50158/06 TRANQUILITY POOLS & SPAS PTY LTD & ANOR v. HUNTSMAN CHEMICAL COMPANY AUSTRALIA P/L
JUDGMENT
1 BRYSON AJ: These reasons deal with Claim 1 in the plaintiffs' Notice of Motion of 27 September 2007 and with the defendant's Notice of Motion of 5 October 2007. These are interlocutory reasons and contain no findings of fact by whch the parties are bound when the ultimate issues come to be determined. The plaintiffs claim and the defendant resists adoption of the Report under UCPR 20 Div. 3 dated 20 September 2007 by Professor Robert Burford. The Court of Appeal and the Supreme Court have often considered the principles to be applied in exercising the discretion to adopt or reject the report of a Referee; the case law relates to proceedings under Pt 72 of the Supreme Court Rules, now continued in substance by UCPR 20 Div 3. In Chocolate Factory Apartments v West Point Finance Pty Ltd [2005] NSWSC 784 at paras 6-8 McDougall J stated 15 principles which his Honour deduced from the case law, and argument before me took place on the basis that those principles should be accepted, which I readily do.
2 The plaintiffs manufacture fibreglass swimming pools and claim damages and remedial orders against the defendant which manufactures chemical products and supplied the plaintiffs with Hetron 922, a vinyl ester resin which the plaintiffs used in the manufacture of 837 fibreglass swimming pools. A component of Hetron 922 is fumed silica, which is a thixotrope. A thixotrope alters the behaviour and viscosity of vinyl ester resin (and of many other materials) according as the material is, for example, under compression or not compressed, or as it is agitated or still. If a hydrophobic thixotrope is used the resin is resistant to permeation and retention of water: if a hydrophilic thixotrope is used the product is tolerant of permeation and retention of water. Unmodified fumed silica is a hydrophilic thixotrope, but fumed silica can be modified so as to be a hydrophobic thixotrope. It is the fact (or for present purposes can be assumed) that at different times the defendant used different kinds of fumed silica in the manufacture of Hetron 922, so that characteristics of the product were different from time to time according as the thixotrope was hydrophilic or hydrophobic.
3 The shell of a fibreglass pool is manufactured by using a spray gun to spray successive resin coats on an upturned mould. The first coat applied is a gelcoat layer and forms the inner surface of the swimming pool in direct contact with the pool water. This layer gives the pool its colour. Gelcoats are semi-permeable: it is possible for water to migrate through gelcoat. The second coat applied is called the mist layer, the third coat is the tie layer and the fourth is the structural layer, which comprises about 80 per cent of the thickness of the pool shell. The fifth and final layer is of gelcoat and enhances the appearance of the outer surface. The tie layer should prevent or resist migration of water into the structural layer. Hetron 922 was the vinyl ester resin used in the tie layer; a mixture of glass fibres and resin was sprayed over the first two layers. The glass fibres are surfaced with size. The glass fibres and resin are fed into the spray gun; the spray gun chops the glass fibres and mixes them with the resin, and the spray produces a thin coat of the mixture. The viscosity of the sprayed material is important: the material sprayed on must hold the position in which it is placed by the spray gun; it must not drip down the side of the mould. If the material is too viscous it cannot be used in the spray process; if it is not sufficiently viscous it will not hold position when sprayed on. Viscosities appropriate to different conditions are achieved by mixing thixotrope in the vinyl ester resin.
4 The plaintiffs' claims relate to 83 fibreglass pools which were manufactured from April 2002 to April 2004, some by the first plaintiff and others by the second plaintiff after transfer of the business on 5 September 2003. During this period Hetron 922 resin supplied by the defendant contained an unmodified fumed silica named HDKN20 which the defendant had obtained from a supplier referred to as Wacker: this silica was hydrophilic. The plaintiffs allege to the effect that many of the pools - 194 when the Summons was filed on 19 October 2006, 261 when the Reference commenced and others since - have suffered from blistering and black spots, referred to as the Pool Failures, and that the plaintiffs have received numerous complaints and claims from retail customers and dealers. At other times the defendant supplied Hetron 922 containing modified fumed silica, which was hydrophobic. According to the plaintiffs' case, vinyl ester resins which they used earlier and later containing hydrophobic thixotrope did not produce Pool Failures. Particulars in the Summons allege:
20. The Pool Failures have resulted from use of the Product.
Particulars
The Product contained, at material times, a hydrophilic thixotrope which is inappropriate for use in the manufacture of fibreglass swimming pools.
5 I give a brief (and from the point of view of a scientist perhaps inadequate) exposition of the processes which, according to the plaintiffs' contentions, are involved. When a pool contains water, water can and does reach the tie layer through the gelcoat and mist layers, which are permeable in some way: perhaps by osmosis. Hydrolysis of water within the tie layer then takes place and reactions occur between products of hydrolysis and other substances within the tie layer. The size which coats the fibreglass can be involved in chemical reaction with products of hydrolysis, causing degradation of the size and producing acidic material. The views of Professor George, who participated in the reference on behalf of the plaintiffs, appear to have led the Referee to the view that the vinyl ester can also be affected by degradation and that products of its degradation can participate in production of acidic material. Blistering and black spots are caused by the presence of the acidic material. According to the plaintiffs' case the presence of water in sufficient quantity to cause Pool Failures after hydrolysis is significantly affected by, and is caused by the use of a hydrophilic thixotrope in the vinyl ester resin: when a hydrophobic thixotrope was used Pool Failures did not occur.
6 The glass fibres which the plaintiffs used were not all obtained from the same supplier; there were obtained from several different glass manufacturers. So there were several different sources of fibreglass and the size applied to the fibreglass, making room for the possibility that varying characteristics in fibreglass and size played a part in causing pool failures. The material put before the Referee relating to glass fibre did not establish in any concrete way what variations there had been. There was no clear basis on which to say what impact variations of that kind may have had on the outcome.
7 The Order of Reference was dated 17 May 2007. The terms of the order including the questions referred were settled by agreement of the parties. The matter referred is stated in the Schedule of the order:
Please provide a report on the following questions. Where there are disputed questions of fact, please resolve the questions to the extent you can on the balance of probabilities. In all respects please explain your reasoning process. If you consider that further testing is required in order to answer the questions, please explain what further testing you recommend.
The questions employ the following definitions:
· "Pool Failures": a problem with blistering and black spots identified in certain swimming pools manufactured by the Plaintiffs;
· "The Product": a vinyl ester called Hetron 922 as supplied to the Plaintiffs by the Defendant.
The questions are as follows:
1. What has caused the Pool Failures?
2. What role, if any, has the Product played in relation to the Pool Failures?
3. What other factors (if any) have played a role in the Pool Failures.
4. If the Product has played a role, to the extent possible please state what proportion of the Pools are likely to suffer from the Pool Failures?
8 Directions accompanying the order included the following:
4. Direct that:
(a) subject to paras (b) and (c) hereof the provisions of Pt 20 r 20 shall apply to the conduct of proceedings under the reference;
(b) the reference will commence on 21 May, 2007 unless otherwise ordered by the Referee;
(c) after taking account of the submissions of the parties as to the manner in which the reference should be conducted, the Referee consider and implement such manner of conducting proceedings under the reference as will, without undue formality or delay, enable a just determination to be made including, if the referee thinks fit:
(i) the making of enquiries by telephone;
(ii) site inspection;
(iii) inspection of plan and equipment; and
(iv) communication with experts retained on behalf of the party;
(d) any evidence in chief before the referee shall, unless the referee otherwise permits, be by way of written statements signed by the maker of the statement;
(e) the referee submit the report to the Court in accordance with Pt 20 r 23 addressed to the Associate to the Commercial List Judge on or before 31 August 2007.
9 The concluding paragraph of the Report is as follows:
SUMMARY
104 I am in general agreement with the Plaintiffs' submission. It is based on facts which are, in the main, agreed.
1) What has caused the Pool Failures?
My opinion based on the available evidence is that the Hetron 922, containing ethylene glycol and in particular hydrophilic thixotrope, that has been used in the tie layer in Tranquillity Pools, has caused failure. Pools which did not use this material as a tie layer, but made by Tranquillity, did not and do not fail. Pools made before April 2002 and after April 2004 have not failed because they do not have the same polymer mixture in the tie layer. No pools made by Tranquillity using identical manufacturing methods, except using other vinyl esters in the tie layer, between April 2002 and 2004 have failed.
2) What role, if any, has the product played in relation to the Pool Failures?
The Hetron 922 supplied to Tranquillity between April 2002 and April 2004 by Huntsman has caused blistering. Although a full scientific understanding of the reasons for this are not finalized, enough is now known to relate this product to Pool Failures. Testing by Huntsman has shown that blistering is associated with Hetron 922 containing hydrophilic thixotrope.
There is no evidence to show that other changes in manufacturing occurred at Tranquillity during the relevant period, nor is there any evidence to suggest that substandard manufacturing standards existed.
3) Is it probable that all of the Pools made by the Plaintiff using the Product will suffer from the Pool Failures?
It is probable that over a decade most if not all Pools will fail.
4) If the answer to question 3 is 'no', to the extent possible please state what proportion of the Pools are likely to suffer from the Pool Failures?
N/A
10 In my understanding the Report is to be understood in whole so as to see what answer the Referee made to the questions referred to him. It will be seen that questions 3 and 4 in para 104 of the Report do not conform exactly with the questions in the Order of Reference. In my understanding, how the Referee dealt with question 4 can be understood by looking at questions 3 and 4 and the material stated by the Referee in answer to them together with all other material in the Report. The Referee's answer to question 3 is to be understood from the terms of the report as a whole.
11 Professor Graham George, Professor of Polymer Science of the Queensland University of Technology who is retained in consultation with the plaintiffs and Professor Robert Shanks, Professor of Polymer Science of Royal Melbourne Institute of Technology University, Melbourne, who is retained in consultation with the defendant, participated as experts in the Reference, on some occasions attending the Referee in the absence of legal advisers or other representatives. The Referee and the experts all have high expertise in Polymer Chemistry. The experts worked collaboratively to attempt to isolate the cause of the pool failures, commencing long before the Reference and the involvement of Professor Burford. They acted as collaborating scientists, not as advocates. They produced a document called "Assessment of causes of blistering of swimming pool laminates fabricated by Tranquility Pools & Spas, Taree, NSW" and made four joint reports before the Order of Reference was made; the first joint report is dated 22 June 2005, the second joint report 21 September 2005, the third joint report must have been made in January 2006 and the fourth joint report was signed on 24 and 28 March 2007.
12 The collaborative work of the experts, extending back to June 2005 if not earlier and well before the reference, was undertaken with method and rigour, directed to identifying the material which caused blistering and establishing the process or processes that had brought that material into existence. Their work included microscopic and spectroscopic examination of cross sections from laminates of blistered pools, examination with energy disbursive x-ray, GC-MS analysis of the fluid recovered from the blisters; and consideration and analysis of published literature relating to blister formation. Their consideration, and the knowledge and material which they had available for the Referee at the outset, were extensive.
13 The issues appear from the Summons and Defence, according to Commercial List practice. The plaintiffs' claim includes a claim that the product supplied was not of merchantable quality, based on a warranty stated in the delivery invoices. The plaintiffs also rely on contravention of s.52 of the Trade Practices Act with respect to four representations made to the first plaintiffs' factory manager Mr Annakin by the defendant's sales representative Mr Rapson before the defendant entered on supply. The plaintiffs allege express representations by Mr Rapson to the effect that the product was a 20-year-old product and a proven product, that it was the same as the Derakane 411 that the first plaintiff was buying from another supplier, and that if anything did go wrong the defendant would stand behind the product. A fourth representation is also alleged to have been made by implication: that the product was of merchantable quality and fit for the purpose of use in manufacturing fibreglass swimming pools. The Defence disputes these allegations and raises numerous issues.
14 The four questions in the Order of Reference are obviously of high importance, but they are not either literally or in substance ultimate issues arising on the Summons and the Defence; the Report should be expected to have a very important part in the consideration and disposition of the litigation by the Trial Judge but its terms and answers to questions do not in my understanding establish without further consideration how any of the ultimate issues should be disposed of. If the defendant had obtained a favourable report on question one excluding causation by its product there could have been little more to debate. Except for this observation, the Report should be understood as undertaken to assist the Trial Judge to dispose of ultimate issues. This is a significant consideration when I address whether the answers are unsatisfactory in some way which might require their rejection.
15 It is important, in the light of some submissions I heard, to notice that the Referee was not asked to report on and did not report on whether the product supplied was of merchantable quality. Whether it was of merchantable quality is a question of mixed fact and law, involving the application of a legal standard to facts, and while the Trial Judge might well find the Referee's report useful or valuable, determination of the facts and the application of the legal standard would be the responsibility of the Trial Judge whose determination would not at any point be precluded from further consideration by the Report. Similar observations should be made about the issue of fitness for purpose.
16 For the plaintiffs' case to succeed it would seem to be necessary for the plaintiffs to obtain findings to the effect that the use of unmodified fumed silica and the hydrophilic characteristics of unmodified fumed silica when used as a thixotrope caused the permeation of water into the layer in which hydrolysis and interaction of products of hydrolysis with size (and perhaps also with vinyl ester resin) occurred; and that if a hydrophobic thixotrope had been used the permeation would not have occurred. Unless these things were established it does not seem possible that the conclusion could be reached that the product was not of merchantable quality, or that it was not fit for the purpose for which it was required. To my mind it is not remarkable, but only to be expected that the questions referred to Professor Burford were phrased in ways which directed attention to the first part of these considerations, but not to the conclusion about merchantable quality or fitness for purpose.
17 The Referee did not conduct the reference in a way closely similar to the way in which a judge would have heard and determined issues in litigation. He was not required by law to do so; the Order of Reference expressly authorises proceeding in various ways which a judge would not usually adopt. The Court would be unlikely to adopt a report if the Referee had not proceeded in a fair way according to broad concepts indicated by the expressions "natural justice" and "due process," but what these require is not narrowly defined, and context and circumstances are important. There was a preliminary meeting between the Referee and counsel on 21 May 2007; there were one or more meetings between the Referee and Professors George and Shanks in the absence of legal representatives, and between the Referee and legal representatives in the absence of Professors George and Shanks. Documents referred to as a Draft Report or as a Summary of Points of Agreement of Experts were circulated among the experts and the Referee; in hindsight it seems a little inept that one of these documents was referred to as "Summary Points of Agreement of Experts" but Professor Shanks (who it seems did not participate in this document) later made another report of his own. There was no transcript or other complete record of most occasions when the Referee met and spoke to legal representatives or experts, but a record was made and transcribed on 17 August 2007 and on 23 August 2007. On 23 August 2007 the legal representatives of the parties each cross-examined their opponent's expert, and the proceedings were recorded and transcribed. Thereafter the parties made written submissions to the Referee, which he considered before making his Report. It is plain from later events that a Draft Report circulated by the Referee on 29 June 2007, which appears to have arisen from the meeting between the Referee and the legal representatives on 15 June 2007, remained well open to consideration; the Referee was presented with significant further material, contention and argument after this Draft Report.
18 The Referee set out the procedural history of the reference and the sources of information he had taken into account in paragraphs 1 to 14 of his Report. In the course of the reference there were meetings which I would describe as collaborative consultation among experts, followed by exchanges of an interim Draft Report and written material prepared by the parties' experts. The Referee prepared an interim Draft Report dated 29 June 2007 of which he says "I noted some of the points of agreement and areas for further investigation." Thereafter there was a meeting on 27 July 2007 which the Referee described as "a technical meeting" and he says "this meeting took the form of a mainly collaborative scientific discourse, where a both I and the experts attempted to discuss and resolve issues from which agreement had not been possible." These, and the communications from the experts which followed, took a form which might be expected in a consultation among highly qualified and informed scientists. There were also events which more closely resembled court procedures - an initial joint meeting on 21 May 2007 at which parties presented folders of written material, a meeting with legal representatives on 29 June 2007, and a meeting and discussion with legal representatives on 17 August 2007 (which appears to have been inconclusive). A transcript of what took place then was made. Then or perhaps earlier the Referee was given four affidavits which (plainly) parties wished him to take into consideration. There was a final meeting on 23 August 2007, with cross examination; a transcript was made. After this meeting the Referee was given written submissions and reply submissions by the parties and some other further information. His Report followed on 20 September 2007.
19 The defendant's Outline of Submissions before me included:
53. Huntsman submits that the report of Professor Burford ought be rejected in totality for following reasons:
(a) The Referee has in substance not answered the questions referred to him;
(b) The Referee has not provided any adequate or sufficient reason for attributing the cause of the pool failures to Hetron 922 and so has not revealed a thorough analytical and scientific approach to answering the questions referred to him;
(c) The opinions expressed by him are based upon obviously incomplete knowledge and are, accordingly, manifestly unreasonable;
(d) The Referee acted unreasonably and in denial of natural justice in rejecting evidence that other fibreglass pool manufacturers, who received the vast bulk of Hetron 922 during the same period, suffered no pool blistering and in refusing or neglecting to otherwise inquire into and/or consider the use of Hetron 922 to by other pool manufacturers;
(e) The report has no utility.
20 The contentions of the defendant against adoption of the Report can be collected into four groups. I am not directly quoting from any submission but in my understanding the groups are these: