Gypsum industry news

Australia: Saint-Gobain subsidiary CSR plans to expand its Welshpool gypsum wallboard plant in Western Australia. The producer plans to upgrade the plant’s production line and expand warehouses that serve it and the neighbouring Bradford building materials plant. CSR said that the upgrade to the Welshpool wallboard plant will reduce its consumption of natural gas and electricity and facilitate its transition to alternative fuels or electricity.

CEO Paul Dalton said "This significant investment will make Welshpool safer and more sustainable, increase capacity and improve productivity and cost efficiency, all while removing risk from our supply chain.”

US: The Oregon Department of Environmental Quality is receiving public comment on its revised 2021 Climate Protection Program, under which natural gas users, including gypsum wallboard producers, will face tighter emissions regulations. The programme will enable plants to buy credits for emissions above regulation level, with the money raised primarily going to fund community-based projects. Local press has reported that the revised rules aim to help realise a 50% reduction in CO₂ emissions by 2035 and a 90% reduction by 2050. The latest revision also shortens companies’ compliance period from three years to two.

Germany: Chemicals company BASF's sales fell by 19% year-on-year to €37.3bn in the first half of the 2024 financial year (FY2024). Its earnings before interest, taxation, depreciation and amortisation (EBITDA) declined by 34% to €4.72bn. As a result, the company now anticipates full-year sales of €73 – 76bn in FY2024, down from the previously forecast €84 – 87bn. It revised its earnings forecast to €4 – 4.4bn, from €4.8 – €5.4bn previously. At the same time, it increased its anticipated reduction in CO₂ emissions for the year. It now expects to generate 17 – 17.6Mt of CO₂ from its operations, down from its previously forecast 18.1 – 19.1Mt.

Belgium: Etex says that it ‘considerably’ progressed its Road to Sustainability 2030 plan during 2023. That year, safety intensity increased by 7%, and Etex established a global diversity, equity and inclusion ambassador community of 110 volunteers across 26 countries. In Europe, the company achieved 70% Environmental Product Declaration coverage as a percentage of its turnover, up from 58% in 2022. Etex raised its total use of recycled materials to 7.6%, and achieved a 23% reduction in Scopes 1 and 2 CO₂ compared to 2018 levels, in line with its 2030 target of 35%.

CEO Bernard Delvaux said “In the EU, more than 40% of energy consumed is used in buildings and more than 30% of energy-related greenhouse gasses emissions come from buildings. Next to new building activities, and according to current high energy standards, renovating old building stock should hence be a top priority. With our portfolio of building materials such as glass wool and extruded polystyrene insulation, gypsum wallboard, fibre cement boards and fire protection materials, Etex has the solutions to reach the ambitious targets. But in view of the huge challenge, a holistic and effective plan to boost renovation is needed, to finance and simplify the renovation process, in each of the EU countries.”

UK: Adaptavate has inaugurated its first pilot line to produce Breathaboard bio-based alternative wallboard. Breathaboard performs in the same way as ordinary gypsum wallboard, but sequesters and avoids additional CO₂ emissions, reducing the board’s total carbon footprint by 4kg/m². Adaptavate's production process uses fibrous and cellulosic by-products from agricultural crops, combined with minerals. It has a minimal water footprint and does not require natural gas.

Chief technical officer Jeff Ive said "The commissioning of our pilot line is the culmination of a year's hard work. We knew the solution had to be scalable for significant impact. With full-size boards produced on a continuously extruded process, we’re turning our vision into reality. This pilot line is a game changer for us, our industry, and the planet, laying the foundation for global replication of our core innovation."

Italy: Saint-Gobain has entered into a 10-year power purchase agreement (PPA) with Switzerland-based utilities provider Axpo Holding. Under the agreement, Axpo Holding will supply 22GWh/yr of renewable electricity from a newly built wind farm in Puglia. The deal will fulfil 11% of Saint-Gobain's Italian energy needs across 10 sites.

The latest PPA with Axpo Italia is Saint-Gobain's fifth in Italy. Collectively, these will bring the group’s reliance on renewables in its Italian operations to 20%.

Canada: CertainTeed Canada has begun upgrading its Montréal gypsum wallboard plant to convert the plant to net zero Scope 1 and 2 CO₂ emissions. The producer says that the plant will become the first net-zero facility of its kind in North America.

Europe/US: Tristan Suffys, secretary general of Eurogypsum, the European gypsum association, presented the association’s net zero roadmap at the Global Gypsum Conference 2023 in Chicago, US, on 9 November 2023. Live and online audiences heard Eurogypsum’s full life cycle-based carbon footprint analysis, according to which European gypsum wallboard currently generates CO₂ emissions of 2kg/m², 14% lower than 2008 levels. On its pathway to net zero by a deadline of 2050, Eurogypsum plans to reduce wallboard’s CO₂ emissions from raw materials by 13%, from transport by 12%, from production by 69% and from end-of-life processes by 6%.

Suffys said “Presenting our roadmap today in Chicago is a clear signal that global warming requires global action. We want to engage with other regional actors along the way to climate neutrality.”

Eurogypsum president Jörg Ertle added “We are committed to making this transition a reality. First examples show that we can move towards net-zero emission production if we have access to low-carbon energy at affordable costs and optimal raw material supply, but this will require significant investment from our sector.”

North America: Saint-Gobain has signed a 100MW solar power purchase agreement (PPA), called Danish Fields, with TotalEnergies. The Danish Fields PPA will supply Saint-Gobain North America with solar energy for 15 years, commencing in 2024. Saint-Gobain says that it expects the PPA to eliminate 90,000t/yr of CO₂ emissions across its operations. This is the group’s third deal of its kind.

Saint-Gobain North America CEO Mark Rayfield said “With this agreement, Saint-Gobain North America will further reduce its CO₂ emissions, demonstrating how fast the manufacturing industry can transform when long term solutions are at hand. This renewable energy project is a new milestone on the way to meeting Saint-Gobain’s commitment to reduce Scope 1 and 2 CO₂ emissions by 33% by 2030 compared to 2017, and to reach carbon neutrality by 2050.”

One can tell that gypsum wallboard is a popular product because companies keep trying to devise alternatives to it. A recent one is Breathaboard. The company making it, Adaptavate, announced in August 2023 that it had generated around Euro2.3m in its latest investment round. It is building a pilot production line in Bristol in the UK and attempting to licence its Breathaboard product, amongst other plans. Its take on wallboard is being marketed as a sustainable substitute that is made from crop waste, that sequesters CO₂ and that then can be composted at the end of its life. It is also promoting the product’s breathability and moisture buffering capabilities, hence the name.

Another new contender hoping to steal some of the gypsum wallboard market is Xeriant’s Nexaboard product. This one uses plastic waste as its alternative to gypsum. Florida-based Xeriant said in July 2023 that it had started to buy equipment and raw materials, was running pilot production and was testing its first samples. It too is working on getting its product used in pilot construction projects.

Both of these examples, and others over the years, have taken a pop at wallboard’s sustainability credentials. Adaptavate is rather quieter about what happens to all of that sequestered CO₂ when its product is composted and Xeriant does not mention the environmental impact of making the plastic it uses in the first place. Yet, it is a valid question to ask how sustainable is gypsum wallboard? This column has covered issues with the supply of raw gypsum from either natural, synthetic or recycled sources previously, so we will stick to the general picture here.

The late-lamented consultant Bob Bruce pulled together data from various studies for the Global Gypsum Conference in 2019 to estimate the CO₂ emissions from wallboard production. He estimated that the global average of CO₂ production by wallboard was around 2.4kg/m², equating to 24Mt/yr of CO₂ for the global wallboard industry. For reference, it is estimated by the Center for International Climate and Environmental Research - Oslo (CICERO) that the process emissions from clinker production alone released around 1.6Gt/yr of CO₂ in 2022. When compared by mass (as opposed to area) to other building materials, wallboard has a lower carbon intensity than many products such as glass, cement (made from clinker), plastics, steel and plywood. Timber, concrete and brick are all better than wallboard though. However, as Bruce pointed out, a lot more concrete is manufactured than wallboard. Bruce came up with a handful of suggestions for how wallboard production could reduce its CO₂ emissions such as the reduction of slurry water, local delivery, co-generation, increasing drying efficiency and so on.

The two big sustainability trends from the sector over the last year have been the drive to support higher recycling rates of gypsum and a move towards ‘greener’ sources of energy. This can be seen in the growing use of electrical energy from renewable sources such as the production of net zero CO₂ gypsum wallboard at Saint-Gobain’s Fredrikstad plant in Norway from April 2023. The group’s Montreal plant looks set to follow in 2024 following an upgrade, potentially making it the first net zero wallboard plant in North America. Chiyoda-Ute in Japan has also started using renewably-sourced electricity at its plants in Japan, but it is uncertain what other energy sources these sites are using. China-based BNBM also claimed in its half-year results that it had built four “nearly zero emission” gypsum board production lines in the reporting period.

Wallboard's market position in North America, Europe and elsewhere seems secure. However, it is in dynamic tension as it is both a potential replacement for more carbon intensive building materials and it could also be susceptible to new emerging products that can improve on its own emissions. The manufacturers of Breathaboard and Nexaboard are clearly hoping for the latter. Yet, as is often pointed out, giving more market share to wallboard from other common building materials could reduce CO₂ emissions from construction massively. The diversification of traditional heavy building materials companies such as Holcim into light building materials in recent years suggests that some businesses are seriously preparing for this possibility. No doubt, if global wallboard usage does start to rise significantly, the pressure will grow to make wallboard more sustainable and to devise even more alternative board products.