEmail: [email protected]

SIMON TAYLORVALSPAR (AUSTRALIA) CORPEmail: [email protected]

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Gerard, in conjunction with our education & training partners, theQueensland government, Composites CRC and various othergovernment and other bodies, has achieved include:

• placing or facilitating the employment of some 50 employees.

• delivering 9 training courses including the Textile ReinforcementCourse, valuable resource for which CA will continue to deliveracross the industry in the future.

• delivering over 25 information sessions for the EmploymentService Providers and various Government bodies.

• training more than 100 people about the composites industrythis year.

• continually monitoring and mentoring the new employees thatwe have brokered for the industry. This is done at both theemployer and employee level.

• working with the Manufacturing and Engineering Skills AdvisoryBody (MESAB) to establish for 2008 a new Cert II pre-vocationalcourse for composites/FRP. This involved writing newcompetencies and assembling the qualification to reflectindustry needs and the capabilities of the Registered TrainingOrganisations. We also helped ensure that the new Cert III inPolymer processing (Composites/FRP) is of sufficient rigor to beviewed as a trade apprenticeship. This should be accreditedfor 2008.

• Working with Manufacturing Skills Australia to ensure that themanufacturing training packages are brought up to bestpractices and reflect what each sector of the industry needs.We are also involved with relevant steering committees for thecontinuous improvement of the composite training packages.

• Securing vital partnerships with a number of external bodies

such as: Industry Capability Network, Australian IndustryProductivity Centres, Invest Australia, Boating IndustryAssociation, Victorian Centre for Advanced MaterialsManufacturing, Queensland State Development, Departmentof Employment and Workplace Relations, Department forVictorian Communities, Manufacturing Learning Australia,Process Manufacturing Industry Training Council WA, AustralianApprenticeships, Council of Textile & Fashion Industries ofAustralia, Worksafe (VIC)

• Placing composite workers laid off due to the impendingclosure of the VESTAS facility in Portland, Victoria back into theindustry, in conjunction with DVC, QLD State Development andVESTAS Windblades.

So where to from here?

In my view, one of our most important challenges is to build ourmembership numbers and in doing so encourage companieswhich haven’t considered membership previously or which wereprevious members and dropped off our rolls.

I encourage all our members to take an active part inComposites Australia, and make this association the pro-activeand constructive organization we would all like it to be.

All the best for Christmas and success for 2008 to you all

The following Composites Australia (CA) events are scheduled for 2008. Please contact Ann Byrne at the CA Secretariat for further details and registration. Don’t forget to check the website for regular updates: www.compositesaustralia.com.au.

Date and Time Venue

Wednesday9th April10.30am – 12.30pm

CA Trainingn Workplace Health & Safety Risk Assessment workshopsn Refreshments will be servedn Free of charge. Supported by the QLD Government

Gold Coast, QLD – TBA

Wednesday27th February10.30am – 12.30pm


Brisbane, QLD – TBA

Wednesday27th February4.30pm – 7.00pm

Members’ Briefingn Free for members and members’ guests. Supported by the QLD Governmentn Refreshments will be servedCA Board meeting

Brisbane Technology ParkBrisbane, QLD

Wednesday16th April10.30am – 12.30pm


Sunshine Coast, QLD – TBA

Thursday 13th &Friday 14th March 8.30am – 5pm daily

CA Annual Conference & Exhibition (in association with Composites CRC)n Presentations and round table discussionsn Trade shown Demonstrationsn Conference dinner

Flemington Race CourseEvents CentreMelbourne, VIC

Thursday 3rd April10.30am – 12.30pm


Cairns/Townsville,QLD – TBA

Wednesday 30th April5.00pm – 7.30pm

Members’ Briefingn Free for members Members’ guests are welcome at $15 eachn Refreshments will be served

Western Australia – TBA

Wednesday11th June4.30pm – 7.00pm

Members’ Briefingn Free for members Members’ guests are welcome at $15 eachn Refreshments will be servedCA Board meeting

EMP CompositesSydney, NSW

Events Schedule2008

This schedule is subject to availability of venues and may change from time to time.

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n Engineered Materials – Floreana Coman (VIC)

n Sunrunner Cruisers – Paul Benjamin (QLD)

n Ten Cate Australia – Amanda Cautela (NSW)

n Ivan Kwong, student (VIC)

n Phil Wilson, student (NSW)

n UV Pacific – Robert Hercus (SA)

Composites Australia Welcomes New Members:

NEW MEMBER PROFILE: TENCATE

TenCate develops and produces materials to increaseperformance, reduce costs and deliver measurable results byworking with our customers to provide advanced solutions.

Backed by the global TenCate group of companies, we offercomprehensive product support and technical development.We supply a diverse range of technical textiles, nonwovens,membranes and composites manufactured under ISO 9000quality assured systems.

With materials made from glass, polyester, polypropylene, aramidand many other polymers our products are found in a broadrange of industries and applications.

With extensive knowledge, worldwide resources and greatcustomer service, TenCate Australia makes the difference to yoursafety, protection, reinforcements, fire and chemical resistanceproblems.

NEW MEMBER PROFILE: SUNRUNNER CRUISERS PTY LTD (SUNRUNNER)

Sunrunner Cruisers Pty Ltd (Sunrunner) is a small but growingAustralian luxury boat manufacturer. Sunrunner was incorporatedin Queensland in 2000 and commenced operations in 2001.Manufacturing and administration are based in Queensland, on the Gold Coast, in the suburb of Molendinar. It has a salesnetwork based on independent dealers who are located in every state.

Paul Smithson, owner of the Sunrunner, is a second-generationboat builder. His son James has joined him in the businessmaking three generations of boat builders. Paul has extensivebusiness experience as an owner and operator of motor vehicleretail companies in NSW, property investment and developmentcompanies and finance companies.

Sunrunner employs staff and contractors of approximately 80people across two manufacturing sites.

Over the past six and half years Sunrunner has developed arange of express cruiser style boats, with five models ranging insize from 28 feet to 48 feet.

Sunrunner has achieved an excellent reputation formanufacturing high-quality, excellent performing power boats,and has received five national awards for manufacture andperformance of their boats. Two top features of Sunrunner boatsare their four-part construction and excellent resale value.

The boats are built in the traditional method of compositelaminate of gel coat, biaxial woven rovings, chop strand mat withstringer and floor systems made from foam and marine gradeply wood, with bulkhead in foam and marine grade ply wood.

Contact: Paul Benjamin, 07 5510 2900 [email protected]

NEW MEMBER PROFILE: ENGINEERED MATERIALS

Engineered Materials Australia is a start up company founded byMr. Miro Miletic and Dr. Floreana Coman.

The company's main objective is to establish an AustralianResearch & Development, manufacturing, marketing anddistribution centre that will provide innovative materials andprocess solutions to aerospace, marine, corrosion, transportationand defence customers in our region.

This will be achieved by developing new sustainable solutions,

working together with research providers and universities andpartnering with local businesses that have existing capabilitiessuitable for our products.

Contact: Floreana Coman, 0400 233 [email protected] [email protected]

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New Technologies and Technical Workshops.Composites Australia recently conducted a number of workshopscovering the textiles used in composite re-enforcements. They were very well received and we will be delivering more of these across all the States in 2008.

What was highlighted was the demand for such courses is high – the practicality of finding the time and money to attend thecourses is not always easy to align.

The evaluations and reviews of these workshops support the needfor additional topics and processes. We must, however, be mindfulof ensuring they are affordable (cost effective) and time managed.

In the New Year we will be rolling out sessions on strategies anduseful templates for preparing for risk assessments across yourbusiness. Plans are also being made to deliver half-day workshopson resins and their applications.

Employment and RecruitmentOur commitment to helping the industry to employ and train the rightpeople starts with assisting the industry to employ apprentices andworking with them to ensure that completion rates are improved.

We have been working with governments in all States to give long-term unemployed and mature age people some basiccomposites training and thus assist them in re-entering theworkforce. We are proud of the positive outcomes of this initiativeand that we were able to gain the support of both Federal andState governments in helping to fund the project. Going forward,the industry itself must now take up this challenge and continue to educate and train its workforce.

Where to next?n Grow the pre-vocational training for new starters

n Upskill our existing workers – Recognition of Prior Learning (RPL)or training them to a qualification where necessary

n Promote the take-up of Apprenticeships.

If the industry is to grow it must put its hand up do this for itself. We should not rely on government funding for such programs –subsidies, for sure, but the composites industry needs to take the lead!

Composite manufacturers that want to grow will up-skill and traintheir employees, as they have recognized that not to do so willsentence them to obscurity.

The cost of labour (unskilled) is very high – the benefits of skilledlabour have to be seen past the cost of wages – things such asreduced waste, reduced re-works and increased productivity areeasily mapped to increased profitability.

At the recent Manfacturing Skills Australia conference oncompetitive manufacturing many case studies highlighted thegains and barriers that a manufacturer can encounter in up-skillingand training its workforce. I strongly advise you to visit this sitewww.mskills.com.au/Info.aspx?TAG=MSA.Conf.2007.ConfHomePage#Downloads and spend some time to take in some ofthese excellent presentations. In particular, have a look at thepapers by Dr Peter Brain, Glenda Hutchinson, Dave Oliver andAndrew Smith.

OEE – The futureThe Office of Education and Employment is now a brand thatComposites Australia can go forward with to ensure that both theindustry and government agencies now recognize the Associationas being the focal point for the composite industry in Australia.

The 2006 survey indicated that the industry was not either awareof or happy with the current VET training sector. A great deal oftime and effort has been put into addressing this aspect in 2007.The rewards for this work will be clearly seen in 2008. In particular,the new Certificate III in Polymer Processing will bring all the statesinto line, and the work being done in partnership with various RTOs,QLD State Development, MSA and MESAB in changing theclassification in ANZSCO will allow the up-take of Apprenticeshipsand the recognition of existing workers’ qualifications and skill-sets.The perception that composite technicians are second-ratetradesmen can now be eradicated, as the training now capturesthe full depth of the skills and knowledge required to work in amodern composite manufacturing environment. We are alsoconfident of being able to access the funding of apprentice tool-box subsidies. We will keep you informed on this aspect to theapprenticeship program.

Australian Industry Productivity CentresThe recent roll-out of the Australian Industry Productivity Centres(AIPC) program presents real opportunities for SMEs to lift theirproductivity and performance and become more globallycompetitive.

The AIPC program was officially declared “open for business” inMelbourne by the Minister for Industry, Tourism and Resources, IanMacFarlane.

The new nationally coordinated program will help businesses toidentify how globally competitive they are, and get support toimplement improvements.

In the first stage of the Program, eligible SMEs are able to receive

a free diagnostic service to help them assess their performanceagainst world best practice, and identify opportunities forimprovement.

Following the assessment, businesses are able to access tailored,professional advice on critical issues such as business planning,process improvement, and lean manufacturing. Such advice canbe simply too costly for many smaller businesses and to addressthis, the Productivity Centres will meet up to 50% of the cost of theservice, up to $20,000.

For further advice on this program please contact Gerard Murphyat Composites Australia on 0401 650 456 [email protected]

Office of Education and EmploymentFROM THE DESK OF THE OFFICE OF EDUCATION AND EMPLOYMENT by Gerard Murphy

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Composites Australia (CA), working with the American CompositesManufacturers Association (ACMA), organised a Mission to the USto attend the ACMA PolyCon Conference & Exhibition (PolyCon)and to take part in a program of tours of US fabricators’ factories,with a view to seeing first-hand what technologies, systems andprocesses are being used by the US industry. As one boardmember remarked, “We need to have a look at the biggestmarket in the world and learn what there is to learn.”

In October 2007, eight participants from CA attended thePolyCon, which was held from 17-19 October in Tampa, Florida,USA. The following week, five CA participants took part in a two-day program of tours to six US factories, organized by CA withassistance from ACMA.

n Much was learnt first-hand about the US industry

n Business was conducted

n Valuable contacts were made

n Key relationships with ACMA and other internationalorganizations were forged

n Composites Australia’s standing as an internationalcomposites association was enhanced and our eventsadvertised on the world stage

The experience exceeded expectations and was rated byparticipants as “very impressive”, “extraordinary” and “a uniqueopportunity”. Comments included, “I definitely picked up somepotential business” and “What I learned was very valuable – and I will absolutely be using the contacts I made.”

“Anyone who didn’t take up this opportunity to tour US fabricatorsseriously missed out”, noted Nick Noble of Quickstep. “To get inplaces that might otherwise view you as a competitor, and seewhat they’re doing and be told how they do it, what they use,and what their tricks of the trade are – the fabricators on this tourmust have been very busy writing up notes every night!”

Nick felt that the sites visited were a good mix, and that the tourwas very well organized. He felt that a larger group of participantswould have enhanced discussions both at and after each factoryvisit, and emphasized to all who did not go that they “missed out”and should not do so again! “Simply to see the diversity, and tofind out what and how the Americans are doing things wasgreat”, he noted, “and the places we went to were super. It wasgreat value for money – in fact it was cheap at the price!”

Michael Cliff of Elaco, himself new to the industry, remarked thathe was extremely impressed with the companies visited and willfollow up with some for possible business. The tour also solidified to him that composites is an “amazing and growing market”. He appreciated the face to face meetings with the contacts at the venues we visited and also with the other delegates, notingthat “informal meetings and gatherings are where you learn themost and where information is exchanged most freely.”

Mission participants have reported that they are now following up potential business with contacts made at both the PolyConand on the tours.

COMPOSITES AUSTRALIA – REPORT ON THE US MISSION – OCTOBER 2007

Tour participants Paul Benjamin (Sunrunner), Norm Watt (Buchanan AdvancedComposites), Ann Byrne (Composites Australia), Nick Noble (Quickstep) and Michael Cliff (Elaco)

Neil McArthur (McArthur Composites) and David Hay (FGI) Larry Cox (ACMA) talks with Norm Watt Andrew Hurd (Nupol Composites)

photo courtesy ACMA

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Contacts made have already begun to benefit the association as well. Meeting face to face with counterpart organizations from differentcountries has helped create an active network for the CA to share resources,ideas, activities and information with other associations. In fact, the CA hasnow been offered a complimentary tabletop booth at SAMPE Asia in Bangkokby the Executive Director of SAMPE, who met with Ann Byrne at the ACMAPolyCon. The contacts made at the show also provided assistance withrecommendations and contacts for the Florida site visits, both with on theOctober trip as well as for any future events.

Future PlansWhether a similar mission is offered again – to the USA or elsewhere - will bedetermined by a number of factors, including Board decisions, interest andinput from members, and the logistics of overseas events. It was announcedin Tampa that the ACMA PolyCon will be moving dates, and will most likely beheld in February 2009, with the location yet to be announced.

Oh – and getting to see the space shuttle take off in person was just anadded bonus!

The full report is now available in the members section of the CA website.

Tour participants viewing a lamp-post base mould at Glassworks of Largo. Scott Lewit of Structural Composites was one of the forwardthinking CEOs we met.

Our view of the Space Shuttle

photo courtesy ACMA

photo courtesy ACMA

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COMPOSITE PRODUCTS IN THE MINERAL PROCESSING AND CHEMICAL INDUSTRIES by Lucy Cranitch

As the boom in the Australian mining industry continues, many companies are striving to get more output from existing plant assets.Others are seeking to expand at a time when materials, including stainless steel, are in short supply. This has led people to take a seriouslook at the durability of plant assets with a focus on using resistant composite materials in corrosive conditions.

Composites in the form of fibre reinforced plastics are not new to companies in minerals processing or chemical manufacture. The 1980s saw a huge surge in the use of these materials in plants producing zinc, copper, nickel, lead, gold, silver, uranium, acid and fertiliser. The increased use of composites was due to their many benefits over steel. The biggest of these is resistance to corrosioncaused by acids, alkalis and solvents, giving the equipment long lifetimes.

Such durable assets need no painting and fewer repairs, reducing operational expenditure. However, savings are also available incapital expenditure.

An Australian company using 70°C sulfuric acid in its process made cost comparisons for the manufacture of a quench tower pumptank in a range of materials. The 3m-diameter, 5m-high tank requires a wall thickness of 6mm for steel tanks, and 15 mm for acomposite tank. However, with a specific gravity of 1.6 for composites compared to 7.85 for steel, the total weight of a composite tank is approximately half that of a steel tank. Please refer to Table 1 for a comparison of these costs.

Since the process fluids contain chlorine and fluorine in addition to the acid, mild steel was not an option, making composites a goodchoice. These figures are based only on fabrication costs. Further savings are secured when installed cost and lifetime cost areconsidered. The light weight nature of composites allows reduced transport fees, lighter cranes and easier access to difficult areas onsite, all saving money at installation. The proven corrosion resistance of composites means lifetimes in a harsh environment of 20 yearsplus, a life span equal to or likely greater than the more expensive stainless steel varieties.

Composites also have a successful history in process and storage tanks, scrubbers, settlers, cooling towers, quench towers, stacks,launders, electrolytic cells, covers and gratings. They have also been effectively used in ducts and pipes. Cost comparisons have been made for DN150 Schedule 10 (700 kPa) pipe, 12m length with one flange, one 90-degree elbow, two joints/welds and two mild steel supports.

Correct design is essential with standards AS2634 and BS4994 being used for composite tanks and equipment. High-tech resins areproduced under strict quality control conditions. This ensures vessels can be used up to temperatures of 120 degrees and higher insome cases and resistance to UV degradation is ensured. Fire resistance can be built into the product if required, ensuring safety on site.

The Queensland Government under the Fibre Composites Action Plan is supporting growth in the use of composites in a range ofapplications including corrosive environments. This includes facilitating collaborative opportunities between businesses involved inmanufacturing composites and those who benefit from their end use. It may well be worth checking out composites when it comes to equipment purchases. You may discover that they last longer and cost less.

About the Qld Fibre Composites Action PlanFibre composites offer unique, exciting and environmentally friendly new ways to create and manufacture products in a host of the Qld’s booming industry sectors, including advanced manufacturing, aerospace, building and construction, defence, infrastructure,marine, mining and transport. A recent survey indicated that composites companies contributed an estimated $1.2 billion toQueensland’s industry turnover in 2004/05, comprising around 300 businesses and employing close to 6,800 people.

The Queensland Government is capitalising on this growth, and Queensland’s growing strengths as a world leader in R&D andcommercialisation of fibre composites technologies, through the implementation of its Fibre Composites Action Plan and significantinvestment under the Smart State Innovation Funds.

Table 1 – Cost comparison of materials for tanks

Tank material Tank cost Cost ratio

SAF2205 Stainless Steel $130,467 1.3

316 Stainless Steel $110,897 1.1

Mild Steel $ 58,710 0.6

Composite $ 99,720 1.0

Table 2 – Cost comparison of materials for pipes

Tank material Fabrication Installation Supply & installation

SAF2205 6.3 1.1 3.6

316 Stainless Steel 1.6 1.1 1.4

Composite 1.0 1.0 1.0

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COMPOSITE ENGINEER’S VIEWPOINT Rik Heslehurst PhD, MEng, BEng(Aero) FIEAust, FRAeS, CPEng

Designing with Composite Materials Part 9 – Design Optimization

In this article, we conduct anoptimization of the design. Withdesign optimization we considerchanges to the design with theaim to reduce weight and/orcost, but at the same timemaintaining or improving theoverall structural performance ofthe component. An equallyimportant aspect of this stage ofthe design process is to check the robustness of the designagainst small changes in design parameters.

During the design optimization process we consider two or threedependent parameters and vary these whilst maintaining theperformance requirements. The results are plotted in a designspace diagram as illustrated (above). The boundaries of therequired performance produce a design space envelope thatdefines the ideal design point. Note that moving away from thedesign point is known as the off-design point performance.Clearly, some performance requirements are more sensitive tooff-design point changes. These are indicated by the higherslope of the boundary curve.

An important part of design optimization is to undertake detailed

design of the structure. These days optimization is typically donewith numerical analysis packages such as finite element modeling(FEM). The application of FEM can provide significant insight intothe areas of major stress states where an increase of the plies istypically needed. Likewise the low stress states can be consideredfor ply reduction (drop-off). There are some issues in using FEM,such as how to effectively model the laminate. Do you useorthotropic properties on a global scale or model individual plies?

In the next article, we look at the final chapter of the designprocess - detailed design and putting the structure together. I alsowelcome questions, comments and your point of view. Feel freeto contact me via [email protected]. I may publish yourquestions and comments, and my response in future newsletter.

Cost

Conference & Exhibition 2008Formula for the Future

Melbourne13-14 March 2008

The Conference theme for 2008 is “Formula for the Future”. Held two days before the Formula 1 Grand Prix, it gives you a great opportunity to stay the weekend in Melbourne. After all, the automotive and transport industriesare important end-users for composite parts. (Remember to book your accommodation and flights early.)

Invitation to Participate n Speakers n Exhibitors n Sponsors n Delegates

Call for Papers – Give a PresentationBy presenting a paper at this conference, you give your organisation invaluableindustry visibility; reinforce your expertise within the composites community; andcreate the opportunity of advising suppliers of your needs.Topics may include new technologies or new uses for technology, inventions,leading-edge processes and training and education of staff. Papers/presentationsmust not focus on promotion of a company or its products – there is a separatesession for Suppliers’ presentations.

New technologies create profound challenges andopportunities for the composites industry. Training and education issues along with research anddevelopment are also vitally connected to these advances in technology. What is your “Formulafor the Future”?

Speaker presentations will be scheduled to suit the final program in time slots of 30 minutesinclusive of question time. Presenters will be eligible for free entry to the conference on the dayof their presentation.

The Supplier SessionSupplier presentations will also be accepted for a session consisting of 10-15 minutepresentations. Abstracts must be submitted for this session in order to be scheduled on the program. There are a limited number of slots in this popular session, so apply early! Submit your abstract today at www.compositesconference.com

Sponsor an eventStand out in the crowd! Apply to sponsor the Conference Dinner, the lunches or morning teas, the conference satchels or welcome drinks. This advertises yourcompany and its support of the industry. All packages include the addition of your company logo on the official conference brochure and signage, and a linkto your website on the Composites Australia Conference website.

Exhibit your products and services – and/orgive a practical demonstration

Trade Display booths (3x3m) are now available – and are going fast! Reserve your space now.Upgrade to a “Booth Sponsor” package and receive your company logo on the conferencebrochure, website and signage; a complimentary conference registration; acknowledgement in the opening & closing remarks to the conference; one satchel insert; and a web link! Invite your customers to visit your booth – complimentary Exhibition-Only day passes areavailable for those who just wish to visit the trade displays. These passes are available throughthe online registration page at www.compositesconference.com

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Melbourne and its surrounds have an abundance to offer in terms of sightseeing, leisure activities,entertainment, relaxation and culture. The weather in mid March is generally warm and sunny.Stay the weekend and attend the Grand Prix; bring the whole family for a mini-holiday!!

Be involved with this major event - as a speaker, an exhibitor, a sponsor or a delegate. Showcaseyour company! Learn, experience, expand your contacts and meet the “who's who” in the worldof composites.

For the first time, the live practical demonstrations will be interspersed throughout thetrade show area. Reserve space to demonstrate your products – there is no additionalcost if you are a booth holder. Applications for demonstrations are limited to members of Composites Australia and should be submitted to Frank Rosselli by e-mail at: [email protected].

Attend – take part in the conference & exhibitionThere are many levels on which composites fabricators, suppliers and end-users canparticipate in this conference. Delegates will have the opportunity to hear invited key-notespeakers and partake in debates on the latest technology in the composites industry.

And what is fast becoming the one industry event not to be missed - the conferencedinner will be held on Thursday 13th on the top floor of the events centre, giving awonderful view of the city of Melbourne and the Flemington racetrack.

There is something for everyone!Register now at www.compositesconference.com

Start your engine and plan now to be there in March!

On Thursday 6th December 2007, some 45 participants attendedthe Composites Australia (CA) industry briefing, Christmas partyand inaugural poker tournament at Hi-Class Composites inBayswater (MELBOURNE), Vic. Chris Wood, our host for theevening, showed us around his new factory and also gave apresentation on doing business in Asia, entitled “Asia! You CanCompete!”. Having spent two years running factories in Thailandafter running an Australian fibreglass factory for 12 years, Chrisoutlined both the advantages and disadvantages one wouldencounter in dealing with overseas Asian fabricators and/or incompeting with them.

Next, Norm Watt, President of CA, reported on the recent Missionto the US and the benefits gained by participants, and showedphotos from both the ACMA PolyCon and the Florida factoriesvisited. The mission report is on page 8 of this magazine, and thereport and powerpoint presentation are also available in theMembers Area of the CA website(www.compositesaustralia.com.au).

Following a delicious and hearty spit roast dinner, the first CA PokerTournament began. This 'just for fun, no real money” competitionwas suitable for all levels, from card sharks like Worthington's Paul“Deuces Wild” Delacorn and Glas-craft’s Malcolm “Big Bad Wolf”Wesener or social players to absolute beginners who've never

played poker before.“Texas Hold-em”, the typeof poker played, is acommunity card gamewhere each player mayuse any combination ofthe five community cardsand his or her own two“hole” cards to make apoker hand, in contrast topoker games like stud or

draw where each player holds a separate individual hand.Because each player only starts with two cards and the remainingcards are shared, it's a favorable game for strategic analysis -and for bluffing - and for just plain fun! Players are out when theirchips are gone, and so the tournament narrows slowly down to afinal winner. Consolation prizes were also awarded for the firstperson to go out at each table.

For a while Eric Sandberg of Victoria University and CA Pres. NormWatt were looking likely to go the distance, with great piles ofchips in front of each, but the final two came down to Phil Bovisof Kangan Batman TAFE vs. Robert McRuvie (QLD Dept of StateDevelopment), who had taken over for CA Executive ManagerKerryn Caulfield when she had to leave. In the end, Robert hauledin the chips and went home with the much coveted trophy!

A good time was had by all and we thank Chris both for hostingthe event and for providing and running the poker night! Chris hasoffered to stage another tournament during the conferenceperiod, so keep a sharp lookout for the notice.

CA Annual General meeting held in MelbourneJust prior to the industry briefing and Christmas party, the AnnualGeneral Meeting of Composites Australia was held on 6December 2007.

Opening the meeting, CA President Norm Watt welcomed the27 attendees and thanked the venue host, Chris Wood of

Hi-Class Composites. He also thanked the Board and ApicalInternational for their work throughout the year, and both theComposites CRC and the Queensland Government (Departmentof State Development) for their partnership in many endeavoursand events.

Following the apologies and acceptance of last year's minutes(see AGM Minutes in the Members' section of the CompositesAustralia website), Norm gave the President's Report and tabled

STATE NEWS

VICTORIA

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On 14 November, Fibrelogic Pipe Systems’ new manufacturingfacility in Lonsdale, South Australia, hosted some forty attendeesat the CA November industry briefing.

Faciliated by Bill Rees and Phil Bovis of Kangan Batman TAFE,representing Composites Australia, the briefing included afascinating and informative presentation from Russell McKay,IMCD Australia, on “Safety Aspects of Thermoset Curing Agents(Organic Peroxides)”, followed by Mark Robinson from Fibrelogicgiving a presentation on “Continuous Winding of Composite Pipe”.Unfortunately the third scheduled speaker, David Lyons from EMPComposites, was a late cancellation due to personal reasons;several attendees remarked that they would be keen to hear hispresentation on “How Engineering Can Reduce Your Risks”, whichwill be rescheduled for an industry briefing in 2008.

Management staff from Fibrelogic then hosted a tour of theirimpressive facility and were on hand to explain the state of the artprocesses they use.

In less than five years, Fibrelogic has gone from obscurity to beingAustralia’s leading GRP Pipe company, with phenomenal growthin staffing, market size and manufacturing facilities. In 2004,

Managing Director Martyn Manuel was awarded a multi-milliondollar government funding grant to assist in the setting up of anew Fibreglass (GRP) Pipe manufacturing facility in Adelaide. Withthis new factory, world class pipe testing laboratory, and a teamof skilled, enthusiastic staff, Fibrelogic is looking to become aleader in water pipelines in Australia

Following the tour of the plant, attendees were treated to drinksand delicious finger food whilst meeting and mingling with theirindustry colleagues.

the Events, Education and Editorial Committee Reports. Treasurer Floreana Comandelivered the Financial Report.

The members of the Board of Directors were introduced. The full report on the meetingand matters presented, including the Reports, is available in the Minutes of the Meeting,which are now available for Members in the Members’ section of the Composites Australia website.

SOUTH AUSTRALIA

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Kent, WA - Magnum Venus Plastech is excited to announce thatour company President, Jim Hedger, Jr. has been invited to jointhe board of the ACMA and has accepted.Having worked in the Composites Industry for most of his career,Jim has had the opportunity to watch the changes that havetaken place in this growing industry through the years. As thePresident of Magnum Venus Plastech, Jim, through the company,has had a hand in influencing many of the changes inequipment, processes and technology that have shaped thedirection of the industry. When government standards beganchanging toward extremely low Styrene emissions, MVP took thelead in providing customers with the best option to meet thesenew standards: Fluid Impingement Technology (FIT®).After its release, MVP worked very closely with the ACMA in testingthe benefits of FIT®, and that technology has become thestandard for open mold processes.MVP has been a long standing member of the ACMA, andbelieves that the organization is vital in moving the CompositesIndustry into the future where governmental restrictions become

even tougher, requiring new innovations that will keepmanufacturers running safely, efficiently and profitably. To thisend, through the recent purchase of Plastech technology andexpertise, M.V.P. now stands poised to further help the industrymeet these tougher governmental restrictions around the world.Jim is looking forward to working with the ACMA on developing anew certification courses that will focus on making cleanertechnology, like RTM, a vital component of Compositesproduction in the future.Jim accepted the position on the ACMA board to help bringmore customers to the organization and to ensure that producersknow what the organization is doing for them. Says Jim on whyhe accepted the position, “I wanted to be able to share myopinions of what we (MVP) see happening in the industryworldwide.” For more information on the ACMA please visit their Web site atwww.acmanet.org, and for information on the full line of M.V.P.Systems, contact MVP or visit their Web site atwww.mvpind.com

PRESS RELEASE: MVP PRESIDENT JOINS ACMA BOARD

The composites industry isn’t alone in issues such as staff and skillsshortages. An issue faced by all businesses is trying to get moredone with less resources. One of the key drivers in a servicebased business is ‘Personnel Productivity’ i.e. getting the mostincome earning capacity from production staff/labour hire.

One way to improve the situation is to do less work but ensure it ismore of the profitable or desirable work. You may have heard ofthe ‘Pareto Principle’, which is the 80/20 rule. An example is 20%of customers, produce 80% of sales and profit. The ‘ParetoPrinciple’ has proven valid since the late 1800s when it wasdiscovered by Vilfredo Pareto, an economist.

It follows then that we should concentrate on the 20% ofcustomers, jobs, services, staff etc that are producing the 80% ofresults. In order to know who the 20% are we need systems inplace for tracking results and who/what is achieving them. If youcould do this then you would probably need less resources toachieve better results.

As a business owner/manager it can be hard to extricate yourselffrom the business for enough time to spend working ‘on’ thebusiness rather than ‘in’ it. If you can be disciplined enough to dothis, it can pay big dividends, in terms of improved efficiency,personal satisfaction and lifestyle for the business owner, andbetter profit and cashflow. What you need to achieve thesebenefits are systems.

In order to set up systems you must get the ‘knowledge’ out ofyour head and into a format that staff can understand and follow.You need to identify what are the most critical actions in yourbusiness, who is responsible for them and how they should bedone. Once you know these things, you can share thisinformation with others and begin to do less of them yourself.Obviously staff needs to be trained and monitored in theseactions, but a little time invested in this area, could pay bigdividends down the track.

Staff who have systems to follow feel much more secure in theirwork and create less distractions for themselves and others.Businesses with good systems and happy staff become the‘employers of choice’. Who wants to work in a business run by‘crisis management’ where everyone is stressed and unhappy?Any Human Resources expert will tell you money often comes waydown on the list of motivators for staff.

An example of critical actions in a service based business is thefulfillment and management of jobs. If you have a good jobmanagement system you have access to

n Information required for staff to do the jobn Information about job profitability for the business ownern Information about hours paid to staff compared to those sold

to customers to make improvements to marginsn Information about ‘Work in Progress’ speeding up invoicing of

jobs and improving cashflowSystems make it much easier to manage a business, as themanager doesn’t have to think of everything all the time – theysimply point staff to the system. This leaves the business ownerfree to work ‘on’ the business rather than ‘in’ it. Documentedsystems also create an environment for improvement. It givesstaff the opportunity to contribute new ideas and see themincorporated into the system – another motivator and retainer ofgood staff.

Systems can take many forms, e.g. manuals or a web basedmethod. Web based methods for many business processes arepopular today. They enable owners to run a business remotelywhen necessary e.g. when on holidays or even just from home. If a staff member has a question you don’t have to scurry back tothe office to explain the answer. You can simply direct them overthe phone to the relevant information and talk them through it.These types of systems are not as expensive as you might think.What price do you put on your own sanity and health?

Another benefit of having systems in place is in added value toyour business. If you wish to one day sell your business and retireor exit, having systems is much more attractive to a buyer than a business that runs from inside the owner’s head.

CAD partners are a team of Advisors who work with businessowners to realize the maximum return from your business, both incashflow/profit and personal lifestyle. Special Offer – A FREE‘Financial Health Check’ session for readers of this magazine.Simply call us on 1300 36 24 36 or visit our website Simply call us on 1300 36 24 36 or visit our website www.cadpartners.biz

There is a FREE e-book on Cashflow control available to readersof this publication. To see further details of this e-book go towww.cadpartners.biz/e-book.htm

SHORT ON STAFF, SHORT ON SKILLS, SHORT ON TIME!

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Two new sponsors have come on board to help support theannual Australian Marine Awards, presented by the AustralianMarine Industries Federation (AMIF).

The new sponsors are Fusion Marine Electronics and the GoldCoast City Council.

AMIF CEO Sherry Donaldson said both organisations had beenlong time supporters of the Australian Marine Awards, but this yearhad enhanced their support with a financial contribution.

“Chris Baird from Fusion has been involved with the AustralianMarine Awards since the early days of the new look awards whichwere established in 2001,” said Ms Donaldson.

“He is always eager to support the national industry and brings not only a cash offering but a genuine concern about ensuringcontinued growth and the exploration of effective ways topromote the industry to the public and government.

“Jim Fountain, from Gold Coast City Council (GCCC) which is avery strong supporter of its local marine industry, has always takenan active interest in the awards.”

“For the first time GCCC is on board this year as an officialfinancial sponsor.”

“To have these major organisations join our sponsorship team is a strong endorsement for the Australian Marine Awards, itsperformance in the past and its objectives for the future.”

Sponsors for the 2008 Australian Marine Awards are OCVReinforcements (formerly known as Saint-Gobain RF), FusionMarine Electronics, Department of Industry, Tourism and

Resources, Sanctuary Cove International Boat Show and the GoldCoast City Council.

Ms Donaldson said the 2007 awards attracted 150 entries leadingto the nomination of 69 finalists.

“A 2007 AMIF survey to 1,400 marine companies and potentialentrants showed support for the event as an important part ofmarine industry culture,” said Ms Donaldson.

“Most respondents indicated they would enter the awards in 2008which will see the Boat of the Year Award categories increasedand redefined and with some changes to the sailing criteria,following marine industry feedback.”

Boats to be considered for 2008 awards will be all those tested bythe AMA media partners in the normal course of their operationsbetween March 1, 2007 and February 22, 2008. (Yaffa Publishing,Modern Boating, Club Marine, The Gold Coast Bulletin andSeaspray)

Ms Donaldson said Australia's recreational boating industry was a huge contributor to the national economy, with a recentinternational study defining the annual value of the marine sector (boats sold, brokered and manufactured) at $A3.6 billion,while the marine industry turnover reached $A6.87 billion.

For more information call Amanda Tweddle (08) 9371 8872 or visit: www.amif.asn.auwww.fusioncaraudio.com orwww.goldcoast.qld.gov.au

PRESS RELEASE: TWO NEW SPONSORS ENDORSE INDUSTRY

Magnum Venus Plastech (M.V.P.)Demonstrated Their Light RTMTechnology Inside the ACMA Composites2007 Exhibition.

Kent, WA – Magnum Venus Plastech waspleased to be the first company everallowed to conduct live demonstrations of their products and technology insidethe hall at the ACMA Composites 2007Exhibition in October.

Historically, organizers of the exhibition andcity fire authorities had denied permissionto conduct such demonstrations in thebooths for safety and health reasons.However, M.V.P. was able to demonstrateto each that the Light RTM Technologybeing demonstrated had reached a levelof safety and technical security such thatthere was no danger in allowing thedemonstrations to proceed.

M.V.P. conducted several demonstrationsthat included the full 15 minute, from thestart of injection to the de-moulding of thepart, closed mould injections of a carbonfiber racing car seat, producing a perfectfill each time with foam and metal insertsincluded in the part. The new Patriot SSBsystem with a safe water based Flush

System was used for these injections. The new “MotoCat” feature on this systemallowed for a change in catalystpercentage producing a rapid cure onthe part after just a 70 second mould fill.

Presenters demonstrated how the entiremoulding cycle is now an automaticsequence that starts with the press of abutton. Jim Hedger, Jr., President of M.V.P.said, “We see the growth of clean, closedmould technology as very important toour clients, so we have invested heavily in

establishing top name expertise andintensive training programs in mouldbuilding and technology transfer.” He continued, “The show's safe, clean andvery professional demonstrations providedvery serious encouragement towardchange so very much needed undertoday's emission control legislation.”

For more information on the full line of M.V.P. Systems and Light RTM Training,please contact MVP or visit their Web siteat www.mvpind.com

PRESS RELEASE: MVP CONDUCTS DEMOS INSIDE ACMA EXHIBITION

On the 5-9 November in Qld, Glas-Craft Australia Pty Ltdconducted its second RTM Lite training school, with great success.This is only the second school to be conducted by RTM Northoutside America or Canada.

Twenty-four students came from all over Australia (and one fromNew Zealand) for the course, held at PARTEC (QLD), a coursesponsor and our training venue of choice. The RTM school isunique to Australia. Doug Smith from RTM North conducts theseschools all over North America, and he was very pleased with theresponse and participation from the attendees in Australia. Thefeedback from the students following the school has been verypositive, with some putting their names on the list for an advancedsession next time it is run, and others wanting to book positions forother employees at their companies.

The school covered everything from mould manufacture tosurface prep, applying sheet wax, flange profile, resin flow andpart thicknesses, with the emphasis on the RTM Lite b-side orcounter mould. The school uses a very hands on approach, with all the students getting in and applying all the techniquesfrom the course on a day to day basis.

With the school spending a lot of the time and focus on thethickness and surface finish of the b-side of the part, studentsrealized the benefits of sheet wax - and also understood why this school requires a full week.

For bookings to the school next year please don’t hesitate to contact Malcolm Wesener directly on 04 3881 2666

RTM LITE TRAINING SCHOOL

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Huntington Beach, CA: The NEW Stretchlon™HT-350 belongs to the Stretchlon™ family ofbagging films.

Known for its high elongation (some over 500%and hence the name “Stretchlon”), makes it easyon the users to cover most areas when vacuumbagging a part. Also, it's a good choice for plycompaction.

Stretchlon™ HT-350 (“HT” stands for HighTemperature) can withstand a higher temperaturethan the Stretchlon™ 200. Also, Stretchlon™ HT-350can be used with all standard epoxy resin systems.This film will stay soft even in low humidityconditions but is not recommended for use with polyesters or vinyl ester.

About Airtech Advanced Materials GroupFounded in 1973 by William Dahlgren, AirtechAdvanced Materials Group consists of AirtechInternational Inc., Huntington Beach, California;Airtech Europe S.A., Differdange, Luxembourg; and Tygavac Advanced Materials Ltd., Rochdale,England. Airtech manufactures vacuum baggingand composite tooling products for theaircraft/aerospace, wind energy, automotive,marine and general composites industriesworldwide. Airtech is an ISO 9001:2000 registeredcompany.

PRESS RELEASE:AIRTECH ADVANCEDMATERIALS GROUPINTRODUCES THE NEWSTRETCHLON™ HT-350.HT-350.

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