Gypsum industry news

New Zealand: Winstone Wallboards says it will increase the supply of gypsum wallboard available for distribution by merchants by 1Mm² from July to September 2022. It said this will equate to a 7 – 8% increase of various types of plasterboard.

Fletcher Building chief executive Ross Taylor said “The increases we will be bringing to market are possible because we will soon commission changes to the configuration of our manufacturing that we have been working on over the past three months which will produce extra, locally produced, volumes. We have also been able to secure and will import additional board from an Australian manufacturer that we can feed into our supply chain.” He added that the allocation model the company has introduced had started to help supply levels and that the completion of the new plant at Tauranga in June 2023 would also help.

In early June 2022 social housing developer Simplicity Living said it had cancelled all of its orders of Fletcher Building Gib board. In an interview with Stuff, Shane Brealey - the managing director of Simplicity Living, said that the company had decided to import wallboard instead. It said it could source equivalent wallboard products at a 20% discount or more. It added that it was taking it eight weeks to import wallboard from South-East Asia compared to eight months from Auckland.

Winstone Wallboards responded to the criticism by saying it previously had been importing wallboard from Etex Australia for around six months until the end of 2021. The arrangement ended as Australia also has a wallboard shortage. However, it added that the import arrangement might restart from August 2022 onwards.

New Zealand: David Thomas, the manager of Winstone Wallboard, has reassured the local market that the company is doing as much as it can to maximise supply of its GIB plasterboard brand despite ongoing shortages. He said that the gypsum wallboard producer is operating its Auckland and Christchurch at ‘record’ levels and considering ways to bring forward the manufacture of wallboard at its new plant in Tauranga, which is currently under construction.

He also added that the company is preparing for an allocation process from July 2022 that was previously announced in February 2022. It has provided merchants with the monthly volumes of plasterboard it is forecasting to supply them from July to September 2022. The allocation model is planned as a temporary measure until the completion of the new plant at Tauranga in June 2023. He also asked for the construction sector to working together to schedule delivery of wallboard as close as possible to when it will be installed to further minimise shortages.

New Zealand: Revenue from Fletcher Building’s Building Products division rose by 9% year-on-year to US$514m in the first half to 31 December 2021 from US$471m in the same period in 2020. Earnings before interest and taxation (EBIT) fell by 6% to US$68.6m from US$64.6m. The building materials producer, distributor and construction company blamed the declining earnings on a coronavirus-related lockdown in the summer of 2021, although it noted improved performance in the following quarter. Overall group revenue and earnings grew in the reporting period.

“With improved operational performance and cost disciplines now embedded across the business, we were able to deliver a strong performance. This was despite the first quarter being heavily impacted by the up to five week-long Covid-19 stringent lockdown in New Zealand and local lockdowns in Australia which impacted EBIT,” said Fletcher Building’s chief executive officer Ross Taylor.

Fletcher Building’s subsidiary Winstone Wallboards is currently building a new 10Mm²/yr gypsum wallboard plant at Tauriko near Auckland. Commissioning is planned for the group’s 2023 financial year that starts in June 2023. Once completed the company says it will have a total national wallboard production capacity of 40Mm²/yr.

New Zealand: Winstone Wallboards has decided to move to an allocation model of supplying its GIB plasterboard products from July 2022 due to mounting lead times in manufacture. It said it would, effective immediately, not be accepting or processing new GIB plasterboard orders for July 2022 deliveries onwards. Instead it plans to assess the situation in the coming months and it anticipates moving to a process where customers order plasterboard products one month in advance.

The gypsum wallboard producer blamed the situation on significant disruption across the building industry caused by local-coronavirus-related lockdowns in August and September 2021. It said that this caused a backlog of orders. Subsequent record manufacturing output and imports were insufficient to alleviate the situation.

New Zealand: University of Canterbury (UC) student Andy (Minhong) Park has developed a biocomposite wall panel that uses seaweed or algae as a bio-filler. Preliminary testing indicates the plasterboard-style product offers similar fire performance to other commercially available products. Using seaweed also provides moisture control properties. The finished seaweed plasterboard product has a glossy marble surface, coloured green, red or brown depending on the type of seaweed used.

“Seaweed is fast-growing at 0.5m/day and is capable of sequestering around 173Mt/yr. It’s easy to cultivate and can be farmed offshore, not competing for farmable land with other bio-based materials, making it an attractive, low-cost farming commodity. Because seaweed can absorb carbon underwater, large wall-panel manufacturers could employ seaweed farming as a carbon offset by growing it,” said Park.

The 12 week project was supervised by UC Product Design Senior Lecturer Dr Tim Huber in collaboration with UC Fire Engineering Lecturer Dr Dennis Pau. While still in the early stages of research, design and testing, the team is working with the UC’s Research and Innovation team to develop a commercialisation plan, and Kaiārahi Rangahau Māori to identify suitable species of seaweed for product development and marine agriculture. The project recently won the UC Innovation Jumpstart Greatest Commercial Potential Award and a US$13,000 prize.

New Zealand: The New Zealand government has announced the lifting of Level 4 lockdown outside of Auckland. Radio New Zealand News has reported that this will enable construction to resume. Inside Auckland, gypsum wallboard is among four ‘critical products’ that the government has allowed to resume production.

The Building Industry Federation (BIF) said that the government had listened to suppliers' concerns.

New Zealand: USG Boral is preparing to stop operations in New Zealand in mid-November 2021. It said that it had been “unable to build a sustainable business,” according to the New Zealand Herald newspaper. 45 jobs will be lost due to departure. The company has offices in Auckland, Wellington and Christchurch and a distribution centre in Auckland. It imports and sells gypsum wallboard, ceiling panels, adhesives, cornices and roofing boards. Its exit will leave the local wallboard market split between manufacturer Winstone Wallboards and importer Elephant Plasterboard.

New Zealand: The New Zealand Ministry of Finance plans to launch a commission to investigate high building materials prices. The New Zealand Herald newspaper has reported that finance minister Grant Robertson said that New Zealanders pay too much for building materials. Robertson indicated that any probe would look into gypsum wallboard among other building materials. Average national building materials prices are 20 – 30% higher in New Zealand than in Australia.

Australia: Boral has updated the market on its transaction with Knauf in relation to its USG Boral joint venture. On 19 March 2020, Boral announced that its view was that the Australian Competition and Consumer Commission (ACCC) was unlikely to approve the call option in relation to the Australian and New Zealand business. In further discussions between Boral and Knauf, it has now become clear that obtaining the necessary regulatory approvals required to allow the transaction to be implemented as signed in August 2019 is not achievable by the 30 June 2020 deadline. Other conditions to the transaction also remain outstanding.

As a result, Boral and Knauf will consider a range of potential options, with Boral’s objective being to target a cash neutral transaction rather than a transaction with a significant funding requirement for Boral. Discussions are at a preliminary stage and any revised transaction remains subject to agreement between Boral and Knauf, and ultimately will also require the approval of regulators including the ACCC and New Zealand Commerce Commission (NZCC). Given this, the company’s pre-existing US$400m acquisition bridge facility, put in place for the purpose of completing the transaction with Knauf, was allowed to lapse.

Australia: Boral, already dealing with financial difficulty even before the coronavirus pandemic, has withdrawn its full-year profit guidance and warned that it will likely have to re-work its complex wallboard buyout transaction with USG / Knauf. The US$441m deal, announced in August 2019 with Knauf will likely need to be changed, after the Australasian component of it attracted the attention of the Australian Competition and Consumer Commission (ACCC).

Under the complicated deal between USG Boral and Knauf, Boral was to pay US$200m for the other 50% of USG Boral that it did not already own in Australia, and US$241m for a 50% stake of the plasterboard joint venture in Asia. Knauf then had a call option to return to 50% ownership of the Australasian business within five years.

However, the ACCC is now looming as a roadblock. "As Boral and Knauf work with regulators as part of an ongoing process to obtain the relevant approvals, Boral's view now is that the ACCC is unlikely to approve the call option in relation to the Australian and New Zealand business," said Boral in a statement. This means a range of other options will be considered for the transaction.