Gypsum industry news

US: USG has reported a deepening net loss of USD115m for the quarter ending 30 September 2011, compared to a loss of USD100m for the same period in 2010. Revenue rose 4.4% to USD792m, from USD758m in 2010.

A weak economy has been blamed for low levels of demand for the company's products. "Many of our key markets continue to experience recessionary levels of demand that are near record lows," said President and CEO James S. Metcalf.

USG's operating loss for gypsum in North America expanded to USD70m, from USD43m in 2010. It also had a USD17m operating loss for building products, compared to a USD24m loss in 2010. Its Worldwide Ceilings unit had a USD25m operating profit.

US: USG has taken ownership of about 180 acres in northwest Citrus County, Florida, to warehouse synthetic gypsum from the nearby Progress Energy power plant. Company spokesman Mark Joseph said that USG plans to store the gypsum until it is transported to company plants in North America.

USG received a trustee's deed on 14 September 2011 from the City National Bank of Florida, which owns about 400 acres near Power Line Road. According to the deed USG is the sole beneficiary of the trust.

Joseph said that the company's plans do not go further than storage of the material in warehouses at present. He added that the company has no plans at this time to manufacture drywall at the Citrus County site. "We took possession of the land to make it a storage facility," he said.

Joseph finished by saying that economic conditions require nothing more now than someplace to store and ship the material. However, he wouldn't rule out expansion, "We don't know what the future will bring... The Florida market is not the best right now for housing."

US: Beta LaserMike, a leading global provider of precision measurement and control solutions, will be giving a technical paper presentation at the upcoming 11th Global Gypsum Conference & Exhibition, which is being held on 17-18 October 2011 in Las Vegas, Nevada. The paper is entitled 'New non-contact, laser-based gauge for measuring length and speed of gypsum board' and will be given by Stuart Manser, Western District Manager for Beta LaserMike. His presentation will provide a technical overview of non-contact laser measurement and describe the advantages of these over contact-type methods for gypsum board production applications. In addition, Beta LaserMike will be demonstrating the advantages of its LaserSpeed non-contact encoder over contact-type measurement methods for gypsum board processing on exhibition stand 27.

The LaserSpeed system uses advanced, laser-based technology to precisely measure the length and speed of gypsum board during production without making contact with the product. The laser encoder projects a unique pattern on the surface of the product. As the product moves, light is scattered back to LaserSpeed. This information is translated into product speed and pulses are produced to determine the product length. Length and speed measurements are captured with better than +0.05% accuracy and 0.02% repeatability.

USA: USG has announced that its chairman, William C Foote, will retire from the company on 1 December 2011. The USG board of directors has elected James S Metcalf, USG's President and Chief Executive Officer, to the additional post of Chairman of the Board effective upon Foote's retirement.

"It has been an honour and a privilege to lead this great company for the last 15 years," said Foote. "I have great confidence in the company's leadership team and its future. I will sincerely miss the many friendships I have developed throughout the company and the industry over the years. I will always be grateful to our board of directors for their steadfast support and wise counsel."

Foote has served as USG's chairman since 1996, after having been elected chief executive officer in 1995 and president in 1994. Foote has nearly 27 years of service, having joined USG in 1984. The youngest chairman in USG's 109-year history, Foote successfully led the company through periods of rapid growth, severe economic contraction and a Chapter 11 bankruptcy related to legacy legal liabilities.

Under Foote's leadership, USG launched a large-scale modernisation of its manufacturing operations in the late 1990s that added more than 1.5Bnm² of low-cost wallboard manufacturing capacity. Foote also directed the expansion of USG's specialty distribution business, L&W Supply Corporation, which now has more than 150 locations and is the only specialty dealer of building materials with a nationwide presence.

He also helmed the firm through the company's legacy asbestos liabilities and led the company through a Chapter 11 restructuring to protect shareholders from a wave of lawsuits. In a Wall Street Journal article at the time USG emerged from bankruptcy, Warren Buffet called it, "the most successful managerial performance in bankruptcy that I've ever seen." Buffett's investment company, Berkshire Hathaway Inc., owns a 16.2% in USG.

Metcalf, who joined the company in 1980 as a trainee, was elected to the USG Board of Directors in 2008 and became chief executive officer on 1 January 2011. Foote remains chairman of the board of the Federal Reserve Bank of Chicago.

US: International Paper Co. (IP), the world's largest pulp and paper maker, has agreed to acquire Temple-Inland Inc for USD3.7bn. Temple-Inland, which is based in Austin, Texas and has four US wallboard plants, previously rejected a bid made by IP on 6 June 2011 because it was too low.

"The strategic benefits of this combination are clear and we are pleased to be able to move forward on terms that are financially attractive for both sets of shareholders," said International Paper Chief Executive Officer John Faraci in a statement.

US: United States Gypsum Corporation subsidiary L&W Supply has announced the closure of eight of its stores, citing a continued weak US housing market. It also announced that it was to wrap up its Nevada-based custom door and frames business by the end of the current quarter. The closure is expected to cost the unit somewhere in the region of USD13-15m in total.

US: Waste-to-energy projects developer Recycled Energy Development (RED) and building products maker National Gypsum Co (NGC) have jointly announced the development of a combined heat and power (CHP) project at NGC's Burlington 32MM²/yr facility in the state of New Jersey.

The project has received a USD1.36m grant from the state through its Clean Energy Solutions ARRA CHP grant programme. The CHP plant will reportedly have an electricity generation capacity of 3.4MW, representing around 210,000MMBtu of thermal energy, which will result in an overall efficiency of greater than 90%.

"The NGC project will increase industrial productivity, generate clean power and reduce CO₂ emissions," said Sean Casten, RED's president and CEO. "We appreciate the State's support and look forward to investing in New Jersey."

"CHP offers a win-win for manufacturers," said John Corsi, VP of Manufacturing Operations and Engineering of NGC. "This facility allows NGC to further strengthen our competitiveness as well as improve our environmental stewardship."

US: Eagle Materials, Inc has released its fiscal results for the first quarter (ending 30 June 2011) of the 2012 financial year. Its revenues were USD119.8m and its net earnings were USD3.1m, with earnings per diluted share of USD0.07.

In a statement Eagle said that demand for building materials and construction products remained weak and that it would continue to streamline its operations in response to these lower levels of construction activity. Revenues decreased compared to 2010, primarily due to lower sales volumes across all of Eagle's businesses sections.

Eagle's 'Gypsum Wallboard and Paperboard' section first fiscal quarter operating earnings of USD4.3m were down by 53% compared to the same quarter of 2010. The section's revenues for the first quarter totaled USD70.3m, a 9% decrease from the same quarter of 2010.

The revenue decline reflects lower sales volumes and lower average net sales prices. The average gypsum wallboard net sales price the quarter was USD90.03/MSF, 8% less than the 2010 quarter. Gypsum wallboard sales volumes for the quarter were 412MMSF, representing a 9% decline compared to the same quarter of 2010.

US: USG Corporation (USG) has reported second quarter 2011 net sales of USD761m, an operating loss of USD21m and a net loss of USD70m. For comparison in the second quarter of 2010, the corporation's operating loss was USD25m and its net loss was USD74m.

US Gypsum wallboard shipments totaled 986MMSF, down on the second quarter of 2010, which saw 1070MMSF shipped. The average selling price was also down, from USD114.17/MSF on average to USD111.55/MSF.

"We are continuing to pursue our near-term and long-term strategic priorities during the protracted recession in our domestic markets," said James Metcalf, President and CEO of USG. "By strengthening our core businesses, diversifying the sources of our earnings and aggressively leveraging our innovation leadership to differentiate USG's products from the competition, we are confident that we can successfully navigate this recession and capitalise on a recovery."

The corporation's adjusted operating loss was USD19m in the second quarter of 2011, which compares to an adjusted operating loss of USD18m in the second quarter of 2010. The adjusted operating loss for the second quarter of 2011 excludes USD2m of restructuring and long-lived asset impairment charges, while the adjusted operating loss for the second quarter of 2010 excluded USD7m.

US: On 21 June 2011 United States Gypsum Co. was assigned a patent for 'Gypsum-containing product and method for producing same.' The inventors were named as Qiang Yu, Steven W Sucech, Brent E Groza, Raymond J Mlinac, Frederick T Jones and Paul J Henkels, all from the US.

According to the abstract released by the US Patent & Trademark Office, 'The invention provides a set gypsum-containing product having increased resistance to permanent deformation and a method for preparing it comprising forming a mixture of a calcium sulphate material, water and an appropriate amount of one or more enhancing materials chosen from condensed phosphoric acids, each of which comprises two or more phosphoric acid units; and salts or ions of condensed phosphates, each of which comprises two or more phosphate units. The mixture is then maintained under conditions sufficient for the calcium sulphate material to form a set gypsum material.'