9 The facts which give rise to the dispute may be stated rather briefly, as there is not very much disagreement about them between the parties.
10 The underground mining of coal inevitably produces readily inflammable material in the form of methane gas and coal dust. Methane is more easily ignited than coal dust, but methane gas in a mine is usually of limited quantity whereas coal dust is present in large quantities throughout the whole mine. Accordingly, even though a methane gas explosion is a very serious occurrence which can kill and maim many miners, an even more serious and devastating explosion occurs if the methane gas explosion produces in turn a coal dust explosion. This can happen when the blast force of the methane explosion blows the coal dust on the floor of the mine into the air and the coal dust is then ignited by the extremely hot flame front produced by the methane explosion.
11 A coal dust explosion usually runs throughout the whole of the mine and it has been found many times that when a coal dust explosion occurs all the workers in the mine are killed.
12 The prevention of explosions in underground coal mines has been the subject of research, investigation and regulation in coal mining countries for many years. It has been found that one way to prevent a coal dust explosion is to render the coal dust in the mine incombustible by combining it with an inert material such as stone dust. Because it is difficult to maintain the correct level of stone dust distribution in certain areas of a mine, a way has been devised of producing a saturation of stone dust in a mine whenever an explosion occurs. The method is rather simple in concept but, of course, it is complex in execution.
13 Plastic bags are filled with stone dust and suspended in rows from the ceiling of the mine at various strategic points. If an explosion occurs the force of the blast will burst the bags and will disperse the stone dust in the air to mingle with and render incombustible the coal dust before the flame front from the explosion reaches it, thereby preventing or suppressing a coal dust explosion.
14 As I say, the idea is simple but carrying it into effect is not so simple. There must be sufficient stone dust to produce the required effect. This means that the plastic bags containing the stone dust must be able to support a weight of 6 kilograms. The bags must be sufficiently strong that they will not break or spill although suspended by hooks for a long time. Nevertheless, they must be able to rupture easily whenever an explosion occurs and they must be able to release their contents in an efficient way.
15 Research on producing the right combination of materials in constructing these stone dust bag barriers was carried out for a number of years in South Africa by an organisation identified in the evidence only by the acronym CSIR. Extensive tests were conducted on a trial and error basis, the most important tests being conducted by setting off real explosions in mines and seeing how various combinations of materials reacted. These 'real life tests' were conducted in mines in South Africa, the United States and Germany and they were, no doubt, expensive.
16 By the beginning of 1997 research on the stone dust bag barrier had been completed and CSIR, through various agents or associated entities, began to manufacture and distribute its bags to the mining industry throughout the world. In late 2000, Alfabs began to distribute the bags to mines in NSW. It purchased from SkillPro the bags and the plastic hooks and collars that were to be used to attach them to coal mine ceiling. The precise relationship between SkillPro and CSIR is not revealed by the evidence. The bags supplied by SkillPro were at first sold under the brand name "DUBACO" and later under the name "ACIRL".
17 Some time in 2000 Alfabs decided that, rather than purchasing the bags from SkillPro, it would itself manufacture and supply bags for use as stone dust barriers. It produced some polyethylene bags, no doubt modelled closely on the ACIRL bags, and commissioned a report from Valley Geotechnical (NSW) Pty Ltd ("Valley"). The report compared the properties of the ACIRL bags with those of the proposed Alfabs bags and commented upon the expected performance of the Alfabs bags.
18 The conclusion reached by Valley was that "the proposed [Alfabs] bags should perform similarly to the current product in use (ACIRL). It is recommended that for certainty the polyethylene bags to be used by Alfabs should have only a single seam across the base and no side seam" .
19 Valley did not test the Alfabs bags or the ACIRL bags using 'real life' explosions, as had been done by CSIR with the ACIRL bags. Valley noted that "without any guidelines available to determine performance and functional data it was decided to test the bags by pressurising to burst and note the mode of failure" . Accordingly, the bags were slowly inflated until they burst. It is common ground between the parties' experts that these testing conditions were quite remote from the 'real life' tests which would have been afforded by controlled explosions in coal mines.
20 Valley's recommendation as to the placement of seams referred to the fact that the ACIRL bags had a single seam at the bottom whereas the Alfabs bags had a seam at the bottom and along one side. Valley considered that it might assist the dispersal of stone dust upon rupture of the Alfabs bag if it, like the ACIRL bag, had only one seam at the bottom.
21 Alfabs adopted Valley's recommendation and procured the manufacture of a bag with only one seam at the bottom. This new version was not submitted to Valley for testing. Alfabs began to sell its bags to coal mines in NSW in late September 2001.
22 Unlike the position in Queensland, in New South Wales a person manufacturing or supplying equipment for use in coal mines does not have to obtain prior approval from the Department of Mineral Resources or any other body. However, under s.61 of the Act the Chief Inspector of Mines is empowered to send Notices to coal mine managers informing them of matters relevant to mine safety. Under s.63 if the Chief Inspector is of the opinion that anything connected with the control or management of a mine is dangerous to the safety of those employed at the mine or is liable shortly to become dangerous, the Inspector may issue to mine owners or managers a Notice stating that opinion and imposing such prohibitions as appear to the Inspector to be necessary for the safety or health of persons employed at the mine.
23 SkillPro soon learned that Alfabs was selling its own bags to the mining industry. On 17 January 2002 Mr Humphreys, a director of SkillPro, wrote to Mr White, the Mining Sales Manager of Alfabs, protesting that Alfabs had copied the ACIRL bags. Mr Humphreys emphasised that the copied bags had not been extensively tested by 'real life' explosions as had the ACIRL bags, so that the Alfabs bags were not only inferior but might be dangerous. Mr Humphreys advised Mr White that SkillPro would be informing the Department of Mineral Resources and all collieries that the research and test results used by SkillPro in relation to its own bags were not applicable to any other bags. In other words, Alfabs was put upon notice that SkillPro would be making representations about the safety of the Alfabs bags, not only to mine operators but also to the Department of Mineral Resources.
24 On the same day, Mr Humphreys wrote to Mr Regan drawing his attention to the fact that Alfabs bags were being manufactured and distributed without having been tested by 'real life' explosions in the same way as had the ACIRL bags. The letter stated:
"… we are extremely concerned that a manufacturer may see fit to supply a critical safety product without any proof that the product is fit for its intended use."
25 On 30 January 2002, Mr Clive Ellis, a Scientific Officer employed by the Department of Mineral Resources, prepared a minute concerning the Alfabs bags. The minute went in the first instance to Mr Fawcett, Manager, Mine Safety Unit, Mr Ellis' superior, and then to Mr Regan. The minute stated that the bagged explosion barrier system developed by CSIR in South Africa and sold by SkillPro as ACIRL had been imitated by Alfabs. It drew attention to the fact that the ACIRL bags had been tested in an extensive programme of experimental explosions in South Africa and Germany, but that the Alfabs bags had only been tested by Valley, which was apparently accredited only for the testing of aggregates and soils.
26 Mr Ellis made the following comments about the Valley report:
"Valley … rely … on an infrared scan of the polyethylene material in the SkillPro and Alfabs bags. The accompanying report from Newcastle University states: 'This is a reasonably comprehensive test and only fine details such as tactility and crystallinity etc would not be revealed by this'.