Quality in Question SUBSTANDARD PRODUCTS
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WWW.PLUMBINGCONNECTION.COM.AU WINTER 2021 INSIDE: ‘ALTERNATIVE’ DRAINAGE SOLUTIONS PVC PIPE RECYCLING LEAD IN DRINKING WATER Quality in Question SUBSTANDARD PRODUCTS: NO MORE EXCUSES
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CONTENTS COVER STORY 14 QUALITY IN QUESTION Substandard plumbing products continue to infiltrate Australasian markets. 12 FEATURES REGULARS 18 AUSSIE MADE 06 Editorial Following a year of international 08 Industry News trade turmoil, local supply 10 New Products channels are regaining popularity. 18 30 Gas Update 32 Copper Connection 20 ‘ALTERNATIVE’ IS NORMAL We showcase a major NZ 38 Estimating development using AHSCA 42 Legal Matters Research Foundation ‘Alternative’ 46 Prove It drainage solutions. 48 Backflow Prevention 52 Training off the Page 24 AFTER COVID-19 56 Box Gutters COVID-19’s legacies are not 60 Standards Australia 24 all bad – we examine how the pandemic has motivated positive 81 Trade Stuff practices. 28 PVC PIPE RECYCLING Where does old PVC piping go? All practitioners have a role to play in recycling waste products. 36 LEAD IN DRINKING WATER 36 The ABCB is considering a range 64 OHS of options to reduce lead in drinking water. 70 LEGAL 74 TRANSPORT 4 PLUMBING CONNEC T ION W inter 2021
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EDITORIAL PLUMBING IN A POST- COVID-19 WORLD www.plumbingconnection.com.au F irst of all, it’s a pleasure to be changed at all over the last decade. GENERAL MANAGER Jeremy Sweet back! Having served as editor As we contend in our cover story jeremysweet@build.com.au of Plumbing Connection for (see page 12), substandard products EDITOR several years over a decade ago, – including WaterMark-certified John Power I’m delighted to have been invited items – continue to infiltrate the 0403 818 579 johnpower@build.com.au back as editor. I would like to wish Australian marketplace due to deep- my predecessor Justin Felix great seated weaknesses in our regulatory EDITORIAL CONSULTANT Jeff Patchell success in his new career. structures. Not only do dodgy jeff patchell@build.com.au My return to Plumbing Connection products jeopardise the health of the EDITOR – ACROSS THE TRADES occurs at a time of profound social population, but they also undermine Anna Hayes annahayes@build.com.au and industrial change. plumbers’ professionalism and lead to Certainly, the plumbing industry costly remedial actions and repairs, STAFF WRITERS Anna Hayes, Sean Carroll is grappling with unprecedented often at the plumber’s expense. GRAPHIC DESIGNER challenges following the pandemic- A solution, we argue, is for greater Sam Elliott based upheavals of the last year – the accountability at point of sale, ADVERTISING TRAFFIC MANAGER world is reviewing the very fabric of combined with far more rigorous and Tracey Glanville public and private sanitation systems, transparent enforcement of product SUBSCRIPTION MANAGER particularly in health and aged care compliance. No one wants to see our Brigitta Novosell 03 9542 9005 facilities, while homeowners are plumbing retail sector swept up in redefining their bathrooms and a culture of US-style litigation; nor CONTRIBUTORS Enzo Alfonsetti, Paul Cott, Peter Damaso, laundries according to new ‘work from do we want to see a continuation John Fennell, Sophi MacMillan, Dr Greg home’ lifestyles. of the existing regulatory system Morwood, Paul Oliveri, Jon Palfrey, Brian Seymour, Ken Sutherland, Ian Todd At a business level, tradespeople that rewards honourable behaviour of all disciplines are learning while shrugging its shoulders at ADVERTISING Angelo Sticca 03 9542 9011 how to interact with customers malpractice. Surely a balance is angelosticca@build.com.au in compliance with new hygiene achievable. TO SUBSCRIBE 1800 623 214 protocols, and coming to grips with As always, this issue of Plumbing Australia 03 9542 9000 New Zealand +61 3 9542 9000 increasing levels of administrative Connection contains an abundance of Fax (with credit card details) 03 9542 9090 responsibilities and workday practical information from our regular interruptions. columnists about new technologies www.facebook.com/tradieconnection As we shake off the horrific chains and products, best practice, and of the pandemic, it is worth asking updates about the latest changes www.linkedin.com/in/plumbing-connection/ whether there are any positive to codes and standards. In addition, www.twitter.com/PlumbingCXNMag legacies of COVID-19. This question we are pleased to present a range is at the heart of our article ‘Life of special features, including an By mail, please write to the address below After COVID-19’ (see page 24), in overview of a new Woolworths PUBLISHED BY: which leading companies reveal the NZ distribution depot, which Lanella Media Pty Ltd 2/18-22 Lexia Place, benefi ts of lessons learned during incorporates customised drainage Mulgrave, VIC 3170 the pandemic, namely faster R&D designs as an ‘Alternative Solution’ AUSTRALIA ISSN 1034-3075 implementation, more diverse supply (see page 20); as well as a timely chains, and tighter bonds with key reminder of the value of Australian Disclaimer: The opinions expressed in this magazine do retail partners. Made manufacturing (see page 18). not necessarily reflect those of the publisher. Although all materials are checked for accuracy, no liability is assumed by the publisher for any losses due to the use SENSE OF DEJA VU Enjoy the read of material in this magazine. Copyright 2021 by Lanella Media. All rights reserved. No part of this publication Having said that, it is fascinating may be reproduced, stored in a retrieval system or to witness how other aspects of transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) the plumbing industry have barely John Power without the prior permission of Lanella Media. 6 PLUMBING CONNEC T ION W inter 2021
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INDUSTRY NEWS TAS GAS CONSIDERS HYDROGEN FREE INTERACTIVE SAFETY GUIDE NEW CEO FOR MPA IN ACT Tas Gas has signed a non-binding Pro-Visual Publishing and their Claire Howe has been appointed as agreement with Woodside Energy partnering industry associations the new CEO of Master Plumbers to begin exploring the possibilities have released the annual Augmented Association ACT. Claire takes over of blending green hydrogen into the Reality (AR) Interactive Educational from Leigh Watson, who left the Tasmanian gas network. Safety Guide for plumbers. Distributed organisation late last year. The heads of agreement provides free across Australia, it’s designed to “I encourage members to touch the framework to blend up to 10% place on the wall as a daily reference base with Claire on 0402 418 123 hydrogen into the network, including to use with your phone, or other smart or ceo@masterplumbersact.asn. renewable hydrogen produced at device, to view augmented content au to introduce yourself and pass Woodside’s proposed H2TAS project. alongside the informative printed text. on any thoughts around benefi ts of The proposed H2TAS project is a The AR component of this piece membership to our organisation,” renewable hydrogen project located makes the learning of key safety says Master Plumbers Association in Tasmania’s Bell Bay Advanced issues far more engaging, and it ACT President Tom Martin. Manufacturing Zone, a heavy industrial becomes a useful go-to piece over precinct north of Launceston. other print material for solo reference, or for training and toolbox talks with SOLAHART WINS AGAIN your team. Comparison site Canstar Blue has NCC SEMINAR SERIES Users download the free #Pro- named Australia’s original solar brand, The ABCB is presenting the National Vis AR app and scan the AR icons in Solahart, as the number one company Construction Code (NCC) Seminar the various sections of the Guide for in the ‘Hot Water Systems’ category series in May 2021. The CPD-accredited additional, relevant resources such (2020) for overall customer satisfaction seminars provide insights into selected as videos, web-links, PDF files and for the second year running. NCC content, and an overview of some landing pages that ‘pop up’ in front of Solahart achieved fi ve stars across provisions proposed for NCC 2022. you in an augmented setting. all categor ies. All sessions will run for three hours For free Guides email marketing@ and additional sessions are available provisual.com.au in some locations. Seminar content RHEEM V-POWERS AHEAD will be the same in each session. The Shell V-Power Racing Team has WE WANT YOUR NEWS! announced that long-time partner Locations: Do you have news to share? Don’t Rheem will continue to support the ∫ Canberra – 10 May, National be shy! Email the editor John Power reigning championship team in 2021 Museum of Australia with details about new products, for the fi fth successive year. ∫ Darwin – 12 May, Darwin Convention professional appointments, as well as Chairman and CEO of Dick Centre company milestones. Email John at Johnson Racing, Ryan Story, says ∫ Perth – 14 May, Perth Convention johnpower@build.com.au it is important to acknowledge the and Exhibition Centre continued support of Rheem, who ∫ Sydney –18 & 19 May, Australian have backed the team since 2017. National Maritime Museum EMPLOYING DISABLED STAFF ∫ Brisbane – 20 & 21 May, Hotel Grand The organization atWork Australia Chancellor says disabled employees are BEWARE OUTSOURCING WEBSITES ∫ Adelaide – 25 May, Adelaide underrepresented in the construction Victorians should be wary of anyone Convention Centre industry. off ering their building or plumbing ∫ Melbourne – 26 & 27 May, Tools like atWork Australia’s services on online marketplaces and Melbourne Convention and ‘Disability Awareness Training’ through apps. Exhibition Centre empower businesses to build a more The Victorian Building Authority ∫ Hobart – 28 May, Hotel Grand accessible and inclusive workplace (VBA) warns that consumers should Chancellor. and confidently support their always check the credentials employees living with disability. of anyone advertising on online Seminar fees are $160 (Inc. For more information about platforms to make sure they are a GST) per registration. Credit card atWork Australia, assistance in the registered or licensed professional. surcharges may apply. recruitment process, and how it can The VBA is currently investigating For more information email: support employers, visit https://www. a number of unregistered people seminars@thisiscreative.com.au or atworkaustralia.com.au/recruiting- advertising their services through phone (02) 8091 2620. people-with-disability/ online forums. 8 PLUMBING CONNEC T ION W inter 2021
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COVER STORY PRODUCT QUALITY Quality in Question PLUMBING PRODUCTS OF INFERIOR QUALITY – INCLUDING WATERMARK-CERTIFIED ITEMS – HAVE BEEN COMMONPLACE IN AUSTRALIA FOR YEARS. HOWEVER, EVER-GROWING NUMBERS OF INDUSTRY PROFESSIONALS ARE SAYING, ‘ENOUGH IS ENOUGH!’ JOHN POWER PROVIDES AN OVERVIEW. P lumbing products that affect human health and safety, in recent years. Like most plumbers, Neale says he relies on i.e. items directly relating to water supply, sewerage, the professionalism of retailers and other product providers and drainage, should be beyond reproach – no to supply reliable and safe goods. Another valuable tool to compromises allowed. help discern quality items in the marketplace is product Nevertheless, our industry is awash with products of inferior certification – prescribed classes of plumbing products quality – from powdery PVC pipes to lead-contaminated deemed to have a direct impact on human health or safety tapware and leaky toilet cisterns – and both plumbers and must carry WaterMark certification, which is a mandatory clients are rightly demanding action to address the problem. national certification scheme based on rigorous performance In this article we will examine how poor-quality product criteria, approved fabrication methods, and full compliance has been able to infiltrate our regulated market, and hunt with relevant Australian Standards. for weaknesses in the structures of our certification and Despite the twin safety nets of retailer integrity and product regulatory processes that might be inadvertently contributing certification, Neale says recent experiences have been to the problem. Finally, we will explore potential pathways dispiriting. In particular, he says he has had to waste time and out of the mire of substandard products, and into a brighter money installing poorly designed and manufactured items, future of complete product trustworthiness. including a toilet for disabled users that lacked holes in the Neale Bookall, a senior plumber from northern Queensland, back for wall anchoring, and which was also prone to leaking says he has observed a consistent decline in product quality through anchor holes at the base of the cistern. 12 PLUMBING CONNEC T ION W inter 2021
“I got them [the holes] to seal by putting Sikaflex all around them and tightening them up really tight, but I don’t know what the next plumber is going to do when he takes that cistern out!” Neale says. “There are multiple things about it that are poorly designed, as far as I’m concerned. You think: why would anybody build something like this?” In addition, Neale explains, he had to grind the pan back to make the unit sit squarely in position. “But I don’t think I should have to grind the back of the pan so that the cistern will sit down right!” Servicing the pump industry for over 50 years Neale’s other recent encounters with substandard products have included a pull-down sink mixer tap that reaches deep into the sink, allowing clean water to intermix with dirty water; as well as a bidet sprayer attached via a T-junction Here comes all the to the valve that fills the cistern, both of which could pose serious backflow hazards. He has also had to deal with a plug water you need. and waste that would not tighten properly due to a skipping thread. “Plumbers don’t want to have trouble, they want to go in and do a job, and when you walk away you don’t want to have a boomerang – you don’t want to have to come back,” he says, adding that poorly made products often lead to costly remedial works at the plumber’s expense. “You want to leave on good terms, and you want the client to be happy with what you’ve done. If you put in something that’s shoddy and it’s going to fail, then you’re going to get a bad name as a plumber and you’re not going to feel good about the work you do. I just feel sad about the way it’s gone.” The abovementioned products, Neale confirms, were all WaterMark-certified, so it is worth examining the processes by which products gain certification, and gleaning possible Lowara shortcomings in the way certifications are granted and e-HM Series & HME Smart Pump subsequently policed. This range of Lowara pumps and tanks are WEAKNESSES 1 & 2 designed for any pumping application involving The Australian Building Codes Board (ABCB) manages the clean and non-aggressive water in household, WaterMark program, with State and Territory regulators small scale irrigation and booster applications. overseeing compliance at installation. If a new product belongs to a class of products deemed • Quiet operation • Dry run protection to require WaterMark certification, an applicant’s first step • Compact design • Protection against is to have the product tested and appraised by a WaterMark • Easy to install excessively frequent starts Conformity Assessment Body (WMCAB). There are 10 • Trouble free servicing • Approved for drinking approved WMCABs in Australia, each of which has authority • Higher efficiencies water (AS/NZS 4020) • Energy savings • European build quality to issue WM certifications based on their own product • Automatic re-set electronic • Large range of models assessments, which often involve rigorous laboratory testing. controllers available NB: every WMCAB is itself subject to stringent performance benchmarks, as overseen by the independent accreditation Suitable for: authority JAS-ANZ (Joint Accreditation System of Australia • Residential • Water supply and New Zealand). • Light-industrial • Irrigation One of the most respected WMCABs is IAPMO Oceana, which • Commercial • Pressure boosting has been a leader in product certifications for decades. When analysing the structure of the WMCAB process, as Contact your local plumbing supplies store described so far, an obvious initial question is: Are all WMCABs and ask about the Lowara pump range from the same? After all, uniform product assessments across all Brown Brothers Engineers. 10 WMCABs must be a prerequisite for a nationally consistent scheme. IAPMO Oceana’s Technical Manager Glenn Tate admits that, “This is very difficult to answer, as IAPMO is not privy to www.brownbros.com.au w w w.plumbingconnec tion.com.au 13 09/20 DELIVERING PUMPING SOLUTIONS
COVER STORY PRODUCT QUALITY how each of the other nine WMCABs operate. All WMCABs must have in place a documented Quality System that meets the ISO 17065 AS/NZS ISO/IEC 17065:2013 “Conformity assessment – Requirements for bodies certifying products, processes and services”. All WMCABs are subject to regular JAS-ANZ audits to verify ongoing compliance. “In saying this, not all WMCABs would have the same level of technical competencies. IAPMO Oceana has some technical staff who have been in the plumbing product certification field for more than 35 years, and others that have had NATA ISO 17025 laboratory testing experience. This level of experience makes IAPMO unique and we pride ourselves as being the premier WMCAB.” Clearly, any diff erences between WMCABs and their methodologies, no matter how small, might lead to hypothetical inconsistencies in product certifications. A far more concerning ‘second weakness’ in the structure of WaterMark certification, one might argue, is a tendency for some applicants to use WMCABs as a ‘first resort’ towards attaining WaterMark compliance, rather than a ‘final stamp of approval’ to verify manufacturing excellence. Market behaviour itself, in the writer’s opinion, would support this claim. According to Glenn, approximately 80% of tested products achieve WaterMark certification ‘at the first go’. This means 20% of submitted products fail to attain minimum WaterMark standards for use in the Australian market when first tested – a troubling figure considering the products in question are intrinsically related to health and safety. One wonders whether other health and safety-critical product classes like Poor-quality products can have a direct negative eff ect car tyres, surgical instruments, aircraft parts, etc, would on human health. Plumber Neale Bookall says he needed a incur certification approval rates of just 80% upon initial grinder to help create a level surface for the cistern. presentation to their respective licensing agencies. Plumbing product categories with the highest initial failure rates, according to Glenn, are diverse. “Thermostatic the limited opportunities aff orded to a WMCAB to inspect mixing valves, and mechanical backflow protection valves factories after certification has been granted. are examples of high failures of a product type; however, we “Since the introduction of the ABCB Single Level WaterMark also see many material failures i.e. AS/NZS 4020 (mainly high Product Certification Scheme, it is only mandatory to lead levels and taste test failures) FBE coatings of DI valves undertake factory inspections prior to the WaterMark failing minimum application thickness; and dezincification certificate being issued, and during the first 12 months after resistance failures.” the WaterMark certificate is issued,” Glenn explains. Such broad-brush failures, arguably, signal a lack of “The next mandatory factory inspection is required at re- willingness by some manufacturers (or importers) to evaluation (after the maximum fi ve-year certification period anticipate Australia’s strict quality requirements. Rather, has elapsed, and re-evaluation and WaterMark recertification some manufacturers might treat the certification process for a further fi ve years is required.” NB: subsequent annual itself as a proving ground gamble, product inspections do not mandate factory inspections. with losers happy to be coached to In other words, this means the manufacturer of a compliance by their WMCAB. WaterMark-certified product can avoid direct scrutiny of their manufacturing systems for more than four years out of each WEAKNESSES 3 & 4 fi ve-year certification period. Given global trade and onion- An even more damaging ‘third layered supply channels, with partnerships changing more weakness’ in the certification often than Melbourne’s weather, this hardly seems adequate process, surely, relates to to assure manufacturing consistency. Of course, WaterMark certificate holders must notify their WMCAB of any substantial changes to design, materials or Glenn Tate, IAPMO Oceana manufacturing processes aff ecting any certified product, and Technical Manager. accept a Design Freeze while any changes are appraised – 14 PLUMBING CONNEC T ION W inter 2021
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COVER STORY PRODUCT QUALITY happily, Glenn says 98% of IAPMO clients, for instance, abide simplify accountability by targeting poor-quality products at by this requirement. Failure to comply can lead to the WMCAB point of sale (POS). impounding existing stock and, in severe cases, issuing a Matters relating to WaterMark compliance and enforcement product recall. have been a PPIG preoccupation for years; in 2018 PPIG Does this happen often? No. Not only does policing of responded to an ABCB Discussion Paper1 on possible WaterMark product compliance fall “squarely” on the WaterMark POS reforms, declaring that, “There is a need for shoulders of the WMCAB, according to Glenn, but there is early point of sale regulation Australia-wide to improve the virtually no practical way to maintain a comprehensive post- efficiency and effectiveness of the mandatory WaterMark certification audit of all WaterMarked products. This ‘fourth Scheme.” Furthermore, “There are gaps in the Scheme’s weakness’ means “it is nearly impossible to determine if design that are allowing too many non-conforming and/or there has been a change in materials or material compliance, non-compliant plumbing products into the Australian market. or to determine if there has been a design modification, or a Consequently, the industry is concerned about the potential change to a manufacturing process, whilst this has for adverse societal outcomes undertaking product inspections not at the caused by material and product failures manufacturing site. in plumbing systems that can cause “It is typically marketplace competitors The best way forward, contamination of the water system and who are providing the bulk of reports of according to Stuart threaten public health.” non-compliant WaterMark products back Henry, Executive According to Stuart, though POS national to WMCABs, rather than a consequence Director of Plumbing reforms have not occurred to date, of the current ABCB WaterMark Product Products Industry they remain the most logical means of Certification Scheme itself.” addressing the problem of poor-quality or Group (PPIG), is to non-compliant product in the marketplace. THE WAY FORWARD simplify accountability A good place to start, Stuart says, The above points, one might argue, highlight by targeting poor- would be the alignment of the WaterMark systemic deficiencies in the structure of quality products at scheme with another mandatory national WaterMark compliance, though the myriad point of sale (POS). program – the Water Efficiency Labelling & agencies involved are no doubt doing their Standards (WELS) Scheme – that operates best to keep their respective cogs in the already as a POS compliance instrument. wheel from jamming. Alignment of the two schemes, he says, A major shortcoming, obviously, relates to the lack of would consolidate compliance administration and reduce effective oversight to identify and penalise manufacturers or regulatory duplications. Such an alignment would also distributors who release dodgy product. In particular, small simplify both schemes in the eyes of plumbing professionals batches of poor-quality product are difficult to monitor, as and consumers alike, and focus attention on POS as the stock may sell out before competitors have time to react. most obvious place to target inspections and enforcement The best way forward, according to Stuart Henry, Executive measures. Director of Plumbing Products Industry Group (PPIG), is to This focus would encourage retailers to pay greater attention to the genuine WaterMark compliance of the goods on their shelves, and ‘fill the gap’ between existing enforcement measures, which are currently split between the WMCABs (which scrutinise individual products as part of WaterMark certification) and State and Territory regulators (who assess WaterMark product compliance and conformance at installation). Increased accountability at POS would have the added benefit of relieving some of the existing unreasonable liabilities on plumbers’ shoulders, according to which plumbers are supposed to serve as guardians of WaterMark product compliance in the field – clearly an absurd obligation, as plumbers are not equipped to test products, ratify the genuineness of labels, or detect fraud or violations of certificates. Another benefit: POS accountability would alleviate pressures on plumbers who are often supplied with (already purchased) products to install, and therefore have no control According to Neale Bookall, this toilet had no holes in the back over product selections or compliances. for wall anchoring, and multiple potential leak points at the POS legislation, Stuart suggests, would be the beginning base. rather than the end of an overall reform package of 16 PLUMBING CONNEC T ION W inter 2021
This installation would not tighten properly due to a skipping thread. WaterMark systems, including more regular examinations of manufacturing facilities. As a guide, he notes that factory audits are conducted twice a year in Europe and USA to make sure fabrication processes and materials accord with specified standards. Regular factory assessments are particularly important in relation to materials like brass, which may comprise high levels of recycled materials with impurities, notably lead. Finally, Stuart says, national State and Territory regulators should follow the lead of Queensland and ban the sale of non- WaterMarked products altogether within relevant categories. This reform would further simplify POS scrutiny and prevent the accidental or deliberate use of poor-quality, non- WaterMarked products in inappropriate installations. ONGOING REFINEMENT In summary, WaterMark certification to date has allowed honorable companies to publicly verify the quality and integrity of their products, but the scheme has been less eff ective in detecting and penalising poor-quality WaterMarked products post-certification. Current systems, which in reality rely on competitors to spot and call out dodgy items in the marketplace, are inadequate in light of the volumes of product involved and the complexity of distribution channels. POS reforms, no doubt, would need to be refined to define a ‘seller’: Is the seller always a retailer? What about developers who import product privately (thereby bypassing local retailers and wholesalers)? Notwithstanding such complexities, the buck has to stop somewhere as far as poor-quality products are concerned – and retail outlets are the most obvious place to start to restore consumers’ trust in products. Footnote 1. ABCB Discussion Paper January 2018, Plumbing Products Industry Group Response 12 February 2018. w w w.plumbingconnec tion.com.au 17
AUSTRALIAN MADE - GREG MORWOOD MADE IN AUSTRALIA: YES, REALLY Manufacturing has been perceived as a messy business, best done off shore where low labour costs and poor environmental standards allow companies to profit. This simply isn’t the case, writes Greg Morwood. T he manufacture of commodity products like those often used for plumbing and drainage has not been the focus of much attention over the last 25 years, with government policy supporting the mining industry and high-profile firms focused on technology. However, Australia has many companies that manufacture locally and bring innovation to the plumbing market, including ASX-listed firms Reliance Worldwide (RWC), GWA and Fletcher Building (FBU). The number of privately held firms is vastly higher, and, although you won’t hear about them on the nightly news, they make everything from tapware to sewer pits. Another misunderstanding is that products made locally have to be fully automated to be cost-competitive with imported products. Modern moulding machines, computer controlled Local manufacturing capabilities not only enhance product quality, but they also machining, even 3D printing now allow streamline supply. the production of any product in a quality, cost-eff ective way. Particularly for bulky products, the cost and delay teams work together to develop new it is in a unique position to weather the in shipping can mitigate the extra cost products that are more suitable for local challenges of the recent interruptions. of supporting local manufacture, and requirements. This isn’t without its challenges: raw in the case of extremely bulky products materials are often not available from like large-bore pipe, manufacturing and WHEN YOU NEED THEM local suppliers, leaving manufacturers distribution become tightly linked. With COVID-19 perversely aff ecting at the whim of global markets and the movement of people and materials shipping, and quick changes in market THE RIGHT STUFF through 2020, there has been a demand for a product line can leave One of the key diff erences in having renewed interest in locally made the manufacturer short of material to a local manufacturing centre is the products. Everyone from the world’s make products. Generally, however, it’s co-location of sales, research and largest company, Apple, to your local possible to store enough raw materials production. When the market provides plumbing supplier has been focused to compensate for this, and the flexibility feedback to the customer support team, on their supply chains and looking to to produce one item of a product range the research and production teams make products in the country they are allows local manufacturers to quickly will hear about it by morning tea. This being sold in. Coming into 2021 with make up for the monthly changes in accelerates the pace of getting the a boom in building work and major building projects. right information and the right products changes in the competitive landscape, out to the market. If the research and the plumbing industry is seeing similar IMPROVED QUALITY development team is local, they can go disruptions in supply to many other Quality is better if you buy from a out in the field and understand first- segments of the economy. PLASTEC, company that both manufactures and hand what the challenges are from the for instance, has been strategically imports products. Australia has a great plumber’s perspective, and then return growing its manufacturing capacity network of wholesalers who support to the factory to build better products. on the Sunshine Coast for the last 25 the plumbing industry by delivering In this case, the development and sales years, and with a close partner off shore, products when they are required, 18 PLUMBING CONNEC T ION W inter 2021
and they take a role in choosing what reports provided to support all of critical items, with a local manufacturer products will be available to the this. These other aspects are left to supplying most of the product to meet industry. They do this in two ways: by the process of certification, in which demand and an international partner selecting preferred supply partners and a manufacturer demonstrates their supplementing this and being on the by directly importing or co-branding products meet requirements through ready if needed. At PLASTEC we have their own products. Both of these help testing and auditing. Many would argue found that the ability to turn on a to ensure products that get into the that the wholesalers should have a role machine locally or increase the number market are of suitable quality; no one in confirming the validity of WaterMark of shifts running in a local factory wants to deal with issues in the field, so certification on products that they gives us an edge over import-only better products get preference. Product resell. competitors. quality is also protected by legislation under the WaterMark scheme, which DEEP UNDERSTANDING is the responsibility of the installer, Manufacturers develop a deep ABOUT GREG not the wholesaler. Unfortunately, the understanding of product standards Dr Greg Morwood is complexity of certifying products under and the performance of their products Research & Development the WaterMark scheme can create through the experience of making, Manager at PLASTEC unforeseen issues. Firstly, plumbers certifying and supporting their items. Australia, Sunshine Coast, Qld. He has a strong are expected to be able to identify a interest in providing correctly WaterMarked product, but SAFER SUPPLY CHAIN plumbing solutions not expected to be able to confirm A supply chain is safer with a dual for local industrial manufacturing sectors. it meets the standards behind the manufacture-import model. PLASTEC specialises in the drain-waste- WaterMark. That would require them ‘Supply chain’ is the term applied vent (DWV) sector of the plumbing industry, to be knowledgeable in manufacturing, to how we get stuff to a plumber – it’s and recently expanded capacity of its PVC plant on the Sunshine Coast. Visit http:// metallurgy, chemistry, water science, pretty boring until it goes wrong. plastec.com.au and check on the validity of the test The safest solution is to dual-source Shore Hire offers one of Australia’s most trusted and complete shoring, propping, traffic, pipe testing, and laser hire fleets. We provide industry-leading temporary works solutions, expert advice, and innovative products. Contact us today to discuss your next project. Visit shorehire.com.au Call us on 1300 SHORE HIRE SYDNEY • BRISBANE • MELBOURNE WOLLONGONG • NEWCASTLE ACT • SUNSHINE COAST Shoring Propping Traffic Lasers Pipeline Testing w w w.plumbingconnec tion.com.au 19
AHSCA / ALTERNATIVE SOLUTIONS - IAN TODD NEW FACILITY HAS ‘ALTERNATIVE’ DESIGNS Following several years of planning and development, the construction of Woolworths New Zealand’s (WWNZ) new $50 million distribution centre in Palmerston North, New Zealand, is forging ahead. Ian Todd reports. P almerston North is centrally located in the lower North Island THE NEW FACILITY of New Zealand. It is a major hub for distribution with other companies such as Ezibuy, Foodstuffs, and Iplex, which have manufacturing and distribution facilities in the area. Woolworths’ new state-of-the- art 39,000m2 facility incorporates warehousing, inbound and outbound goods, company offices and a full-blown commercial kitchen, all under a single roof. Trucks will be loaded and unloaded inside the building with a staff of 150 handling around 450,000 cartons of food for other stores through the central North Island from Gisborne on the east coast to New Plymouth on the west coast. The new distribution centre has been designed and built to target a 4 Star Green Star rating. The new facility features 39,000m2 of roofing, which called for complex stormwater I&L Consulting was engaged by drainage solutions. Courtesy of Woodhams Meikle Zhan Architects. WWNZ (Woolworths New Zealand) to tackle the design of the hydraulic services, including sanitary and trade ROOF PLAN waste drainage, water supplies and the most critical element – disposal of stormwater off the massive 39,000m2 roof. NZ BUILDING LEGISLATION How does New Zealand building legislation work? All construction in New Zealand is covered under the New Zealand Building Code, which was first introduced in 1992 under the new Building Act. The intent of the code was to introduce a set of performance- based guidelines. The Building Code is broken down into clauses relating to disciplines such as sanitary drainage, water supplies, and surface water drainage. Each clause has an Overall roof plan – sanitary and stormwaster drainage. Courtesy of Woodhams objective, functional requirements, and Meikle Zhan Architects. 20 PLUMBING CONNEC T ION W inter 2021
performance criteria. In brief, if the designer can demonstrate to the territorial authority that their design will achieve these three criteria, then the design is deemed to meet the Building Code conditions and hence the design can be granted building consent. This is known as an ‘Alternative Solution’. Alternatively, designers can use the ‘Acceptable Solutions’ presented in each clause. Acceptable Solutions present prescriptive approaches to achieve compliance, often referencing New Zealand or Australia/New Zealand Standards such as AS/NZS3500. This approach provides a smoother path through consent but works on the principle of ‘one size fits all’ rather than tailoring a solution to the project. Since the inception of the New Zealand Building Code most designers have opted to use Acceptable Solutions instead of the performance-based approach, as local authorities, quite understandably, apply very strict testing regimes to Alternative Solutions. PROJECT CHALLENGES The Scale of the Project The obvious challenge for this project was the disposal of stormwater off 39,000m2 of roof area. During the inaugural meeting of the New Zealand chapter of the Association of Hydraulic Services Consultants Australia (AHSCA), Mark Alexander and Professor Terry Lucke from the AHSCA Research Foundation presented a performance-based roof drainage system that eclipsed the performance of any current codes or Standards. This immediately piqued my interest, as the Acceptable Solution for stormwater drainage under section E1 of the NZ Building Code does not detail downpipe sizes beyond 150mm diameter nor a roof catchment area greater than 350m2/downpipe. This solution offers no commentary on the use of rainwater heads or downpipe flow rates, leaving the designer to extrapolate data and hence enter the realm of an ‘Alternative Solution’. A follow-up conversation with Mark resulted in me visiting Australia to attend a training module and obtaining the requisite qualifications to gain access to the research foundation’s online calculator. The calculator allows project- specific data to be imputed to determine the optimum sizes for gutters, rainwater heads and downpipes. The net result being a project-specific solution rather than a ‘one size fits all’ outcome. The system developed by the AHSCA Research Foundation was the result of three years of testing, employing a purpose- built test rig at the University of Sunshine Coast. As a result, the foundation developed their online calculator which allows the designer to input a combination of gutter, rainwater head and downpipe sizes to find an optimised solution. Convincing the Client and Local Authority In floating the concept of using an ‘Alternative Solution’ with WWNZ, they came back with three questions: 1. Does it comply with the Building Code? 2. What are the risks? 3. What are the costs? w w w.plumbingconnec tion.com.au 21
AHSCA / ALTERNATIVE SOLUTIONS - IAN TODD heads, downpipes and terminal drainage WALL SECTIONS connections. The result was a $60,000 saving by employing the Research Foundation’s solution. HOW THE FIGURES COMPARE (A) AS/NZS3500.3 solution to a maximum flow rate of 16 litres per second: ∫ A maximum roof area of 850m2 per down pipe. ∫ Down pipes would be spaced at 8.6m centres. ∫ 50 x 150mm downpipes required, complete with custom-fabricated rainwater heads and low-level protective shrouds. ∫ 50 x 150mm laterals and connections to connect downpipes to the civil drainage system. (B) AHSCA Research Foundation Distribution Centre wall sections. Courtesy of Woodhams Meikle Zhan Architects. performance-based design solution: ∫ A maximum roof area of 2441m2 per downpipe or a flow rate of 49 litres In response to question one, and 1. A design complying with NZBC, clause per second. based on my training, I was confident E1/AS1 (acceptable solution 1). This ∫ Downpipes at a maximum of 24m the system could be designed to achieve would have involved 110 x 150mm centres. the requirements of NZBC, clause E1, diameter downpipes. With a rafter ∫ A minimum of 16 x 225mm downpipes which calls for rainwater from a 1:10- length of 98m this would mean a required, complete with custom- year event, drained to an eaves gutter, 150mm downpipe every 3.5m along fabricated rainwater heads and to be kept from entering the building. the exterior wall. This option was low-level protective shrouds. To Question 2 – The next challenge was quickly discounted as impractical. coordinate with architectural graphics to obtain provisional approval from 2. A design complying with AS/ the decision was made to add an the local authority NZS3500.3:2018. additional downpipe on each elevation. to pursue an Surprisingly, this ∫ 18 x 225mm laterals and connections alternative design. solution is not an to civil drainage system. These discussions acceptable solution ∫ 180x 600mm diameter surges with Palmerston As is often the case, under NZBC, E1, chambers (one per downpipe). These North District the client’s approval to so it would need were installed at the base of each Council were fruitful pursue an ‘Alternative to be off ered as downpipe to facilitate the transition when I outlined the Solution’ came down an ‘Alternative between the high-volume downpipe background research to cost. Solution’. This and the civil drainage system. undertaken, the solution permits fact the design downpipes to a would be checked maximum flow ABOUT IAN and validated by rate of 16 litres Ian Todd is Managing the AHSCA Research Foundation, and per second. Using this solution a total Director of I&L Consulting a design certificate (complete with of 50 x 150mm diameter downpipes in Auckland, New Zealand. $10 million professional indemnity would be required. He has more than 35 years’ experience in certificate) issued. the construction and Question 3 – As is often the case, To confirm costs, a full design was plumbing industries the client’s approval to pursue an drafted up for the AS/NZS3500.3 and holds a Bachelor of Property Administration ‘Alternative Solution’ came down to solution, and another one using the degree from Auckland University. Ian is a full cost. Initial ‘thumb suck’ estimates AHSCA Research Foundation solution. member of the Australian Hydraulic Services pointed towards the performance- These designs were presented to a Consultants Association (AHSCA). professional quantity surveyor, complete Email: ian@iandlconsulting.co.nz based solution being cheaper than the alternatives, of which we had two: with details of guttering, rainwater 22 PLUMBING CONNEC T ION W inter 2021
TRALIA US N A DESIGNE URED CT D & M A ANUF DWV SWJ HEAVY DUTY FITTINGS MOULDED IN AUSTRALIA PRODUCT RANGE COVERS FROM DN100 - DN150 PRODUCT ISO TYPE 5 CERTIFICATION WATERMARK CERTIFIED BEP APPROVED WSAA APPRAISED RANGE OF BENDS, JUNCTIONS ,INSPECTION OPENINGS, REDUCING JUNCTIONS, LEVER INVERT TAPER COMING >P[OHTT^HSS[OPJRULZZJVTWHYLK[VZ[HUKHYK+>=Ä[[PUNZ/LH]`+\[`:>1Ä[[PUNZHYLKLZPNULK SOON [VOLSWYLK\JLHUKYLTV]LYPZRZMYVTNYV\UKTV]LTLU[ -LH[\YPUNN\ZZL[ZHUKL_[YHYPIZ\UKLYPUZWLJ[PVUVWLUPUNZMVYHKKP[PVUHSZ[YLUN[O www.holmanindustries.com.au/plumbing
PANDEMIC LIFE AFTER COVID-19 The impacts of COVID-19 have been far-reaching and, in many cases, devastating. However, as John Power reports, some positive legacies are also worth highlighting. T hink back to March 2020: the world’s industries were “During the pandemic we have continued to invest in R&D grappling with the onset of an open-ended and little- to the same level as pre-COVID,” she says. “We have taken our understood pandemic. Would it be over in a few weeks? insights from life under COVID as an opportunity to reassess A few months? Perhaps never? our R&D priorities; we feel the emphasis on hygiene and In the face of such uncertainty, reactions across the wellbeing for vulnerable people will drive further innovation plumbing sector ranged from ‘business as usual’ to complete across the health, aged care and education sectors.” trading stagnation. Now, as vaccines begin to take eff ect Not only has COVID-19 stimulated renewed optimism in internationally, it is worth reviewing the actual eff ects of the R&D projects, but it has also served as a trigger for swifter pandemic on supply chain management and research and R&D implementation as an ongoing priority. “If anything, the development (R&D), and noting some of the more positive pandemic has shown that ideally we should have the capacity practices arising from COVID-19 that will, in all likelihood, to shorten our product development and innovation cycle in linger long after the disease has had its claws pulled. order to meet unexpected changes to market expectations Vicki Edler, CEO of Enware Australia, says reliable supply and demand,” she says. “A shorter innovation cycle combined chain management immediately took centre stage when the with local manufacturing abilities leaves us uniquely placed to pandemic struck, leading to ongoing refinements. respond to rapid changes in market demand.” “The pandemic has forced us on several occasions to review the potential for supply risks within the supply chain, as CULTURE SHIFT diff erent countries went through various lockdowns and waves One of the most important of the pandemic,” Vicki says, adding that Enware’s principal ramifications of COVID-19 – but supply partners largely escaped severe interruptions. perhaps the hardest to define – is a “We did move some component supply back onshore where permanent culture shift in the wider supply was deemed critical to projects that were underway trade sector, based on a humble or scheduled to commence across 2020–21. Being a local recognition that ongoing success often manufacturer we try to support local supply chains wherever relies on fundamentals like the solidity we can, and, as a consequence, more than 50% of our supply and goodwill of long-term partnerships. chain remains with local businesses. Domestic supply chains Gerry Fernandez, General Manager have become more predictable in regards to meeting supply of Fluidmaster Australia, says Gerry Fernandez dates. We have not had to adjust stock levels as such, but Fluidmaster’s international presence in have adjusted our approach to lead time management.” China, North America and Europe served as a buff er against A far more long-lasting impact of COVID-19, Vicki says, sudden trade lockdowns in Asia in early 2020, allowing has been renewed market interest in hygiene and sanitation- manufacturing of some key lines to shift to alternative based technologies and products. Far from reducing R&D in locations such as Mexico. This flexibility, established pre- the wake of the pandemic, Vicki says Enware has kept working COVID-19 mainly as a tool to overcome momentary peaks to meet demand for new equipment in these critical product and troughs in market activity, took on a much greater categories. significance with the onset of the pandemic, and is now part of the core fabric of the business. As Gerry summarises, “We have a broad supply base with ENWARE AUSTRALIA long-term partnerships, and we also have a focus on multi- During COVID-19 the importance of student sourcing for our critical components – the global footprint hydration and wellbeing never went away, means we’re very flexible, especially with on-time supply. according to Enware Australia, but new So our supply chain has been very stable throughout the methods of delivery needed to be found to pandemic.” increase hygiene factors as a top priority. Enware’s rapid R&D response to this need led While Fluidmaster’s supply chains have been steady to the development of a range of bottle fillers throughout the pandemic, increased demand for core that provide an easy and convenient way for products has prompted the company to think on its feet to students to fill their water bottles routinely throughout the day whilst reducing the risk of respond to quickly evolving public buying trends. ‘mouth to water’ cross-contamination. “Fluidmaster provides quality, premium products that are Enware’s CEO, Vicki Edler (pictured) enjoyed of value to our many important consumers,” Gerry says. “It testing the first batch of bottle fillers from the production line under has been good to see that our core products have remained the watchful eye of their Factory Supervisor, Rahim Arifin. in strong demand through this pandemic, especially our 24 PLUMBING CONNEC T ION W inter 2021
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