BITN Boral In The News Issue 2, August 2012 BORAL DELIVERS MARATHON CONCRETE POUR AT PORT BOTANY P3 NEW IPSWICH BORAL DESIGN PLANT AWARDS Boral’s new Redbank Showcasing architectural Plains asphalt plant will talent and innovative use leverage our integrated of materials. network. P20 P4 BITN – Boral In The News – Issue 2, 2012 CONTENTS A Message from Boral’s CEO Ross Batstone 1 What’s happening in OH&S? 15 Praise for integration of new Queensland businesses 2 Recycling innovation for the nation’s capital 16 Boral delivers marathon concrete pour at Port Botany 3 Oklahoma sales representative recognised by NAHB 17 New Ipswich plant for Boral Asphalt 4 Versetta Stone adapted to customer needs 17 Boral supplies to the Hunter Expressway project 5 Boral Cultured Stone in garden show winner’s circle 18 Timber reflects healing and renewal at Flinders Sales and Marketing Momentum 19 Cancer Centre 6 ‘One Boral’ in South Australia is engaging with specifiers 19 Boral partners with Disney on house at EPCOT 7 Boral Design Awards continues to showcase Members mull over Marulan operations 7 architectural talent 20 Boral recognised for Health & Safety Performance Boral hosts workshop for Lend Lease project engineers 22 and Innovation 8 Indonesian customers share in the excitement Celebrating Ten Years of Partnership with of plasterboard re-branding 22 the Bangarra Dance Theatre 9 Boral on show at Indonesian Building Technology Expo 23 A new schools program with Boral’s oldest partner 9 Boral Cement is Leading for Success 24 A LEAN update 10 Children draw for Safety Month at Boral Gypsum LEAN makes big improvements in the West 12 in Vietnam 26 Concrete and LEAN – what does it mean? 13 Introducing PULL systems in the South Australian Roofing business 14 Front cover image: Boral delivers marathon concrete pour at Port Botany. Boral In The News is published by Boral Limited ABN 13 008 421 761 If you have an item of news that you would like to submit for publication please send your story and photographs to [email protected] or Corporate Affairs Manager, Boral Limited, GPO Box 910, Sydney NSW 2001. This publication can be downloaded from the Boral website at www.boral.com.au, or printed copies can be ordered from Boral by telephone (02) 9220 6300 or international +61 2 9220 6300. © 2012 Boral Limited 1 A MESSAGE FROM BORAL’S CEO Ross Batstone It has been a busy but very exciting time since I took on the role of CEO in May. Ross Batstone, Chief Executive Officer. In June I travelled with the Board to our Our collective focus in FY13 must be to US operations in California, Alabama and significantly lift the company’s financial North and South Carolina. We visited five returns, with strong cash flow retention. plants and met with management and Building the Boral business key customers. We also heard directly from dozens of plant operators about This means we all need to effectively the developments in LEAN and Safety use the key areas of The Boral Way - Management in their businesses. The Boral Production System, Leading Safety, Sales and Marketing Excellence The Board was very pleased with the and Innovation in our workplace - I now progress since their last visit to the US believe we have the right mechanisms to two years ago and complimented the allow our operations to enable these in our teams on their efforts. workplace to lift the performance of Boral. On the way back from the US, I visited As I have communicated in my recent the BGA head office team in Kuala Lumpur presentations, I am allowing you to take and subsequently I have completed a accountability within your business to strive series of presentations to employees to support and enable our people so they around Australia. can achieve these Boral Way priorities. I see It has been heartening to see the these processes becoming “the way we enthusiasm and dedication of our people. work around here” and I am relying on you I particularly enjoyed meeting many Boral to inspire ambition and create the vision colleagues for the first time and having an for your teams. opportunity to listen to their comments As we move forward, I will be working and suggestions. closely with your management team to Boral is a great company ensure we collectively focus on safely meeting our objectives with our people in Boral is a great company. I have seen it this opportunistic market environment. go through some tough periods over the past 20 years only to emerge a stronger Thank you again for all your efforts and and better organisation. This persistence the support you have show to me since certainly reflects the dedication and skills taking on this role. I am very proud of the of our people. commitment people are showing and I look forward to working with you to We will all need to play our part in dealing ‘build something great’. with the real challenges we now face. We are experiencing a severe slowdown in new dwellings construction in Australia at a time when housing in the US persists at a post “great depression” low. The building markets uncertainty we currently face, in an environment of the Ross Batstone strong Australian dollar and escalating Chief Executive Officer costs, is amongst the most challenging Boral Limited I’ve seen in my 21 years at Boral. 2 BITN – Boral In The News – Issue 2, 2012 PRAISE FOR INTEGRATION OF NEW QUEENSLAND BUSINESSES The acquisition of three significant businesses in Queensland late last year has been a huge logistics and branding exercise. By John Prior, Regional Sales Manager, Boral Construction Materials QLD/NT. Boral’s acquisition late last year of Mt Isa “Having the support of the logistics staff at Quarry, Sunshine Coast Quarries and Wacol has made the transition seamless… Wagners Construction Materials saw the always a friendly voice on the other end Construction Materials business increase by of the phone willing to help,” Wade Clark, 27 sites; 300 employees; 1500 customers; Toowoomba Logistics. 140 trucks and trailers and 95 concrete “The transition has been well coordinated, agitators and this happened in the space well controlled and well received by our of seven weeks. new employees. By combining plants from Working to tight timeframes with almost 1,500 two local independents, Q-Crete is now a deliverables in the project plan, the integration successful nine plant operation focused team and support functions did a magnificent on leading the small cap market.” job. Some of the highlights included: Max Arthur, General Manager Q-Crete. Gympie Concrete Plant. • Staff were inducted in Week One. With the Boral Production System rollout underway, employees are excited to design • Operational employees were provided and deliver innovative solutions to improve a Boral uniform on Day One. their businesses and are already achieving • Sites were ticketed using Boral dockets real results. on Day One. Conditions have been challenging for the • Customers received a welcome letter team during the wet season. However, before or within one week of integration. with some fine weather and good sales volumes flowing through in the regions we • Customers were provided credit facilities are well on our way to building something on Day One. really great. • Site safety audits were conducted for the Moy Pocket Quarry. entire portfolio. • 90% of employees were transitioned to Boral Enterprise Agreement terms and conditions. • Kronos was introduced, where applicable, and the Boral Production System rollout commenced. Many favourable comments have been received from the new employees. “Feedback has been extremely positive about the transition and Boral. Like me, employees feel Boral is a great place to work” Joe Sultana, Logistics Operations Manager, Cement. All operations employees in Boral uniforms on Day One. 3 BORAL DELIVERS MARATHON CONCRETE POUR AT PORT BOTANY It took great planning and an incredible feat of engineering for Boral to deliver 2,500m3 of concrete in one of the biggest elevated continuous pours in NSW history. By Julie Adamo, Regional Sales Manager NSW/ACT, Boral Construction Materials. Boral customer, Baulderstone is the As the post tensioned bridge comprised Managing Contractor on Port Botany’s a 400mm deck and 2,200mm deep girder, Grade Separation works. Boral utilised its technical knowledge to design a low heat, high durability, high The project involves a large elevated bridge/ workability (160mm slump, small aggregate) roundabout that will streamline traffic mix to achieve Sydney Ports Corporation’s access to Port Botany’s T3 and Brotherson wet and hardened concrete requirements. Docks. Spanning more than 75 metres the new roundabout required a continuous The project required significant logistics pour of concrete to ensure the optimal post- to ensure around 400 loads of concrete tensioning sequence of the support girders. performed satisfactorily, requiring individual This would also minimise the number of slump tests and approximately 400 test construction joints for high durability. cylinders. Geoff McDonnell, the Sydney Metro Boral Concrete collaborated with Boral Concrete Operations Manager, carefully Quarries, Cement and Logistics to ensure planned delivery of the pour for several the success of the project with supply of weeks. When it took place on a weekend • 4000 tonnes coarse/fine aggregates, Above: Boral Agitators ready to deliver their loads. in March this year it involved more than Main Pic: Boral agitators delivering concrete 60 concrete trucks and 18 testers working • 1200 tonnes cement during the night shift. over two shifts to successfully deliver the Five boom pumps were required to successfully deliver Baulderstone was extremely pleased with 3 concrete via five boom pumps over an 2,500m over the 18 hour continuous pour. Boral’s service, with the Site Supervisor 18 hour period.