Review of Operating Divisions - Australian Construction Materials
Plasterboard continues to benefit from a strong safety culture, with only one lost time injury (LTI) in the last two years. Plasterboard won the 2009 Boral Excellence Award for Safety. The year was challenging for the division, with the commissioning of our new plant in Pinkenba (Queensland), exiting the Northgate site and the relocation of our South Australia business from Gillman to new premises at Woodville. At our Pinkenba plant, our people developed skills in the new plant technologies. By year end, our confidence and understanding had increased to a level where the plant is now delivering lower energy and water usage, enhancing the sustainability credentials of the Plasterboard business.
Energy and BSDT
Review Of Operating Divisions Page Nav Human Resources Environment Marketplace and supply chain Social responsibility
  Our performance Our goals/plans
Human resources
Health
and safety
  • Employee LTIFR of 0.7 versus target of 0.9, with 0.03% hours lost in line with target.
  • Contractor LTIFR of 3.1 and % hours lost of 0.05.
  • Over 2,100 actions raised, with 95% closed out by the agreed date, well above the FY2009 targeted rate of 85%.
  • More than 11,000 safety conversations recorded in FY2009 (and over 40,000 since FY2005).
25% improvement on last three year average LTIFR and % hours lost.
  • Continue focus on high risk activities and use of national management systems.
  • Continue to implement lead indicators, encouraging behaviours needed to sustain performance and to develop a “caring” culture for both employees and contractors.
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  Our performance Our goals/plans
Environment
Energy conservation
and climate change
  • Energy use increased by 5% to 1.7 million GJ; GHG emissions increased by 3% to 119,800 tonnes of CO2. GHG emissions were up 1% excluding increased scope and were due to increased production volumes associated with commissioning of the new plant.
  • Energy use per unit of production decreased by 1% and GHG emissions per unit of saleable Australian plasterboard remained steady year on year due to the commissioning at Pinkenba, which was offset by mill efficiencies at the new plant.
  • Boral’s equity interests in Australia (GRA and Rondo) generated 5,000 tonnes of CO2, while Boral’s share of the Asian plasterboard joint venture LBGA emitted 131,000 tonnes of CO2.
Reduce emissions per unit and offset increases in absolute emissions as a result of market demand growth.
  • Review energy efficiency assessments at Port Melbourne.
  • Reduce GHG emissions per tonne of production at Pinkenba through the use of new technologies.
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Water conservation, extraction
and protection
  • Mains water usage decreased by 13% year on year and mains water usage in Queensland was down 49% in FY2009, due to reliance on rainwater harvesting at Pinkenba despite the overlap of producing at two plants during the commissioning of Pinkenba.
  • Mains water per unit of board sold decreased by 12%.
Reduce mains water consumption across the division.
  • Commission rainwater harvesting initiative at Port Melbourne and investigate rainwater harvesting opportunities at Camellia to reduce dependence on mains water.
  • Reverse osmosis water from Luggage Point to replace remaining mains water at Pinkenba.
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Waste and resource management, recycling and
re-use
  • As a net consumer of waste, plasterboard recycled/re-used 68,500 tonnes of waste in FY2009 and recycled/re-used 114% of its own waste from production including from existing stockpiles.
  • Developed ENVIRO™ plasterboard products, which have a minimum of 10% recycled content.
Minimise waste from operations and increase waste re-used and recycled that would have otherwise gone to landfill.
  • Investigate further waste recycling opportunities including the introduction of higher recycled content products and recycling at Port Melbourne.
  • Continue reducing all forms of waste through further development of lean manufacturing skills.
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  Our performance Our goals/plans
Marketplace and supply chain
Sales and marketing
  • Developed ENVIRO™ plasterboard range, which has a minimum of 10% recycled content. Available in 13mm Enviro Regular and 13mm Enviro SoundStop formulations.
  • Supplied plasterboard and ENVIRO™ board to Australia’s first 9 star house, Harmony 9.
  • Through the Gypsum Board Manufacturers of Australasia (GBMA), Lifecycle Inventory of plasterboard now available at www.boral.com.au/plasterboard/
Continue to develop sustainable products and promote sustainability of existing products.
  • Further develop new ENVIRO™ boards in response to market demands and product development initiatives.
  • Investigate new manufacturing technologies and product performance criteria to enhance sustainability credentials of our product range.
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  Our performance Our goals/plans
Social responsibility
Community relations and engagement
  • Boral Plasterboard is an active member of community and industry bodies including GBMA, and Camellia and Pinkenba community groups.
  • Participated in the JDRF’s Walk, Spin and Ride for a Cure events.
  • Actively promoted introduction of apprenticeship qualifications in wall and ceiling lining in three states.
Maintain the support and goodwill of communities surrounding Plasterboard’s activities through engaging and consulting on relevant issues.
  • Actively participate in lifecycle assessments through industry bodies.
  • Support the Construction & Property Services Industry Skills Council to promote trade-based apprenticeships.
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About Plasterboard
A leading source of value-added wall and ceiling solutions, products and services with emphasis on plasterboard and plasterboard systems. The division has: four operating sites and 49 distribution sites under Boral management; a 50% share of Gypsum Resources Australia (under GRA management); a 50% share of Rondo Building Systems (under Rondo management); and a 50% share of LBGA (under LBGA management working under Lafarge systems). Boral Plasterboard operates with approximately 680 employees in Australia.
1 In preparation for reporting under the National Greenhouse and Energy Reporting Guidelines, Scope 2 factors have been applied for electricity in FY08    and FY09. In previous years, Boral applied full lifecycle (Scope 2 and 3) to electricity emissions. Historical comparisons have been adjusted.
   Non-operating sites reported for the first time in FY09.
2 If quantitative waste data is not available, waste is calculated through a mass balance equation or estimated through sampling. Waste recycled/re-used    includes both internal waste and external by-products consumed.
3 Indexed to 100% in FY06 as base year. Calculations based on total divided by square metres of saleable plasterboard produced for Australia only.