Review of Operating Divisions - Australian Construction Materials
Boral USA’s continued focus has been to manage the business during the most severe market downturn in the USA since the Great Depression. We continue to strive to meet our sustainability objectives through Bricks Silver-to-Gold, shifting production to our most efficient facilities and selling bricks from plants closer to customers, ongoing development and use of alternative fuels and the continuation of health, safety and well-being programs. It has been an extremely difficult year, with the reduction at any one time of around 50% of the workforce; however, employee morale has still remained high and safety has improved. Milestones achieved this year include the LEED Silver certification for the Terre Haute brick facility and Cradle to Cradle certification for US Tile products.
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 1.4 versus target of 2.7, with % hours lost of 0.12, in line with target, achieved through training and commitment from frontline supervisors.
  • Contractor LTIFR of 0 for 2009, compared to 1.8 for 2008.
  • 21% reduction in overall rate of incidents resulting in less days away from work, restricted duty or temporary transfer to another position.
  • Workers' compensation claim costs decreased by 17%, with number of claims down by 40%.
25% reduction on last three year average LTIFR and % hours lost.
  • Develop standardised auditing system to ensure safety compliance.
  • Focus on lead indicators to encourage safe behaviours for employees and contractors.
  • Enhance risk awareness and employee/contractor engagement through increased safety conversations and information sharing.
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  Our performance Our goals/plans
Environment
Energy conservation
and climate change
  • Energy use of 3.8 million GJ and GHG emissions of 230,000 tonnes CO2 decreased by 38% and 41% respectively, due to temporary plant closures in response to market conditions.
  • Energy and GHG emissions per unit of brick production increased by 2% and 1% respectively, due largely to fixed electricity agreements at facilities which were temporarily closed and the inefficiencies in operating brick kilns at less than full production.
  • Renewable energy use for brick production up by 5% to 18% of energy consumed.
Reduce emissions per unit and offset increases in absolute emissions as a result of market demand growth.
  • Continue to increase use of biofuels such as landfill gas and wood waste.
  • Continue to improve energy efficiency by shifting production capacity to higher efficiency plants.
  • Readiness for the US emission trading scheme.
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Water conservation, extraction
and protection
  • Mains water use decreased by 35% year-on-year, reflecting lower overall production.
  • Mains water use per unit of production was up 12% for Tile and up 45% for Bricks due to line leakages which have subsequently been repaired. The US Bricks increase was also due to the addition of the new Terra Haute plant and substitution back to mains water at another brick plant.
Reduce water consumption across the division.
  • Improve collection and recycling/re-use of water.
  • Continue elimination of unnecessary and unintentional water use.
  • Evaluate water requirements per facility (eg production, maintenance, sanitation) and focus on establishing efficiency targets.
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Waste and resource management, recycling and
re-use
  • USA continues to be a net consumer of waste, re-using/recycling 2.7 million tonnes of external and internal waste and by-products, down 22% on FY2008; the largest component of waste used is fly ash, a coal combustion by-product.
  • 97% of internal production waste re-used or recycled.
  • Bricks reduced waste production on a per unit basis by 50% year on year by operating the more efficient plants and improved re-use and recycling.
Minimise waste from our operations and increase the amount of waste re-used and recycled that would otherwise go to landfill.
  • Increase use of waste materials in product mix.
  • Generate less production waste from new plants and kiln retrofits.
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  Our performance Our goals/plans
Marketplace and supply chain>
Sales and marketing
  • US Tile achieved Cradle to Cradle certification for its products.
  • US Tile has partnered with a solar panel supplier to provide a uniform roofing system with embedded solar capability.
  • Bricks conducted an extensive sustainability training program for over 150 sales managers and customers.
Continue to develop sustainable products and promote sustainability of existing products.
  • Investigate product certification to applicable and reputable “environmental” standards.
  • Continue product development and innovation with the goal of enhancing the product’s environmental footprint.
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  Our performance Our goals/plans
Social responsibility
Community relations and engagement
  • US$63,000 was donated to JDRF in 2009 through US employee donations, fundraisers and the company’s US$25,000 match.
  • HomeAid partnership continues with a donation of clay roof tile for use in a working ranch project designed to rebuild self-esteem in victims of child abuse.
  • Six means-tested college scholarships of US$4,000 p.a. each given to employees’ children, assisting families that would otherwise not have the means to fund a college education.
Maintain the support and goodwill of communities surrounding Boral’s activities through engaging and consulting on relevant issues.
  • Support HomeAid through provision of materials for selected projects in 2009/10.
  • Continue the Boral Scholarship Award program at the same level.
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About USA
Boral’s US operations include clay brick (Boral Bricks) and roof tile manufacturing (US Tile), fly ash marketing and re-use (BMTI) and concrete and quarry operations in Denver, Colorado. and Oklahoma City, Oklahoma. The division has 97 operating sites and 56 distribution sites under Boral management and around 1,600 employees in the USA. Boral owns 50% of the MonierLifetile concrete roof tile JV, which is under MonierLifetile management. Boral is alsoa 50% joint partner in a clay roof tile operation in Trinidad. Sustainability data reported for 100% owned businesses with limited reporting for MonierLifetile. This is the first year of reporting for the concrete and quarry operations in Oklahoma.
1 Greenhouse gas emissions and mains water year-on-year comparison excludes additional scope. Construction Materials – Oklahoma was 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 or as a percentage of    production. Waste recycled/re-used includes internal waste, external waste and by-products consumed.
3 Indexed to 100% in FY06 as base year. Calculations are based on total energy, GHG emissions and mains water for Bricks USA or Clay Tiles divided by    tonnes of product produced.
4 The FY06 and FY07 date in the printed 2009 Sustainability Report has been mis-stated.