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Challenging client brief results in innovative creation of ThermaMax panels

5 April 2017

1 Min


The brief was to design and construct 15 flare enclosures for APLNG Upstream, a multi-million-dollar gas extraction project for principle Origin Energy. When faced with this unique challenge, ModularWalls discovered there were no products that currently matched these specific requirements – so they created one. ThermaMax, a thermal heat control panel, was designed with modular building methodology in mind, resulting in swift installation periods of just 12 days for each flare enclosure.

ModularWalls, in collaboration with contractors Laing O’Rourke and Monadelphous, both Tier 1 builders, worked to provide an alternate design for a specified, complex solution that required large footings and cumbersome construction methodology. The structure was to exceed thermal requirements of withstanding flares of up to 200°C during flare operations, with a minimum design life of 20 years. The ultimate goal was to save the principle and contractor time and money, and provide a safe solution, without compromising performance.

Flare perimeters measured 65 metres square and almost 12 metres high. The newly designed ThermaMax panels were used in conjunction with universal beams and constructed off a base-plated configuration, as well as custom-made 4 metre commercial gates, all with a design life of 50 years – more than doubling the original requirement. A vast improvement to the principle’s specified design, which called for cladded shipping containers, ModularWalls saved the client over 40% of costs, halved the installation period, improved environmental and safety factors by taking 1100 trucks off the road and achieved a superior aesthetic, all without compromising the thermal performance.