A Story Of Progress In New Zealand Manufacture

Press, Volume C, Issue 29467, 20 March 1961, Page 20

A Story Of Progress In New Zealand Manufacture

Prior to 1927 substantial quantities of plaster wallboard were imported from U.S.A. and Canada, but in this year a new company was incorporated in Auckland, know as N.Z. Wallboards Ltd., with the object of manufacturing a similar type of wallboard, which eventually was given the registered trade name of “Gibraltar Board.” As is usual with such new enterprises many difficulties had to be overcome, but the quality was such that continued expansion made it necessary to obtain more and more capital. Two years later Winstone Limited acquired a financial interest in the enterprise and at the same time, because it was realised that their organisation merited the appointment, they were appointed Master Distributors of the Company’s “Gibraltar Board” production. Investigations were commenced overseas so that the plant could be brought up to modern standards. During the year 1929, 3,500,000 ft of board was produced, but it was evident that this was the limit unless modern modern methods were utilised. From details and information gained in America, new machinery was procured ana after six months of experiments and tests a new world innovation of a plaster and pumice core was advocated to replace the plaster-sawdust combination that was being produced. The new plant was completed in 1932 and from then on the board manufactured was more than equal in quality to similar products manufactured overseas. During 1940, 14,600,000 ft. of Gibraltar Board was produced and marketed, this increase being due to further extensions to the plant. Although figures become tiresome, it is interesting to note this comparison. In 1930, the staff consisted of 18 men and the plant produced 5,000,000 ft. and in 1945, 20,000,000 ft. was manufactured by 50 men. At this stage the demand for the material far exceeded the output and it became necessary to control the distribution to that work awaiting completion. To relieve this position in 1946 the Wellington plant commenced production and from the outset has been successful in turning out a high-class material. In 1951 the Auckland plant was extended and the latest automatic equipment and continuous drying machinery was installed. Through these expansions and by a vigorous business organisation, a thriving market was further developed. Inevitably in the scheme of New Zealand expansion, South Island requirements loomed into the picture. For many years Gibraltar Board had been shipped in ever increasing quantities from the Balmoral Road Auckland Factory to the South Island. The many months of planning ahead, coming to fruition with the advent of the Christchurch Factory ensures the ample sufficiency of Gibraltar Board through the South Island to meet future market demands. MANUFACTURE: The basic principle in the manufacture of Gibraltar Board appears as a simple process. One could almost describe the plant as being a mixing machine with an extensive conveyor belt on which the board is sufficiently hardened as it travels to be cut in desired lengths. Heat is applied as it passes through the dryers to eliminate further moisture and the Gibraltar Board is then ready for inspection and despatch. Of course there is much more detail than that mentioned above and the quality of the “Gibraltar Board” is constantly under the watchful control of our Laboratories and technical staff. Board as supplied from the North Island plants consists of a combination of pumice and plaster mixed with water to form the desired consistency. Because Pumice is not available in the South Island, the new Christchurch factory will produce a foamed plaster core. This core will in practice be identical to that which is used by overseas manufacturers. The plaster, the foam ingredient, and other raw materials are added together with water at the pin-mixer this mixture is then deposited on a wet feed belt which transfers the foamed plaster to the making machine placing it between the paper envelope which moves forward to the forming rollers. The mix is then compressed between two layers of durable N.Z. made wallboard paper which is drawn from half-ton rolls situated behind the making table. The Board now appears as a continuous sheet Jin

in thickness on the long conveyor belt system. In the proceai of passing through the forming rollers the edges are neatly turned, pound, and glued. The continuous ribbon of formed board progressively hardens as it travels down the 400 ft. conveyor belt. By the time it reaches the cutting apparatus at the end of the conveyor, the final set has taken place. The cutter is operated by an electrically controlled trip and the machine can be set to cut the board into all the popular sizes that are required by the Builder. A photo electric cell automatically controls the transfer and tipple movements of the board from the cutter to its return journey through the 200 ft. drier. Heat is generated by an oil burning boiler and distributed throughout the length of the 8-tier drier by steam pipes controlled in three zones. The three or four ft. wide sheets are transported through the drier on eight levels and each tier is fed alternately from top to bottom two or three sheets abreast, according to width being manufactured. Approximately one and a half hours later, after moving slowly through the drier, the “Gibraltar Board” emerges perfectly formed and dried. At this stage the board is palletised for ease of handling by forklift trucks and taken into stock. Local carriers can be speedily loaded at the despatch bays. In fact the ease of handling of Gibraltar Board from the factory to the job is a vital factor in reducing the handling costs to the end user. FIXING AND STOPPING: Gibraltar Board is recommended as an inside lining but it has been specified for ceiling canopies and soffit work, and the durability can be gauged when it is recorded that, after a thorough coating of paint, sheets have been used and withstood the weathering of many years as an exterior wall. The product will equal that manufactured overseas and can survive all the tests that are required for a sound building commodity, namely durability, versatility, and economy. Gibraltar Board’s properties are fire and vermin resistant, insulation against heat and cold and the passage of sound, ease of application and decoration. Countersunk flat headed galvanised nails are used to fix the sheets. Joints can be battened or, as in the usual case, plastered smooth with stopping plaster, providing a surface ideal for papering, painting or textured finish. “Time costs money” is an ancient truism, but it will readily conceded that speed of operation, constant flow of material, coupled with expert workmanship all play an essential part in retaining building costs at a reasonable level. Evety working day throughout New Zealand Gibraltar Board plays an ever increasing part as a basic building material at an extremely economic price. CHRISTCHURCH AND SOUTH ISLAND: The inauguration of the Christchurch Factory, can be expected to show the following advantages to the Building Industry in the South Island. The daily serving, by cartage fleets, of Christchurch and surrounding areas. Consistent supplies by daily rail service to areas outside Christchurch. A reserve production based on the latest technical developments, to ensure continuity of supply amply sufficient to meet expanding building requirements through the South Island. A diversity of sizes in 3 and 4ft. widths, and from 6ft. to 12ft. lengths which will allow considerable freedom in “setting out” contracts on the “tailor made” principle. CONCLUSION: In ending we look back. In 1929 3,500,000 sq. ft. was produced, in 1960 rather more than 72,000,000 sq. ft was produced and used in New Zealand. Gibraltar Board is we feel a household word throughout the country, and in common 'with many other successful products, its emergence to a successful place in New Zealand Industry, surely belongs to the confidence and driving energy of the pioneers who originally attempted to produce a locally manufactured wallboard. Last Friday was opening day, we commenced it was the knowledge that our trio of factories at Auckland, Wellington and Christchurch have ample reserve production to keep abreast of the country’s building requirements.