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In this issue:
Industry events
Beaut Ute promotion
Boral FireWALL

Borals new plasterboard

plant in QLD
Green building with Boral
plasterboard
Trouble-free plasterboard
ceilings
green building with Boral plasterboard
A NATIONAL BORAL PLASTERBOARD PUBLICATION MARCH 2007
Boral4Builders - A NATIONAL BORAL PLASTERBOARD PUBLICATION
2
Industry Events
Australian Institute of Building Surveyors 2007
International Conference
Adelaide Convention Centre
5 - 7 March 2007
Urban Development Institute of Australia
National Congress 2007
Perth Convention Exhibition Centre
12 - 15 March 2007
HIA Building & Business Expo
Melbourne Exhibition & Convention Centre
7 - 15 April 2007
Designex and Form & Function Expo
Melbourne Exhibition & Convention Centre
19 - 21 April 2007
HIA Building & Business Show
Sydney Convention and Exhibition Centre
10 - 11 May 2007
Boral FireWALL

provides a light-weight
option for industrial buildings
While light-weight fire-rated wall systems are widely used in commercial and multi-
residential construction, until now they had limited application in industrial buildings.
This is likely to change with the release of Boral FireWALL

system. Boral FireWALL

comprises a range of fire-rated plasterboard systems suitable for use as area separation
walls in steel framed buildings such as factories, warehouses and the like.
The first system of its kind, Boral FireWALL

takes into account behaviour of steel

structure in a fire situation and is designed to ensure that the specified fire rating is
achieved in the event of the fire. Boral FireWALL

will provide designers and builders

of industrial buildings with all the benefits of light-weight construction and is available
in fire-ratings of up to 4 hours and acoustic ratings up to Rw=78dB. For more
information visit www.boral.com.au/firewall or contact Boral TecASSIST 1800 811 222.
'BEAUT UTE' PROMOTION A GREAT SUCCESS!
Boral Plasterboard has broken new ground by giving
away a brand new vehicle in a national promotion.
Leanne Compton, Boral Plasterboard's Manager Retail
Development, said that the aim of the promotion was to
raise awareness and improve sales of Boral Plasterboard
BaseCote products throughout Australia.
A promotion of this size, giving away a car, had never been
done in Boral Plasterboard, she said. Nationally, 136
distribution outlets and stores were involved in the promotion,
which was aimed at end users - the plastering contractors -
over the period between 1 July and 27 October 06.
Called the 'Boral BaseCote Beaut Ute' promotion, it gave
anyone who bought a minimum of six bags of the product a
chance to win a new Ford Courier worth up to $20,000 or
prizes of free fuel worth $5000 or $2500. The promotion was
run through hardware stores and independently-owned and
company-owned Boral Plasterboard outlets, and was a great
success, she said.
This is only the first of many promotions that Boral
Plasterboard will be bringing to you in the future.
MARCH 2007
Boral's $106m investment will see Australia's
largest plasterboard plant built in Queensland
Work is now under way on Boral's new, state-of-the-art plasterboard manufacturing and distribution base at Pinkenba
on the Brisbane River.
Plasterboard is of growing importance to Australia's residential and commercial construction markets -
particularly in Queensland where the market is being driven by population growth and a strong resource
sector, said Ross Batstone, Executive General Manager of Boral Plasterboard.
The new manufacturing facility is expected to be fully operational before October this year and will have
plasterboard capacity 40 million square metres annually, almost double that at the current site which will
close when the new facility starts, said Ross.
It will also deliver state- of- the- art energy
efficiency, automation and product quality.
Boral's commitment to sustainability is
reflected in best practice water re- use to
reduce dependency on public water resources
which, when combined with gypsum handling
direct from ship to plant, will create a long
term, low cost position with a sound
environmental footprint.
3
Boral4Builders - A NATIONAL BORAL PLASTERBOARD PUBLICATION
4
Introduction
The term 'Green Building' is widely used to describe creation of
sustainable and healthy building environments.
Green Building is concerned with the project's life cycle impact on
the Environment and on health and comfort of the building
occupants. One of the key principles of Green Building, therefore,
is the selection of sustainable and 'healthy' building materials.
This article outlines the Green Building credentials of Boral
plasterboard and is aimed at providing the Regulators, Specifiers
and Builders with factual information in support of Boral
plasterboard products on Green Building projects.
Plasterboard life cycle
Mining of gypsum
Gypsum (calcium sulphate dihydrate CaSO4.2H2O) is a naturally
occurring mineral found widely throughout Australia. Most
gypsum deposits are considered to be precipitates formed during
the evaporation of sea waters saturated with soluble salts.
The gypsum used in manufacture of Boral plasterboard is sourced
at Lake MacDonnell in South Australia. Lake MacDonnell is the
largest known commercial gypsum deposit in Australia and has
reserves of at least 500 million tonnes of high purity (>90%)
gypsum distributed over an area of some 80 square kilometres.
The gypsum is extracted by open cut mining and is stockpiled on
site for several years to allow for the salt content to be reduced to
acceptable levels through washing by natural rain fall. The gypsum
is then transported by rail from the mine site to the port of
Thevenard where it is then loaded onto a ship to be transported to
Boral Plasterboard's manufacturing plants in Melbourne, Sydney
and Brisbane.
At the mine site, a remediation plan is in place whereby the
overburden previously stripped is replaced to create a gently
undulating landscape allowing re-growth of native local vegetation,
mostly salt bush.
Manufacturing plasterboard
Standard core plasterboard manufactured by Boral comprises
93% naturally occurring gypsum, 5% recycled paper as the
linerboard that encases the gypsum core with the remaining 2%
of ingredients being required in the manufacture of the product
and to improve the stiffness and quality of the finished board.
Electricity and natural gas are used in the manufacture of
plasterboard. Electricity drives the many motors in the plant while
natural gas is used to provide the heat required to calcine the
gypsum and then later dry the plasterboard.
Manufacture of plasterboard also requires the use of water to
produce gypsum slurry.
The new plasterboard plant at Pinkenba in Queensland, will be a
state-of-the-art manufacturing facility setting new standards in
water recycling and energy efficiency.
Distribution of plasterboard
Plasterboard is transported to distribution warehouses and to
building sites by diesel engine trucks and is unloaded by forklifts
powered by LPG. Plasterboard packs are stored on billets
manufactured from reject plasterboard.
Plasterboard can be ordered in many standard sizes that allow the
builder to reduce the amount of waste by ordering the most
efficient lengths. For large projects special lengths can be
manufactured to order.
Installation of plasterboard
Plasterboard installation involves fixing to substrate and flush
finishing of joints between the plasterboard sheets. Plasterboard
installation is carried out with the aid of manual and light
mechanical tools.
Plasterboard is cut on site to required lengths prior to installation
on walls or ceilings. This can result in an amount of waste
plasterboard left over after the job is completed. In some states
plasterboard waste is collected from building sites and turned into
soil conditioner used in the agricultural industry or recycled back
into new plasterboard. Another option is for the waste
plasterboard to be rotary hoed into the site where it will work to
condition the soil on the site namely by, breaking down clay and
making it more permeable to water.
Green building with Boral
5
MARCH 2007
Removal and disposal of plasterboard at end of useful life
If plasterboard is removed with a degree of care that limits the
amounts of contamination by other building materials such as screws,
studs, rubble etc it is possible for the demolished plasterboard to
be recycled into new plasterboard or soil conditioner.
As a soil conditioner, the gypsum can be used to combat transient
salinity and sodicity in soils where the gypsum assists in the
leaching of salts to below the root zone.
Embodied energy
The amount of embodied energy used in the manufacture of a
particular material or component is termed The Process Energy
Requirement (PER) while the total of all the energy required for
the manufacture, transport and installation of a particular material
or component is indicated by The Gross Energy Requirement (GER).
Due to variations in energy required to transport the product to its
point of use, most embodied energy figures are quoted as PER.
As shown in the following table, embodied energy (PER) per kg of
plasterboard compares favourably with other common lining materials:
Embodied energy (PER) of lightweight construction is also lower
than that of traditional heavy weight alternatives:
Indoor air quality
Indoor air quality is dependant on a number of factors including
the level of toxic emissions from building materials and air
circulation within the building.
Consisting largely of natural gypsum and recycled paper, Boral
plasterboard does not contain the toxics inherent to a number of
other manufactured building materials. Being relatively porous, it
also allows buildings to 'breathe' thus contributing to creation of
a healthy internal environment.
Noise reduction
Excessive levels of noise can have detrimental effect on the
health and comfort of building occupants. Boral offers a wide
range of plasterboard products and building systems that meet
acoustic isolation requirements of the Building Code of Australia
and help to reduce noise levels within residential and commercial
buildings.
Fire safety
Protection of life and property in the case of a fire is paramount to
creating a safe building environment. Chemical composition of
plasterboard makes it an ideal material for use in fire resisting
construction. Classified as a non-combustible material under the
Building Code of Australia, plasterboard retards the spread of fire
and is widely used in construction of fire-rated walls and ceilings.
Boral offers a wide range of fire-rated plasterboard products and
building systems with fire resistance levels of up to 4 hours as
defined in the Building Code of Australia.
ASSEMBLY PER Embodied
Energy MJ/m
2
Timber frame, timber weatherboard, plasterboard
lining
188
Cement stabilised rammed earth 376
Timber frame, aluminium weatherboard,
plasterboard lining
403
Timber frame, clay brick veneer, plasterboard lining 561
Steel frame, clay brick veneer, plasterboard lining 604
Double clay brick, plasterboard lined 906
MATERIAL PER Embodied
Energy MJ/kg
Plasterboard 4.4
Fibre cement 4.8
Particleboard 8.0
Plywood 10.4
MDF 11.3
Hardboard 24.2
Source: Building Materials Energy and the Environment, Bill Lawson, The Royal
Australian Institute of Architects, 1996.
Source: Building Materials Energy and the Environment, Bill Lawson, The Royal
Australian Institute of Architects, 1996.
For more information on the Green Building credentials of Boral
plasterboard please contact TecASSIST 1800 811 222.
plasterboard
Boral4Builders - A NATIONAL BORAL PLASTERBOARD PUBLICATION MARCH 2007
6
Achieving trouble-free
plasterboard ceilings
Proper Fixing Substrates
In coming to terms with the deterioration of plasterboard ceilings due to the effects of the ageing process, unquestionably the cause in
most cases can be attributed to shortcuts and a misguided perception that if it can't be seen, then who's going to know?.
One frequently, and purposely, overlooked area is known as the background framing. The background is the foundation for internal linings.
Let's start with the framing: if the ceiling is not battened, chances are the framing background for direct fix plasterboard will be insufficient
and the perimeter fixing will be inadequate.
All too often fixing substrates for plasterboard linings are constructed with the thought that if it's not complete, the plasterer will provide
any required extras. Don't be so sure: it may never happen! Can you imagine the painter setting a couple of joints, just because the
plasterer didn't complete his job? I don't think so.
To achieve a trouble-free plasterboard ceiling, it is important to ensure that background framing complies with Australian Standards and
Boral Plasterboard recommendations.
Australian Standard AS2589-1997 requires that ceiling trimmers are to be provided as part of the framing system where primary framing
members change direction within a room.
Boral Plasterboard also recommends that clipped furring channels should be used under trussed roofs subject to significant structural movement.
Ceiling joist or bottom cord of
end trusses Trimmers
Furring channels
Boral plasterboard sheets Ceiling joist or bottom cord of
main trusses
Ceiling joist or bottom cord
of end trusses Trimmers
Boral plasterboard sheets Ceiling joist or bottom cord
of main trusses
Fig.1 Direct fixed ceiling Fig.2 Furred ceiling
This is the first in a series of articles contributed by Jim Browning, Boral Plasterboard's Technical Manager, Queensland.
7
Building Approvals
Number of Residential Dwelling Units by Type of Building
The % Change columns refer to the percentage change of the December
2006 quarter compared with the September 2006 quarter.
Source: Australian Bureau of Statistics
Total
Houses
%
Change
Total
Other Res
%
Change
Total
Res
%
Change
NSW
Dwelling Approvals - December Quarter 2006
Regions
Sydney 1,529 -14.72 2,736 -4.47 4,265 -8.42
Hunter* 582 -13.91 355 -46.05 937 -29.76
Illawarra 346 -4.68 209 60.77 555 12.58
Richmond-Tweed 180 -28.85 109 55.71 289 -10.53
Mid-North Coast 249 -26.33 87 -65.88 336 -43.34
Northern* 143 -17.82 40 5.26 183 -13.68
North Western 88 -25.42 8 -46.67 96 -27.82
Central West 172 -7.53 29 7.41 201 -5.63
South Eastern 207 -15.51 40 -39.39 247 -20.58
Murrumbidgee 154 -4.35 40 83.33 194 10.23
Murray 141 -25.79 22 0.00 163 -19.31
Far West 2 -77.78 0 0.00 2 -77.78
NSW 3,793 -15.82 3,675 -11.45 7,468 -13.72
QLD
Dwelling Approvals - December Quarter 2006
Regions
Brisbane* 2,581 -2.93 1,201 12.77 3,872 1.56
Gold Coast* 1,103 4.15 510 -35.36 1,163 -12.72
Sunshine Coast* 553 -11.94 327 85.80 880 9.45
West Moreton* 141 -28.43 5 -28.57 146 -28.43
Wide Bay-Burnett 681 1.04 201 74.78 882 11.79
Darling Downs 291 -7.91 80 -31.62 371 -14.32
South West 16 -20.00 0 0.00 16 -20.00
Fitzroy 394 -7.73 50 -61.24 444 -20.14
Central West 2 -75.00 2 0.00 4 -50.00
Mackay 274 -23.68 24 -84.42 298 -41.91
Northern* 405 -11.76 68 -73.44 473 -33.85
Far North 533 21.14 155 -16.22 688 10.08
North West 12 71.43 28 366.67 40 207.69
QLD 6,986 -3.68 2,651 -11.62 9,637 -6.00
VIC
Dwelling Approvals - December Quarter 2006
Regions
Melbourne 4,436 -17.84 2,035 15.56 6,471 -9.63
Barwon 447 -26.72 77 83.33 524 -19.62
Western District 156 -1.89 26 73.33 182 4.60
Central Highlands 241 -18.86 14 0.00 255 -18.01
Wimmera 43 -39.44 3 -92.50 46 -58.56
Mallee 147 -2.65 9 -85.25 156 -26.42
Loddon 306 -25.55 10 42.86 316 -24.40
Goulburn 336 -13.88 13 -27.78 349 -13.83
Ovens-Murray 155 20.16 16 100.00 171 24.82
East Gippsland 149 -32.27 2 -50.00 151 -32.59
Gippsland 380 0.53 64 33.33 444 4.23
VIC 6,796 -17.24 2,269 12.44 9,065 -11.39
Total
Houses
%
Change
Total
Other Res
%
Change
Total
Res
%
Change
SA
Dwelling Approvals - December Quarter 2006
Regions
Adelaide 1,408 -1.88 418 -18.99 1,826 -6.41
Outer Adelaide 336 -3.45 49 58.06 385 1.58
Yorke &Lower Nth 117 6.36 0 -100.00 117 4.46
Murray Lands 110 -9.09 5 150.00 115 -6.50
South East 69 -33.65 9 28.57 78 -29.73
Eyre 50 16.28 0 0.00 50 16.28
Northern 94 25.33 6 -66.67 101 7.53
SA 2,184 -2.33 487 -15.45 2,671 -5.01
WA
Dwelling Approvals - December Quarter 2006
Regions
Perth 3,676 -2.85 996 -22.13 4,672 -7.72
South West 860 -15.27 122 -74.48 982 -34.23
Lwr Grt Sthern 112 -21.68 28 154.55 140 -9.09
Upper Grt Sthern 21 -30.00 0 0.00 21 -30.00
Midlands 139 -7.95 13 555.00 152 -0.65
South Eastern 110 29.41 6 200.00 116 33.33
Central 99 -27.21 9 -43.75 108 -28.95
Pilbara 95 66.67 4 -50.00 99 52.31
Kimberley 67 -9.46 19 26.67 86 -3.37
WA 5,179 -5.41 1,197 -33.90 6,376 -12.49
TAS
Dwelling Approvals - December Quarter 2006
Regions
Greater Hobart 313 5.03 5 -78.26 318 -0.93
Southern 83 -3.49 1 -91.67 84 -14.29
Northern 163 5.84 26 85.71 189 12.50
Mersey-Lyell 143 32.41 15 -34.78 158 20.61
TAS 702 8.67 47 -34.72 749 4.32
NT
Dwelling Approvals - December Quarter 2006
Regions
Darwin* 157 -17.83 121 -40.10 250 -30.36
NT - Balance 39 -17.95 6 -68.42 38 -34.48
NT 196 -17.86 127 -42.53 288 -30.94
ACT
Dwelling Approvals - December Quarter 2006
Regions
Canberra 297 -31.09 122 -54.14 419 -39.89
ACT - Balance 0 -100.00 0 0.00 0 -100.00
ACT 297 -31.25 122 -54.14 419 -39.97
* Boundaries of these statistical divitions changed in July 2006.
8
VICTORIA
Brunswick
72 Nicholson Street,
Brunswick VIC 3056
Telephone (03) 9388 9555
Facsimile (03) 9388 9655
Campbellfield
1932 Hume Highway,
Campbellfield VIC 3061
Telephone (03) 9357 0714
(03) 9357 0440
Facsimile (03) 9357 8796
Caroline Springs (Deer Park)
1037 Western Highway,
Deer Park VIC 3023
Telephone (03) 9449 5344
Facsimile (03) 9449 5439
Doveton (Dandenong)
22 Princes Hwy,
Doveton VIC 3177
Telephone (03) 9791 2855
Facsimile (03) 9791 2523
Geelong
12 Crown Street,
Geelong South VIC 3220
Telephone (03) 5222 2541
Facsimile (03) 5229 8515
Mildura
1095A Benetook Avenue,
Mildura VIC 3500
Telephone (03) 5023 3238
Facsimile (03) 5021 3574
Murrumbeena
983B North Road,
Murrumbeena VIC 3163
Telephone (03) 9570 1288
Facsimile (03) 9570 2084
Port Melbourne
17- 47 Turner Street,
Port Melbourne VIC 3207
Telephone (03) 9645 1877
Facsimile (03) 9646 5824
Sale
16 Walter Street,
Sale VIC 3850
Telephone (03) 5144 4265
Facsimile (03) 5144 6031
Sunbury
158 OShannassy Street,
Sunbury VIC 3429
Telephone (03) 9740 6888
Facsimile (03) 9740 8511
Traralgon
37 Standing Drive,
Traralgon VIC 3844
Telephone (03) 5176 0757
Facsimile (03) 5176 0368
NEW SOUTH WALES
Albion Park Rail
Lot 31 Rivulet Crescent,
Albion Park Rail NSW 2527
Telephone (02) 4256 4555
Facsimile (02) 4256 2615
Coffs Harbour
Cnr Hi Tech Drive & Craft Close,
Toor Mina NSW 2452
Telephone (02) 6653 3488
Facsimile (02) 6658 2377
Castle Hill
Unit 3, 15 Carrington Road,
Castle Hill NSW 2154
Telephone (02) 9659 7168
Facsimile (02) 9659 3568
Fyshwick
7 Barrier Street,
Fyshwick ACT 2609
Telephone (02) 6280 4243
Facsimile (02) 6280 5816
Lurnea
7 Lyn Parade,
Lurnea NSW 2170
Telephone (02) 9607 3744
Facsimile (02) 9607 2785
Nowra South
14 Bellevue Street,
Nowra South NSW 2541
Telephone (02) 4421 0799
Facsimile (02) 4421 0423
Revesby (Stud & Track)
71 Milperra Road,
Revesby NSW 2212
Telephone (02) 9792 3022
Facsimile (02) 9774 3781
Rozelle (Stud & Track)
32A Roberts Street,
Rozelle NSW 2039
Telephone (02) 9810 6800
Facsimile (02) 9870 6815
Penrith (Stud & Track)
Cnr Coreen Ave & Coombes Dr,
Penrith NSW 2750
Telephone (02) 4731 2888
Facsimile (02) 4731 2761
Thornton
10 Hartley Drive,
Thornton NSW 2322
Telephone (02) 4964 2063
Facsimile (02) 4964 1396
West Gosford
423 Manns Road,
West Gosford NSW 2250
Telephone (02) 4324 6777
Facsimile (02) 4324 6007
QUEENSLAND
Browns Plains
43 Eastern Road,
Browns Plains QLD 4118
Telephone (07) 3809 0877
Facsimile (07) 3809 0942
Bundaberg
Shed 8, Lester Street,
Industrial Estate,
Bundaberg QLD 4670
Telephone (07) 4153 2550
Facsimile (07) 4153 1438
Caboolture
10 Piper Street,
Caboolture QLD 4510
Telephone (07) 5428 2540
Facsimile (07) 5428 2205
Cairns
5 Elphinstone Close,
Cairns QLD 4870
Telephone (07) 4035 5999
Facsimile (07) 4035 5977
Capalaba
Cnr Smith & Hook Street,
Capalaba QLD 4157
Telephone (07) 3245 6748
Facsimile (07) 3245 5366
Garbutt
29 Caldwell Street,
Garbutt QLD 4814
Telephone (07) 4779 3077
Facsimile (07) 4779 3080
Gladstone
7 Willunga Place,
Barney Point, Gladstone
QLD 4680
Telephone (07) 4972 8948
Facsimile (07) 4972 8396
Labrador
Unit 2/328 Brisbane Road,
Labrador QLD 4215
Telephone (07) 5563 8000
Facsimile (07) 5563 8511
Northgate
733 Nudgee Road,
Northgate QLD 4013
Telephone (07) 3215 2288
Facsimile(07) 3215 2296
Rockhampton
Cnr Johnson & McLaughlin St,
Rockhampton QLD 4702
Telephone (07) 4936 2288
Facsimile (07) 4936 2100
South Brisbane
28 Cordelia Street,
South Brisbane QLD 4101
Telephone (07) 3255 2111
Facsimile (07) 3255 2144
West Burleigh
8 Junction Road,
West Burleigh QLD 4220
Telephone (07) 5593 5722
Facsimile (07) 5593 5085
SOUTH AUSTRALIA
Gillman
113-117 Bedford Street,
Gillman SA 5013
Telephone (08) 8240 8888
Facsimile (08) 8341 1004
Marleston
156 Richmond Road,
Marleston SA 5033
Telephone (08) 8443 7222
Facsimile (08) 8443 7233
Seaford Meadows
1 Seaford Road,
Seaford Meadows SA 5169
Telephone (08) 8386 1966
Facsimile (08) 8327 2819
NORTHERN TERRITORY
Winnellie
147 Coonawarra Road,
Winnellie NT 0820
Telephone (08) 8984 4484
Facsimile (08) 8984 3778
WESTERN AUSTRALIA
Albany
366- 368 Middleton Loop,
Albany WA 6330
Telephone (08) 9842 8970
Facsimile (08) 9842 3816
Bunbury
11 Allnut Court,
Bunbury WA 6230
Telephone (08) 9725 6766
Facsimile (08) 9725 6799
Canning Vale
132 Bannister Road,
Canning Vale WA 6155
Telephone (08) 9456 0610
Facsimile (08) 9455 4377
Mandurah
Lot 9, 57 Reserve Drive,
Mandurah WA 6210
Telephone (08) 9581 6815
Facsimile (08) 9581 6816
Wangara
29 Innovation Circuit,
Wangara WA 6065
Telephone 1300 652 666
Facsimile (08) 9302 6994
West Perth
15 Gordon Street,
West Perth WA 6005
Telephone (08) 9486 8238
Facsimile (08) 9486 8239
TASMANIA
Moonah
93 Albert Road,
Moonah TAS 7011
Telephone (03) 6278 9966
Facsimile (03) 6278 9865
Launceston
57 Dowling Street,
Launceston TAS 7250
Telephone (03) 6331 9922
Facsimile (03) 6331 8441
Boral Plasterboard Store Locations
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