Gypsum industry news
UK: Knauf has maintained its 'Excellent' rating for BES 6001 Responsible Sourcing of its wallboard, laminated plasterboard and gypsum powder products, a rating that it has held since 2019.
The BES 6001 standard is a means of securing certification to demonstrate through independent, third-party certification, that raw materials for products certified against the scheme have been responsibly sourced and that Knauf manufactures these products in a way that minimises the impact on the environment and natural resources. Knauf said that this was a 'significant achievement,' requiring input from all areas of its business, from procurement and manufacturing activities to distribution to customers.
Japan: Chiyoda Ute has reported that it has produced 100% climate neutral and 100% recycled wallboard at its Yokkaichi factory in Mie Prefecture. The company says that, to the best of its knowledge, this is a world first. The board was produced on 1 August 2022.
Speaking about the achievement, Frederick Knauf, Chiyoda Ute’s representative managing director said “We do not know whether another manufacturer has achieved this already on an industrial scale, but it shouldn't matter who was first, as the whole industry needs to come to this point. Being second, third or 25th is the same achievement from my point of view."
CGC to build new gypsum wallboard plant in Alberta
03 August 2022Canada: USG subsidiary CGC plans to build a US$160m gypsum wallboard plant in Wheatland County, near Calgary in Alberta. The Government of Alberta and Invest Alberta Corporation will support the project with around US$3m from the Investment and Growth Fund. It is also set to benefit from local tax benefits. The new unit is expected to create over 100 new jobs once it is operational. Plant construction is scheduled to begin in 2023.
“Our customers in Western Canada have said they want a more efficient way to access our CGC wallboard products they’ve been buying for over 100 years. Shipping our products from Eastern Canadian or American manufacturing plants no longer meets their growing demand,” said Chris Griffin, President and chief executive officer of USG Corporation.
The proposed plant’s kiln will be powered using gas. Renewable electricity will be provided by an onsite solar power farm. The unit will also be the company’s first plant in Canada built with the technology to manufacture USG Sheetrock Brand EcoSmart Panels.
US-based USG became a subsidiary of Germany-based Knauf in 2019.
Uzbekistan: Germany-based Knauf has launched a new 17Mm2/yr gypsum wallboard plant at Fergana. The unit can also produce 40,000t/yr of dry building mixes. The project had an investment of just under Euro19m. It is the company’s third production plant in the country.
Knauf issues update on cyber attack
26 July 2022Germany: Knauf Group says it has made “good time in restorations” following a cyber attack in late June 2022. It said it was continuing to work on reinstating operating procedures and was on its way to achieving this. It added that many of its online systems and email were back to normal functionality and that other processes were still being restored. In separate coverage, Bleeping Computer reports that the Black Basta ransomware gang has claimed responsibility for the attack.
Philippines: Knauf Gypsum Philippines has opened its first gypsum board training centre in the country in Quezon City. The ‘Knauf Academy’ is intended to help train local construction workers, according to the Business Mirror newspaper. Mark Sergio, the managing director of Knauf Gypsum Philippines and Alexander Schmidt, Acting Deputy Head of Mission at the German Embassy, attended the opening event.
Sergio said “The intent of the training centre is two-fold: we want to make sure that we can improve the capability, the workmanship quality and skills of Filipino installers. We also want to make sure that because of this, we’re able to deliver the best customer experience for our architects, developers and contractor-partners.”
Japan: Chiyoda Ute has issued a share sales request as part of ongoing plans to form a joint-venture with Germany-based Knauf. Knauf is expected to acquire the outstanding shares. Shares in Chiyoda Ute will then be delisted in late July 2022. The move follows a tender offer from Knauf that was issued in April 2022. The eventual plan is form a joint-venture between the companies with Knauf holding a 75% share.
Knauf reports cyber attack
08 July 2022Germany: A cyber attack compromised Knauf's computer systems on 29 June 2022, leading the producer to opt for a complete services shutdown. The group said that its information technology (IT) unit successfully isolated the breach and has launched an investigation.
Knauf thanked customers for their understanding and trust. It said "We are currently working heavily to mitigate the impact to our customers and partners – as well as to plan a safe recovery. However, we apologise for any inconvenience or delays in our delivery processes that may occur."
UK: Portugal-based Gypfor has agreed to sell its upcoming Newport gypsum wallboard plant to Germany-based Knauf. Gypfor began building the plant at Associated British Ports’ Port of Newport in March 2021. Knauf estimates that it will commission it later in 2022, and commence full operations in 2023. The plant will be equipped with solar and wind power plants, as well as on-site gypsum wallboard recycling facilities. 54 people will be employed in gypsum wallboard production at the site. Knauf says that the addition of the new plant to its existing facilities at Immingham, Lincolnshire, and Sittingbourne, Kent, will enlarge its UK capacity by 20%.
Knauf’s UK managing director Ian Stokes said “This new plant will significantly increase our ability to service customers throughout the UK, and particularly those in South Wales, the Midlands and the South-West of England. It is a very exciting move for Knauf and, following recent investment in increasing the capacity of Knauf Insulation, reflects the confidence of the Knauf Group in the UK construction sector.”
Eurogypsum at 60: The door is open
16 June 2022Members of Eurogypsum, the European Gypsum Association, gathered at the Les Atelier des Tanneurs in Brussels on 27 - 28 April 2022 to formally celebrate the 60th Anniversary of their association, despite a delay of 12 months due to Covid restrictions. Over two days, they participated in meetings and panel sessions reminiscent of pre-pandemic times. Attending the Open Congress session on 28 April 2022, Global Gypsum found the event to be very dynamic and surprisingly open.
The Open Congress began with welcomes from the moderator, Knauf Insulation’s Sian Hughes and outgoing Eurogypsum President Emmanuel Normant, of Saint-Gobain. He introduced the past 60 years as one of ‘enormous change’ for the sector, but this was not meant to be a retrospective. Turning to the next 60 years, Normant said that gypsum’s inherent benefits, including its low embodied CO2 emissions, recyclability, high degree of safety and ease of use, would make it even more crucial to global development in the future than in the past.
A series of quick-fire presentations from the industry’s big hitters then highlighted a wide range of ways to increase the sustainability of our sector.
Saint-Gobain’s Klaus Birk introduced Gyproc's project to switch its Fredrikstad wallboard plant in Norway to use a 100% electric wallboard production process by 2023. This will use renewable energy, predominantly sourced from hydroelectric power, and lead to a 70% drop in CO2 emissions. This approach could be applicable to any wallboard plant with access to sufficient renewable power.
Knauf's Jörg Demmich then spoke about a project to extract gypsum from the ‘waste’ from the lithium production process. Even the best lithium ores only contain 3 - 6% lithium by mass, leaving 94 - 97% currently unused. As electric mobility grows, by-product gypsum from the lithium sector could partly offset the expected fall in flue-gas desulphurisation (FGD) gypsum supplies.
Iryna Yermakova introduced the Etex Group's approach to the wallboard plant of the future. One area she highlighted was the potential for prefabrication at the wallboard plant before panels reach the job site. This has the potential, on some projects, to save up to 10% of the wallboard cost, transport cost and CO2 emissions of the board used. Surely a quick win for contractors.
Nikolai Halle from Cobuilder introduced the Define tool, freely-available to the construction sector. Define will act like the Swift payment system, but for sustainability data instead of financial data. This would unify different sustainability metrics to cut through the confusing terms used by producers and reveal the 'real' performance of different products, rather than how effectively their attributes are marketed.
The keynote presentation, from the former European Commissioner for the Environment Janez Potočnik – ‘The Father of the Circular Economy’ - then highlighted why innovation is key, not only to the future of the gypsum sector, but to the planet itself. At current rates, the mass of man-made material will be three times larger than all biomass by 2040.
To avoid this, Potočnik argued that the entire economy needs to become service-based, rather than product-based. Under such a model, wallboard producers would become part of the ‘building envelope services sector’ rather than selling wallboard. The desire is then to sell wallboard with a long service life, that can be repurposed and recycled, rather than selling ever-increasing volumes of board.Taking this approach across the entire economy would help society to maximise gross domestic product while reducing environmental impacts, eventually decoupling them from each other entirely. Potočnik concluded that nature is already the 'perfect' circular economy. Humans just need to reintegrate into it.
To say that the panel discussion that followed was ‘lively’ would be an understatement. Member of the European Parliament Iskra Mihaylova, speaking the day after Russia halted gas supplies to her native Bulgaria, said that talk of energy independence and solidarity was 'not enough' and that Europe needed to act on the European Union Green Deal, particularly with a view to energy and resource efficiency and security.
Josefina Lindblom, the European Commission’s Policy Officer for Sustainable Buildings for Circular Economy, introduced what she hoped would become the next buzzword: ‘sufficiency’ - properly taking pause to consider what is truly required of new buildings. This includes the need to apply full circularity to renovation projects.
Adrian Joyce, from the European Alliance of Companies for Energy Efficiency in Buildings, asked the audience to think not in terms of 'energy efficiency,' but 'conservation of energy.' The two terms are subtly different, with the latter akin to ‘sufficiency.' Both point to the need to reduce the use of resources, not just the effectiveness which we use increasing amounts of resources.
Tristan Suffys, Secretary General of Eurogypsum, said that gypsum is well suited to fit into the low-CO2, low-resource-use sector of the future. He called for re-use of derelict buildings, re-purposing and optimising the use of space by building above existing buildings.
The Open Congress drew to a close with a speech by the incoming President of Eurogypsum (and Head of Corporate Social Responsibility at Etex) Jörg Ertle. He told Eurogypsum members that the 'doors' marked 'Green Deal,' 'Decarbonisation,' and 'Recycling' were all 'open' and that they should be making the most of the opportunities behind each. From Global Gypsum’s perspective, it seems that they have burst through each of the doors into the rooms behind. Some are even measuring up for wallboard.
In conclusion, it appears that the European wallboard sector is at the start of a major increase in sustainability efforts. This will be backed by politicians who are keen to decouple their economies from Russia’s and a public that is increasingly asking for change. And, with three major global producers - Knauf, Saint-Gobain and Etex - based in Europe, between them sharing 47% of the world’s wallboard capacity, we can expect to see these innovations spread to other regions rapidly.
Here’s to the next 60 years!