March 2016 marked the completion of a landmark eight month project for powder coating specialists Climate Coatings, supplying 145,000m² of ClimateLine powder coated plasterboard sheets to ATCO Structures and Logistics, one of Australia's largest producers of modular buildings.

The project, a workforce accommodation camp for a large natural gas project in Western Australia comprises 500 pre-fabricated accommodation buildings to house 2,000 workers, plus support service buildings such as dining rooms and ablution blocks.  

For ATCO, it was the first time using powder coated plasterboard. General Manager Brad Tucker explains that while this presented an element of risk (especially on a project of this scale), he was motivated by the significant advantages and value the product offered both ATCO and their client. A visit to Climate's factory in Auckland gave Brad the assurance he needed.

"I was extremely impressed with Climate's processes and the efficient and clean operation. I left Auckland feeling very confident we were making the right decision to use the product."

Programme Efficiencies

A key driver for using ClimateLine was the speed of production it allowed, says Brad. "Project time frames were tight. Using the pre-finished product meant we didn't need wet trades on the factory floor, which allowed us to easily achieve an ambitious programme of four (15 x 4.2m) buildings a day."

Climate delivered the ClimateLine sheets to to ACTO's plant in Perth in house-lots of cut-to-size panels ready to simply slot into place. Completed units were then transported more than 1500kms to the project site. 

Cost Savings

Board waste on the project was less than 1% compared to the industry standard of 15%, which provided a significant cost saving. "The price of the material (board for board) is slightly higher than standard plasterboard," explains Brad. "But by the time we added up the cost savings on labour, wastage and clean up we actualised a cost saving." 

Superior Finish and Performance

Created by the application of Climate Decor Shield powder coating, thermally fused to a plasterboard substrate, ClimateLine's finish is consistent, VOC free and durable. ATCO was extremely pleased to deliver such a high-performing product to the client.   

"From a supplier standpoint Climate was one of the success stories of the project," Brad says. "We are very happy to continue working with Climate and using ClimateLine."