Gypsum industry news

Canada: Saint-Gobain plans to carry out a US$70.9m upgrade and 40% capacity expansion of its 30Mm²/yr Montreal gypsum wallboard plant in Quebec. The project includes the replacement of natural gas with renewable electricity and a 30% reduction in energy consumption through efficiency improvements. As a result, it will turn the facility into North America’s first zero-carbon gypsum wallboard plant. Work will commence in mid-2023, with the commissioning of the upgraded plant following in late 2024.

Saint-Gobain’s vice president environmental, social, governance (ESG) North America and managing director, circular economy solutions Dennis Wilson said "Today we begin a historic new chapter at our Montreal gypsum plant, leading our industry towards a more sustainable future while increasing our production capacity at a time of unprecedented customer demand," said. "We thank our partners in the Quebec Government, the City of Saint-Catherine and Hydro-Québec for their support, and we thank our team for pushing the limits of technology and imagination to bring this bold project to life. The electrification of our Montreal plant is a massive step forward in our broader goal to decarbonise construction materials and a significant step towards our global goal of carbon neutrality by 2050."

US: CertainTeed has completed a US$1.3m upgrade to its Nashville wallboard plant in Arkansas to use recycled waste gypsum and paper. The plant will reuse 65,000t/yr of waste materials generated from the production process. The company plans to increase the amount of recycled materials in its gypsum wallboard in the future.

“In Nashville and at our manufacturing sites around the world, we remain laser-focused on reducing waste, reducing our consumption of natural resources, and increasing recycling and circularity throughout our value chain,” said Jay Bachmann, Vice President and General Manager of CertainTeed Gypsum.

UK: The Competition and Markets Authority (CMA) is considering whether the proposed acquisition by Saint-Gobain of GCP Applied Technologies could result in the creation of a relevant merger situation or lessen market competition generally. It has asked any interested party to comment on the transaction by mid-June 2022.

Saint-Gobain said it had agreed to buy construction chemicals producer GCP Applied Technologies for Euro2bn in late 2021 with a conclusion date to the transaction by the end of 2022.

Canada/US: Saint-Gobain has acquired exterior building materials company Kaycan for US$928m. After the closing of the transaction in 2022, Kaycan’s US distribution arm will undergo divestiture to a third party. Kaycan currently employs 1300 people at 12 sites in Canada and the US. Saint-Gobain noted that the acquisition will complement its leadership in Canada, expanding its light and sustainable construction solutions offering in that market.

Portugal: Saint-Gobain has acquired Fibroplac, which operates the 10Mm²/yr Pombal gypsum wallboard plant in Central Portugal. Saint-Gobain already operates 10 plants, in addition to a research and development centre, in Portugal. Additionally, the France-based group acquired steel structures producer Falper.

The group said that the acquisitions align with its Grow & Impact strategy, which it says is being successfully implemented in Portugal."

France: Saint-Gobain says that it is confident it can offset inflation in raw material and energy costs in 2022 through price rises and hedging its energy costs. In an update on its first quarter results the group said that it expects its energy and raw material costs to increase by around Euro2.5bn in 2022 as a whole compared to 2021. Much of this inflation is related to the European market where the company says it has hedged around 80% of its natural gas and electricity purchases for 2022. It noted that it increased its prices and sales volumes by 14.5% and 1.9% year-on-year respectively in the first quarter of 2022.

The company added it had prepared contingency plans in Germany, Poland and the Czech Republic should there be any disruptions to natural gas supplies from Russia. These include the classification of priority industries, using alternative energy sources already prepared at certain sites, and increasing the flexibility of its production capacities.

Saint-Gobain’s sales rose by 16% year-on-year to Euro10.4bn in the first quarter of 2022 from Euro12bn in the same period in 2021. The group said growth was driven by building renovation in Europe and by construction in the Americas and in Asia.

Turkey: France-based Saint-Gobain and building materials producer Dalsan have signed a joint-venture agreement, pursuant to which they will merge their gypsum wallboard operations in Turkey. The merge will give the new joint venture a gypsum wallboard production capacity of over 100Mm²/yr. It will also see the companies’ plaster production consolidated under their new subsidiary.

The partners said “This partnership will offer Turkish customers access to the most innovative and complete portfolio of light and sustainable solutions for the construction and renovation of the building envelope, as well as internal partitioning.”

France: Placo and Serfim Recyclage have revealed that they started operating a new 140t/day plaster recycling plant at Quincy-Voisins near Paris in October 2021. The companies say that the Pari Plâtre site is the first in the Paris region to be solely used for recycling plaster waste from construction sites.

Daily deliveries via the Placo Recycling network bring plaster waste from within a 250km radius to the site. The waste is then sorted by hand along an 80m production line to remove wood, ceramic, cardboard and polystyrene fractions. These materials are recycled separately. The plaster is crushed and screened with a 98% recovery rate. The plant stores reclaimed gypsum in two 80m³ silos. The gypsum is then transported to Placo’s gypsum wallboard plant at Vaujours for use as a secondary raw material.

Placo says it is the leading recycler of gypsum in France. Following the opening of Pari Plâtre the company has increased its plaster recycling target in 2030 target to 200,000t/yr. This will allow the subsidiary of Saint-Gobain to use up to 30% of recycled materials in the production of its wallboard products.

Canada: Saint-Gobain has shared plans to install a US$3.19m waste heat recovery (WHR) system at its Vancouver gypsum wallboard plant in British Columbia. It has secured US$1.12m in funding from the provincial government’s CleanBC Industry Fund for the project. The producer says that the installation will increase the plant’s energy efficiency and reduce its CO₂ emission by 10%.

Saint-Gobain said “This project will help our company to maximise our positive impact for our customers and the communities where we do business, while minimising our environmental footprint. We thank the CleanBC programme for its support, and look forward to many more years of sustainable, state-of-the-art manufacturing in Vancouver.”

Canada/US: Saint-Gobain North America and its subsidiary CertainTeed say they have reduced their CO₂ emissions from electricity usage by about a third in 2021 through the use of renewable energy contracts. In February 2020, Saint-Gobain entered into a 12-year virtual power purchase agreement with the Blooming Grove Wind Farm in McLean County, Illinois. At the time, the agreement was the largest renewable energy deal in Saint-Gobain’s 356-year history. Saint-Gobain worked with Edison Energy, an industrial energy advisor, on the arrangement.

“We’re thrilled with the results of our partnership with the Blooming Grove Wind Farm, and will continue to look for ways to maximise our positive impact, for our customers and the communities where we do business, while minimising our environmental footprint,” said Mark Rayfield, the chief executive officer of Saint-Gobain North America and CertainTeed. “In this next chapter of our company’s history, our team will strive to lead our industry towards a more sustainable future.”