Gypsum industry news

US: Eagle Materials sold 139Mm² of gypsum wallboard during the first half of its 2024 financial year (1 April 2023 – 30 September 2023), a decrease of 5% year-on-year from 147Mm² in the same period in the 2023 financial year. This contributed sales worth US$428m, down by 2.9% and corresponding to 35% of total group sales. Overall, group revenue rose by 4.9% to US$1.22bn.

President and chief executive officer Michael Haack said "Market conditions for our construction materials remained resilient during the quarter, even as the Federal Reserve continued to raise interest rates and tighten money supply to contain inflation. Several factors helped offset the higher rates and supported demand for wallboard, including limited housing supply, strong homebuyer demand, increasing infrastructure awards and significant investment in domestic manufacturing facilities.” Haack added “the backlog of housing construction supported resilient wallboard shipments and orders, but we recognise the significant increase in interest rates may have an impact on residential construction activity in the future. Nonetheless, we expect that our portfolio of businesses will remain well-positioned for the second half of fiscal 2024."

US: Beneficial Reuse Management (BRM) has acquired Pennsylvania-based gypsum wallboard recycling firm USA Gypsum (USAG).

BRM board chair Dave Schuurman said “The acquisition of USAG gives BRM an opportunity to further diversify our sources of gypsum to include recycled scrap wallboard, as well as to grow our geographic footprint. USAG’s operations will complement our existing gypsum processing operations, which provide gypsum in pelletised form to agricultural and other markets. This acquisition aligns perfectly with our mission of providing sustainable solutions for the management of industrial byproducts to divert materials away from landfills.”

US: Georgia-Pacific has officially opened its new gypsum wallboard plant at Sweetwater in Texas. The project had a budget of US$325m and it is the first new wallboard plant that Georgia-Pacific has built since 2004.

David Neal, president of Georgia-Pacific Gypsum said “The two operations combined will supply customers and distribution partners with more than 92Mm² of gypsum products each year and create more than 100 new jobs. This investment strengthens Georgia-Pacific's capacity to meet growing customer needs in Texas' residential, commercial, and industrial construction markets.”

The new plant is adjacent to Georgia-Pacific’s first gypsum wallboard facility in Sweetwater, purchased by the company in 1996. The existing facility has been operating in Nolan County since the 1950s. Over the last year, Georgia-Pacific has invested approximately US$16m in technical and safety upgrades at the plant, including an Energy Optimization System (EOS), auto-guided vehicles (AGVs), an automated robotic riser system, auto-splicing equipment, and upgraded packaging equipment. It has also upgraded the employee facilities.

US: Saint-Gobain has acquired the remaining equity interest and assets of Seven Hills Paperboard, including a gypsum paper board liner manufacturing plant in Lynchburg, Virginia, from its joint venture partner WestRock. The purchase adds to the gypsum wallboard operations of Saint-Gobain’s CertainTeed Interior Products Group. The company said that the internal integration of gypsum paper board liner production represented a “significant” step in strengthening the supply chain for this material.

Mark Rayfield, President and Chief Executive Officer of Saint-Gobain North America and CertainTeed Canada said “The acquisition of these assets represents our continued commitment to our customers to provide quality gypsum wallboard products.” He added, “I would like to welcome our 80 new team members in Lynchburg and look forward to your contributions to our purpose, ‘To Make the World a Better Home.”

Canada/US: Saint-Gobain has signed a 15-year renewable electricity supply agreement (PPA) with TotalEnergies for the purchase of solar power for its 125 industrial sites in the US and Canada. This 100MW PPA, known as the Danish Fields Solar Project (Danish Fields), is expected to offset Saint-Gobain’s North American CO₂ emissions from electricity (scope 2 emissions) by 90,000t/yr. The project is expected to come online by the end of 2024.

Danish Fields is the third PPA signed in North America by Saint-Gobain. The first PPA, with the Blooming Grove Wind Farm in Illinois, was signed in 2020, and the second, with TotalEnergies’ Cottonwood Bayou Solar Project in Texas, was signed in 2022. All three projects have been supported by Edison Energy, a leading energy and sustainability advisory that consults with the largest commercial, industrial and institutional energy users.

Mark Rayfield, the chief executive officer of Saint-Gobain North America, 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.”

The three projects combined are expected to represent a reduction of more than 70% in Saint-Gobain North America’s scope 2 emissions, compared to 2017 levels.

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.”

US: Two members of GMS’ board of directors, Peter Browning and Teri McClure, have won national awards for corporate leadership. Browning won the National Association of Corporate Directors’ Lifetime Achievement Award, which recognises commitment to the improvement of corporate governance. Meanwhile, McClure won DirectWomen’s Board Excellence Award for women lawyers who have served with distinction.

GMS chair John Gavin said "On behalf of the entire board of directors of GMS, I congratulate Peter and Teri for these well-deserved honours. It is gratifying to see that organisations like these recognise the incredible talent that we on the board get to experience every day. The selections of Peter and Teri for these important distinctions speak not only to this level of talent but also underscore our commitment to the highest level of corporate governance standards and promoting diversity and corporate governance principles. We are fortunate to have directors of such high calibre serving on our Board and benefit from their extensive knowledge and experience."

US: Xeriant has hired the National Fire Protection Association (NFPA) and another accreditation agency to test its NEXBOARD waste plastic-based wallboard for the construction market. The producer says that tests will include the NFPA 286 and the ASTM E84 fire safety tests, as well as tests of tensile strength, hardness, water resistance, acoustic and thermal insulating performance, and volatile organic compound emissions.

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.

US: GMS’ net sales grew by 4% year-on-year to US$1.41bn in the quarter to 31 July 2023 from US$1.40bn in the same period in 2022. Sales of wallboard increased by 10% to US$571m from US$522m. However, the company’s earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 2% to US$165m from US$169m.

John C. Turner, Jr, president and chief executive officer of GMS, said “We were pleased to deliver a solid start to fiscal 2024 with first quarter results that were in line with our expectations, continuing to demonstrate the resilience of pricing in wallboard, ceilings and complementary products, as well as the strength and stability that our balanced end markets provide.”