boral limited level 39, amp centre 50 bridge street sydney

29
4 May 2012 The Manager, Listings Australian Securities Exchange ASX Market Announcements Level 14, Exchange Centre 20 Bridge Street Sydney NSW 2000 Dear Sir Boral Plasterboard Presentation We attach a presentation which is being given today at Boral’s Plasterboard site at Pinkenba, Queensland during a briefing for analysts and investors. Yours faithfully Margaret Taylor Company Secretary Boral Limited ABN 13 008 421 761 Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney NSW 2000 GPO Box 910 Sydney NSW 2001 T: +61 (02) 9220 6300 F: +61 (02) 9232 5195 www.boral.com.au For personal use only

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Page 1: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

4 May 2012 The Manager, Listings Australian Securities Exchange ASX Market Announcements Level 14, Exchange Centre 20 Bridge Street Sydney NSW 2000 Dear Sir Boral Plasterboard Presentation We attach a presentation which is being given today at Boral’s Plasterboard site at Pinkenba, Queensland during a briefing for analysts and investors. Yours faithfully Margaret Taylor Company Secretary

Boral Limited ABN 13 008 421 761

Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney NSW 2000 GPO Box 910 Sydney NSW 2001

T: +61 (02) 9220 6300 F: +61 (02) 9232 5195

www.boral.com.au

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Page 2: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

BORAL PLASTERBOARD AUSTRALIA Pinkenba Analyst and Investor Visit, May 2012

Mark Selway, Chief Executive, 4 May 2012

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Page 3: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

Boral Plasterboard Australia

AGENDA – FRIDAY 4 MAY 2012

2

Welcome Mark Selway

Plasterboard Australia Overview Ross Batstone

Safety Briefing, Plant and LEAN overview Andrew Pittle

Tour of production facilities

Lunch and discussion

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Page 4: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

BORAL PLASTERBOARD AUSTRALIAPinkenba Analyst and Investor Visit, May 2012

Ross Batstone, Divisional Managing Director, Boral Building Products, 4 May 2012

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Page 5: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

Boral Building Products Australia

BORAL BUILDING PRODUCTS AUSTRALIA BUSINESS IS HIGHLY LEVERAGED TO NEW HOUSING CONSTRUCTION

(A$m) 1H FY10 2H FY10 1H FY11 2H FY11 1H FY12

Revenue 608 598 624 526 530

EBITDA 67 74 73 49 49

EBIT 37 46 46 22 22

Boral Building Products relies primarily on new housing construction in Australia, including alterations and additions

Declines in residential construction and reduced government stimulus work has impacted volumes particularly since 2H FY2011

A streamlined organisational structure has been implemented to maximise the potential of all businesses, particularly Clay & Concrete Products

The right-sizing of installed brick capacity, improvements in operating efficiency and reduction in overhead costs will provide cost benefits

Further residential activity declines impacting Building Products performance in 2H FY2012

Boral Building Products – Australian businesses

Revenue (A$m) 1H FY12 1H FY11 Var %

Plasterboard 192 210 (8%)

Clay & Concrete 229 271 (16%)

Timber 109 143 (24%)

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Page 6: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

11

19

29

-

10

20

30

40

50

EB

IT (

$m

)

EBIT - current EBIT - reshaped EBIT - reshaped with o/head savings

Results for the half year ended 31 December 2011

BORAL BUILDING PRODUCTS Clay & Concrete Restructuring as announced to the market in February 2012

We will exit the QLD Roofing business and close the Carole Park plant

East Coast Masonry has been loss making for the past 5 years

We will market test the sale of the East Coast Masonry business

EBIT losses from QLD Masonry and Roofing were $8m in FY11 and a further $10m in overhead savings will result from the restructuring

The Cairns and Mackay operations were successfully divested in early 2012

Reorganisation Footprint

Carole Park

Cairns

Mackay

Deer Park

Labrador

Prospect

Wacol

Exited Operations

FY11 Revenue $106m

FY11 EBIT loss ($8m)

RoofingMasonry

6 East Coast Masonry sites : 266 employees

QLD Roofing : 32 employees

499

393

-

100

200

300

400

500

600

Rev

enue

($m

)

Revenue - current Revenue - reshaped

FY07 FY08 FY09 FY10 FY11

Revenue ComparisonsClay & Concrete Products

5

FY07 FY08 FY09 FY10 FY11

Profit ComparisonsClay & Concrete Products

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Page 7: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

Boral Building Products Australia

THE AUSTRALIAN BUILDING PRODUCTS PORTFOLIO IS UNDERGOING SIGNIFICANT CHANGE

6

In June 2011, we closed our Plywood business based at Ipswich (QLD) and our Masonry plant located at Somersby (NSW)

We have reduced operating brick capacity from 620 to 390 million SBE (37%) over the last 12 months through permanent plant closure or temporary mothballing:

- 60 million SBE permanently closed in QLD at Darra (completed June 2011), 65 million SBE mothballed in NSW at Badgerys Creek (completed April 2012) and 105 million SBE mothballed in WA at Middle Swan (completed April 2012)

- Sales volumes are now greater than operating capacity, to help inventory reduction with LEAN

We are closing our Roof Tile business in QLD (to be complete June 2012)

We have sold our Cairns/Mackay based Masonry businesses (completed April 2012)

We are market testing the sale of our remaining Masonry businesses in QLD, NSW and Victoria (targeting June 2012 for resolution)

We are streamlining Overhead structures in Clay & Concrete and in Building Products

When complete these measures are expected to reduce the number of Building Products’ employees (excludes Asia) by 800 (28%) from a total of 2,880 in January 2011

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Page 8: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Masonry plantSite closed

Site sold / held for sale

Wacol

Prospect

Deer Park

Mackay

Cairns

Labrador

Byron Bay

Somersby

PoorakaCanningtonJandakot

Midland

Capacity(‘000 tonnes)

PreviousPost sale / closures

NSW 252 0

VIC 120 0

QLD 315 0

SA 122 122

WA 170 170

Total 979 292

Boral Building Products Australia

BORAL MASONRY – CAPACITY TO BE REDUCED BY 70%

(A$m) FY07 FY08 FY09 FY10 FY11

Revenue 119 122 114 121 124

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Page 9: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Scoresby

Thomastown

Albury BringellyBadgerys Ck

Kempsey

Darra – 1 line closed

Midland

Brick manufacturing siteSite mothballed

Site closed

Boral Building Products Australia

BORAL BRICKS – CAPACITY REDUCED BY 37%

(A$m) FY07 FY08 FY09 FY10 FY11

Revenue 305 307 277 292 260

Capacity(million SBEs)

PreviousPost closures /

mothballing

NSW 127 62

VIC 118 118

QLD 105 45

WA 270 165

Total 620 390

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Page 10: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Carole Park

Springvale

Emu Plains

Pooraka Wyee

Concrete roof tile plant

Terracotta roof tile plant

Site closed Wyee Terracotta Plant

Boral Building Products Australia

BORAL ROOFING – CAPACITY REDUCED BY 21%

(A$m) FY07 FY08 FY09 FY10 FY11

Revenue 108 120 119 124 115

Capacity(million tiles)

PreviousPost

closure

NSW – Terracotta 17.2 17.2

NSW – Concrete 26.0 26.0

VIC – Concrete 21.0 21.0

QLD – Concrete 22.0 0

SA – Concrete 16.6 16.6

Total 102.8 80.8

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Page 11: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

56,2

01

51,0

68

49,0

25

42,9

27 57,9

15

54,2

26

52,3

52

44,7

47

47,1

57

25,5

62

24,0

30

22,5

68

16,1

00

21,0

41

31,5

64

29,4

40

29,8

71

25,3

50

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

100,000

1H 2H 1H 2H 1H 2H 1H 2H 1H 2H

2008 2008 2009 2009 2010 2010 2011 2011 2012 2012

Housing Other Dwellings

Boral Plasterboard Australia

WE HAD FORECAST 136,000 COMMENCEMENTS FOR THE YEAR ENDING JUNE 2012 – BEFORE Q3 RAIN IMPACTED

10Source: ABS 8752.0 Table 33 to 1H 2012, Boral forecast for 2H 2012

26% below 2H FY10

15% below 2H FY11

4th lowest 2H in 30 years

Rain has impacted actual east coast starts and the timing of materials usage

WA and SA are weaker than we had expected

Equates to 63.5k 2H starts which is:

Australian Dwelling Commencements

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Page 12: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

0

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

180,000

200,000

Jan-0

7

Mar-

07

May-0

7

Jul-07

Sep-0

7

Nov-0

7

Jan-0

8

Mar-

08

May-0

8

Jul-08

Sep-0

8

Nov-0

8

Jan-0

9

Mar-

09

May-0

9

Jul-09

Sep-0

9

Nov-0

9

Jan-1

0

Mar-

10

May-1

0

Jul-10

Sep-1

0

Nov-1

0

Jan-1

1

Mar-

11

May-1

1

Jul-11

Sep-1

1

Nov-1

1

Jan-1

2

Mar-

12

May-1

2

Domestic Framing Sales Volume¹

Structural Imports²

Total Australian Softwood Framing Sales Volumes

FY2008156,861 Starts

FY2010164,746 Starts

FY2011156,410 Starts

FY2012136,000 Starts

¹ Source: Domestic Framing Sales from Industry sales data compiled by the Australian Forests Products Association using untreated Structural softwood productsless than 120mm in width and Treated H2F Structural Sales

² Source: ABS import statistics for structural softwood imports from Europe and USA

Boral Plasterboard Australia

THE LOW LEVEL OF STRUCTURAL SOFTWOOD FRAMING SALES EVIDENCES WEAK NEW HOUSE CONSTRUCTION

11

JanFebMar

Australian Softwood Framing Timber Sales Volumes by Source (Rolling Three Months Average)

FY2009130,620 Starts

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Page 13: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

Supply Issues

Supply of adequate affordable land (where people want to live)

Government charges and infrastructure levies that are biased against new developments

Tight funding, particularly for Developers

Skilled trades shortages and higher costs with new regulations and the carbon tax

12

Boral Plasterboard Australia

TODAY MOST DRIVERS OF NEW DWELLING VOLUMES LOOK TO BE UNFAVOURABLE

Short Term Demand

Long Term (Underlying) Demand

A range of factors, including Europe, rising energy costs, employment prospects outside of resources, interest rates and uncertainty with the carbon tax, seem to be weighing against confidence to spend

Purchasing power of “gen Y”

Broad Economic Impacts

Affordability and the confidence to buy a new dwelling or to renovate

Relative price point of new and existing dwellings and the perception prices may fall

Withdrawal of stimulus programs

Continued strong population growth

Dwelling stock deficiency levels (NSW the main area of undersupply, but also QLD and WA)

Impact of “fly in, fly out” workforces?

Positive for dwelling construction

Negative for dwelling construction

KEY:

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Page 14: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

Boral Plasterboard Australia

NEW DWELLINGS CONSTRUCTION IS A KEY DRIVER OF AUSTRALIAN PLASTERBOARD DEMAND

13

FY2011 Australian PlasterboardDemand by Region and Market Segment2

¹ Source: ABS 8301.0² Source: Boral estimate

VIC / TAS

NSW / ACT

QLD / NT

WA

SA

Detached Houses

Other Dwellings

A&A

Non-Residential

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

By State By Segment

156

147

159

149

140142144146148150152154156158160

Jul-08

Sep-08Nov-0

8Jan-0

9Mar-09May-0

9Jul-09Sep-09Nov-0

9Jan

-10Mar-1

0May-1

0Jul

-10Sep-10Nov-1

0Jan-1

1Mar-11May-1

1Jul

-11Sep-1

1Nov-1

1Jan

-12Mar-1

2

132

114

123

139

149 148143

148 149

157153 153

110115120125130135140145150155160165170

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

Australian Plasterboard ProductionYear ended June (millions of m²)¹

Australian Plasterboard ProductionMoving annual total (millions of m²)¹

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Page 15: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

PRICING HAS IMPROVED CONSISTENTLY SINCE 2007, DESPITE FLAT VOLUMES AND CAPACITY INCREASES

14

0

20

40

60

80

100

120

140

160

180

200

Sep-1

990

Sep-1

991

Sep-1

992

Sep-1

993

Sep-1

994

Sep-1

995

Sep-1

996

Sep-1

997

Sep-1

998

Sep-1

999

Sep-2

000

Sep-2

001

Sep-2

002

Sep-2

003

Sep-2

004

Sep-2

005

Sep-2

006

Sep-2

007

Sep-2

008

Sep-2

009

Sep-2

010

Sep-2

011

Plasterboard Producer Price Index1

¹ ABS 6427.0 Table 11² Production: ABS 8301.0; Capacity: Boral estimates

QLD NSW VIC WA Total

Boral 40 18 28 86

CSR 20 21 28 7 76

Knauf 18 17 35

BGC 13 13

Total 60 57 73 20 210

Current Industry Plasterboard Capacity (millions of m2)

176 176

196 196 203

152.8 149.4 157152.9148.3

0

50

100

150

200

250

2007 2008 2009 2010 2011

Capacity ABS Production

Plasterboard Production Versus Industry Capacity2

Year ended June (millions of m²)

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Page 16: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

UNIT PRODUCTION COSTS ARE ADVERSELY IMPACTED AS OUTPUT FALLS, BECAUSE OF THE IMPACT OF FIXED COSTS

15

Typical Unit Production Cost Breakdown Index10mm Recessed Edge Plasterboard Product

48 weeks p.a., 7 days per week, 24 hours per day

48 weeks p.a., 5 days per week, 24 hours per day

48 weeks p.a., 5 days per week, 16 hours per day

Materials 51 51 51

Energy 11 11 11

Total Variable Cost 62 62 62

People 18 17 18

Other Cash 12 18 25

Depreciation 8 10 15

Total Fixed Cost 38 45 58

Total Cost 100 107 120For

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Page 17: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

BORAL IS THE LEADING INTEGRATED PLASTERBOARD SUPPLIER

Plasterboard production

Plasterboard distribution

GRA Gypsum mine (Boral/CSR JV)

Rondo Building Systems (Boral/CSR JV) production

Rondo Building Systems distribution

Boral supplies from Pinkenba & Port Melbourne plants by sea

Boral supplies from its east coast plants

Boral capacity is 40 million m2

at Pinkenba

Boral capacity is 28 million m2

at Port Melbourne

Boral capacity is 18 million m2

at Camellia

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Page 18: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

PINKENBA PLANT, QUEENSLAND – RECEIVES GYPSUM DIRECTLY FROM SHIP – CLOSE TO MAJOR ROADS

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Page 19: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

CAMELLIA PLANT, NSW – WELL LOCATED TO SERVICE NSW AND ACT MARKETS

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Page 20: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

PORT MELBOURNE PLANT, VICTORIA – RECEIVES GYPSUM DIRECTLY FROM SHIP – CLOSE TO MAJOR ROADS

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Page 21: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

PORT MELBOURNE PLANT - WET COMMISSIONING IS WELL UNDERWAY – WILL RAMP TO RATED CAPACITY QUICKLY

20

Port Melbourne upgrade status

Wet commissioning underway

Experienced team from Pinkenba assisting with start-up

The new 40,000 tonnes gypsum store

The new gypsum receiving system hopper at Wharf 26

The new gypsum receiving/conveying system over Lorimer Street

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Page 22: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

NEW PLANTS IN QLD AND VICTORIA GIVE BORAL LOW PRODUCTION COSTS

21

Major Cost Advantages at New Plants

Gypsum

Direct gypsum delivery to wharf eliminates cartage costs

Self-unloading ships reduce discharge time

Energy New mills and dryers reduce energy

use

Sustainability

No gypsum trucks on-road

Enclosed gypsum storage

Low processing energy

Water harvesting (Pinkenba only)

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Page 23: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

BORAL OPERATES THROUGHOUT THE PLASTERBOARD SUPPLY CHAIN AND SERVICES ALL END USER SEGMENTS

End Use

Installers

Distributors

Manufacturers

Housing Other Dwellings A & A Non -Residential

Builders Others

Manufacturer owned Independently ownedSpecialist plasterboard distributors

Hardware/Merchants

Plasterboard contractorsIndependently ownedBoral Interior Linings

Raw Materials

Boral CSR Knauf

Imports

ImportBGC

CSR

Boral Knauf BGC Unbranded CSR BGCKnaufPM

BoralDirect

50% of Gypsum Resources Australia (GRA) Others

CSR

BGC (WA only)

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Page 24: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

A KEY FOCUS IS THE DESIGN/SUPPLY OF SUSTAINABLE, APPLICATION SPECIFIC BUILDING SYSTEMS

23

Partiwall®

Separating walls for attached dwellings

IntRwall®

Separating walls for high rise apartment buildings

Multiframe™Complete Timber framed solution for low rise apartment buildings

OutRwall®

Fire rated external walls for residential and commercial buildings

Firewall®

Separating walls for industrial buildings

Fireclad®

Fire rated external walls for industrial buildings

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Page 25: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

WE ALSO PACKAGE OUR OFFERS FOR SPECIFIC MARKET SEGMENTS

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Page 26: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

THE OUTLOOK FOR PLASTERBOARD GROWTH IS POSITIVE

Low substitution risk

Low material cost

Short installation times

Ease of fixing (lower skilled trade)

Innovative solutions

High performance boards for speciality needs

- Fire, acoustic, impact

Systems solutions have created new categories

- Multi-residential partitions

Continued global demand growth

Demand in emerging markets increases with adoption of modern building methods

Continued innovation should increase penetration in existing markets

Attractive characteristics

Flexibility in design

Lightweight

Strong environmental credentials

Naturally fire resistant

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Page 27: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

PLASTERBOARD LINING SYSTEMS HAVE UNIQUE BENEFITS WHICH HAVE HELPED TO DRIVE ADOPTION

Increased AdoptionIncreased Adoption

Environment

Low embodied and lifecycle energy

Recyclable

Can be manufactured from recycled inputs

Proven safe to use

Flexibility and Performance

Ease of reconfiguration and repair

Naturally fire resistant

Various design solutions for specific requirements (fire, acoustic, wet area, impact etc.)

Lightweight

Reduced building mass –reduced foundation costs

Lower thermal mass

Education systems EchoSTOP ceiling panelsEnviro board

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Page 28: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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Boral Plasterboard Australia

THE INTEGRATION OF BORAL GYPSUM ASIA (BGA) IS PROCEEDING TO PLAN – SYNERGIES ARE SUBSTANTIAL

27

Best Practices Working actively with our Asian operations to share manufacturing,

engineering, product range/quality and customer service best practices

Procurement Leveraging increased scale for purchasing raw materials

Working to increase lower cost Asian sourcing

Network Investigating potential to leverage regional manufacturing footprint and

to grow innovation and system penetration

Boral is now the leading Asia Pacific plasterboard wall and ceilings solution supplier (and a leading global player) with:

- Plasterboard plants in Australia, China, India, Indonesia, Malaysia, South Korea, Thailand, and Vietnam (533 million m2 of capacity with a further 120 million m2 either under construction or planned)

- Plasterboard ceiling tile plants in China, Indonesia, Malaysia, South Korea, Thailand and Vietnam

- Metal stud and track plants in China, India, Indonesia, Philippines, Thailand and Vietnam

- Jointing compounds and building plaster plants in Australia, China, Indonesia, Malaysia, South Korea and Thailand

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Page 29: Boral Limited Level 39, AMP Centre 50 Bridge Street Sydney

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END

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