DSI Australia (Holdings) Pty Ltd v Garford Pty Ltd
[2013] FCA 132
At a glance
Source factsCourt
Federal Court of Australia
Decision date
2013-02-28
Before
Yates J
Source
Original judgment source is linked above.
Judgment (38 paragraphs)
background 21 Mr Hedrick described bulbed cable bolts in the following terms: Bulbed cable bolts are rock anchors comprising steel tendons with bulbs, which are inserted into bore holes in the roofs and walls of mines and rock tunnels to help prevent cave-ins and rock falls. Typically, such tendons are of steel cable having a central or 'king wire' around which further - usually six - steel wires are wound. The bulbed cable bolts are inserted into the bore holes and grout is pumped in under pressure. The grout fills the bore holes and fills the bulbs and also enters any gaps or fissures in the surrounding rock. The force caused by the bulbs against the grout, wedges them into the bore holes. Once set in place, a plate is put over the protruding end of the strand and against the rock and a barrel and wedges are used to hold the strand against the plate and are tensioned. 22 This description of cable bolts and their manner of use accords generally with the other evidence given at the hearing. There was no challenge to this description. 23 Garford claims to be the leading manufacturer of bulbed cable bolts in Australia. At the hearing, Mr Hedrick gave an account of how, in earlier years, Garford went about manufacturing continuous bulbed cable for use as cable bolts. This evidence was supported by Mr Alington's evidence. There had been an initial challenge concerning the feasibility of manufacture according to this method - thereby calling into question a claim by Garford that it used the method to make continuous bulbed cable on a commercial scale - but, ultimately, the DSI parties did not persist with that particular challenge. 24 The following account represents my findings of fact. 25 Until early 1995, the only bulbed cable bolts which Garford manufactured were relatively short, bulbed cable bolts from precut links of steel cable. 26 In late 1994, Mr Hedrick conceived the idea that there might be a market for bulbed cable bolts that were formed directly from steel cable (of whatever length) and rolled into coils (continuous bulbed cable). Initially, Mr Hedrick thought that the continuous bulbed cable could be wound onto 1,300 metre coils, with the coils then being sent to mines where the mine operators could cut them into lengths suiting their own requirements for cable bolts. He thought that coils of that length would be suitable because non-rotating framed receiving dispensers used by mine operators to hold plain strand (that is, unbulbed) cable usually held a volume of 2,600 metres of plain strand per coil. He estimated that the volume which the bulbed cable would take up as a coil in one of these receiving dispensers would be about double that of unbulbed cable. In the event, 1,300 metres of continuous bulbed cable, as a coil, fitted well into the receiving dispensers. 27 Between January 1995 and October 1999, Garford used a particular method to make continuous bulbed cable from plain strand steel cable placed on a rotatable supply reel. The method required two operators - one engaged principally to operate a bulb-forming mechanism (which formed three bulbs); the other engaged principally to operate a take-up reel on which the continuous bulbed cable was wound, following bulb formation. Plain strand steel cable was pulled from a rotatable supply reel. This was achieved, at least for some considerable part of the process, by the winding of the formed continuous bulbed cable onto a take-up reel. By this means, the plain strand steel cable was pulled into a bulb-forming mechanism from the supply reel. The bulb-forming mechanism was placed between the supply reel and the take-up reel. It is not in question that the manner in which the bulbs were formed was substantially in accordance with the general method described in the first Garford patent (to which I make further reference below) using apparatus of the general kind there described. The apparatus included an hydraulic valve which was operated manually. 28 Mr Hedrick described the process in the following terms: One man principally operated the bulbing mechanism and the other principally operated the take up reel. Movement of the steel cable was stopped manually for the formation of each set of 3 bulbs, and was re-started manually after the bulb-forming operation was complete. The man operating the bulbing mechanism would walk forward to the take up reel after each set of bulbs formed and watch for the last bulb to reach the stop mark and then tell the man winding to stop. Then the first man would return to form another set of 3 bulbs and the process would be repeated. The distance from the last bulb in the set of 3 bulbs to the position enabling the next bulb to be formed was measured manually, initially with chalk marks and later (to enable changes of bulb frequency per metre) by using a sliding metal adjustable bar. A ratchet with a stopper on the take up reel prevented any unravelling of cable from the take up reel or any reverse movement and the leading end of the cable was attached to the take up reel with a barrel and wedges to prevent dislodging. The 2 men could operate the apparatus without over exertion of effort and certainly without health or safely concerns … [As in original] 29 I accept this evidence. Mr Hedrick provided other details about the specific manner in which the take-up reel was operated. It is not necessary for me to descend to any further detail in that regard. 30 In about 1996, Mr Hedrick experimented by fitting a small motor and gearbox to the shaft of the winder on the take-up reel to assist in winding the continuous bulbed cable. The operator was required to turn the motor on and off each time the set of three bulbs was made. The motor had to be turned off early so that the take-up reel did not continue to wind and cause the cable to run past the stop marker. It was therefore necessary for the operator to continue to wind the winder manually for some part of the progress of the cable. Mr Hedrick came to the view that this modification would not be practical or efficient in a fully-automated machine. 31 From 1995 until 1997, all completed coils of continuous bulbed cable manufactured by Garford were 1,300 metres in length. These coils were loaded onto pallets and sent to mining sites. Mine operators dealt with them using their existing equipment. Although there is no direct evidence on the matter, Mr Hedrick said that, so far as he was aware, these mine operators would use their standard non-rotating, square-framed dispensers, from which the continuous bulbed cable was pulled from a central axis. There was no challenge to this evidence as representing the likely state of affairs. The continuous bulbed cable was cut to a desired length and installed in a manual process which was slow and labour-intensive. 32 Early in 1997, Mr Hedrick decided to adapt a machine called a Tamrock Cabolter to be used with continuous bulbed cable. Up to that time, the Tamrock Cabolter had been used at mining sites to install cable bolts made from plain strand cable. The machine operated by boring a hole into the mine wall or roof; forcing a tube to the top of the hole; filling the hole with grout or resin under pressure; and then pushing the cable bolt into the hole through the grout or resin. The machine operated with an attached cassette to receive coils of cable. It is my understanding of the evidence that, in operation, the Tamrock Cabolter cut the bulbed cable to a desired length for use as a cable bolt. 33 The process of bulbed cable bolt installation using the modified Tamrock Cabolter was less labour-intensive and approximately three times faster than the manual method by which these bolts had been installed previously. As a result, demand for continuous bulbed cable increased and, from April 1997, Garford started to receive and fill orders for continuous bulbed cable coils in lengths of less then 1,300 metres (generally under 700 metres) to suit appropriately modified Tamrock Cabolter machines. 34 Using the particular method of production I have described, Garford was capable, if required, of manufacturing 650,000 metres of continuous bulbed cable per year. However, Garford was never required to manufacture to this capacity, and not all lengths were made to order. Demand was not predictable and fluctuated from month to month. In this period, Garford made continuous bulbed cable in lengths of 1,300, 700, 600, 550 and 500 metres and stored it on site in advance of receiving orders, so that it could meet demand in a timely fashion. 35 The continuous bulbed cable made by Garford in the period 1995 to October 1999 was supplied to a number of customers in the mining industry. There is no doubt in my mind that this supply was on a significant commercial scale. I am satisfied that Garford manufactured and sold hundreds of kilometres of continuous bulbed cable in this period. The particular method by which Garford carried out this manufacture was not, however, made public. 36 With the increasing orders for continuous bulbed cable brought about by the modifications to the Tamrock Cabolter, Mr Hedrick turned to consider the building of a machine that would enable Garford to achieve increased output and efficiency. 37 He described the development of this machine in the following terms: For approximately 2 years leading up to September 1999 I was working when I could, between other work, to create and build a new machine. I knew that the inclusion of an accurate, reliable and consistent automated means of bulb spacing measurement was crucial. This is because the mining industry requires bulbs at different set lengths along the cable bolt to suit different rock contexts. If the distances between bulbs were variable, the bulbed cable bolt may not be suitable for the rock contexts in which they are to be installed. Bulb spacing is therefore a critical quality control issue which changes in accordance with each customer's assessed requirements. I realised that obtaining accurate measurements could be complicated by a number of factors, including over-run of the take up reel, general slippage of the cable, and movement of the cable during bulb formation. I realised, in particular, that the interaction of the measurement means and the take up reel was crucial. From my experience in operating the manual method I also realised that we needed a way to get the plain strand from the 3 tonne coils of cable as delivered to us into the machine in an automated and reliable and even manner without twisting the cable and that the measurement means and the take up reel had to be fully synchronized. I made the entire new machine from scratch. I could not just buy off the shelf components for the machine. The only components I could buy were the hydraulics, pneumatic cylinders, bearings, valves, fittings hoses, electrics, switches, chains and sprockets. The remainder of the new machine, including frames, guide wheels, pusher wheels, the mechanism for blocks for cylinders, supply reel, supply reel gates and expanding leaves, fastening devices to clamp the inside end of the strand onto the supply reel, gripping jaws, bulb sensing device, brake, bail arm, bail arm frame, take up reel and take up reel gate, air valve cabinet, hydraulic cabinet and attachments, motor and gear box attachments for bail arm, bail arm, linear breaking frame were all designed and built by me. It took me about 2 years to develop and build the new machine, working between other jobs, with many months spent by me in designing, making prototypes, trialling, testing, fixing and changing plus, I estimate, the equivalent of at least 7 months of full time work just to manufacture all the components for and put together the machine. I developed the design for the new machine by making and testing prototypes not by the use of drawings. As stated already, this work was done by me in the Garford factory which was not open to the public and only accessed by employees of Garford. [As in original] 38 I accept this evidence. 39 There was some controversy in the evidence as to when the new machine was deployed to manufacture commercial quantities of continuous bulbed cable. Garford's case was that production of this kind did not take place until around the second week of October 1999, after the priority date of the claims (13 September 1999). The DSI parties submitted that the new machine was deployed for purposes other than reasonable trial or experiment before the priority date. I will return to this controversy when considering the case on secret use advanced by the DSI parties.