Gypsum industry news
IMARC Group forecasts 2.6% composite annual growth rate in North American gypsum market up to 2023
11 March 2024North America: Market research company IMARC Group has quantified the North American gypsum wallboard market at 2.9Bnm2 in 2023. In a report detailing the outlook for the nine years up to 2032, IMARC Group forecast a composite annual growth rate (CAGR) of 2.6%, resulting in sales volumes of 3.6Bnm2 in 2032.
US gypsum wallboard consumption falls slightly in 2023
01 February 2024US: National consumption of gypsum wallboard dropped by 4.3% year-on-year to 2.51Mm2 in 2023, according to United States Geological Survey (USGS) data. Demand for natural gypsum was 45Mt, up by 3% from 43.7Mt in 2022. The market imported 8.1Mt of gypsum throughout the year, up by 18% year-on-year.
Domestic production of crude gypsum in the US dropped by 1.3% year-on-year in 2023, to 22Mt. Exports grew by 15% to 45,000t.
US: Eagle Materials recorded sales of US$1.78bn in the first nine months of the 2024 financial year. This corresponds to a rise of 6.2% year-on-year from the corresponding period of the 2023 financial year. The producer’s light materials sales fell by 4.6% to US$703m, and its gypsum wallboard sales volumes fell by 4% to 206Mm2. The group raised its net earnings by 11% to US$401m.
Georgia-Pacific invests US$2bn in 2023
21 December 2023US: Georgia-Pacific made total investments worth US$2bn throughout 2023. Major capital expenditure (CAPEX) investments include its US$325m construction of its second Sweetwater gypsum wallboard plant in Texas.
Georgia-Pacific Gypsum president David Neal said "Georgia-Pacific is keenly focused on the future and committed to innovation and meeting the needs of our customers. The two [Sweetwater gypsum wallboard plant] operations combined will supply customers and distribution partners with more than 93Mm2/yr of gypsum wallboard 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."
US Geological Survey records slight drop in natural gypsum production in first nine months of 2023
14 December 2023US: The US Geological Survey reported domestic natural gypsum production volumes of 16.3Mt during the first nine months of 2023, down by 0.3% year-on-year from 16.4Mt during the corresponding part of 2022. Meanwhile, calcined gypsum production volumes grew by 1.2%, to 14Mt from 13.8Mt. Throughout the period, the US imported 5.91Mt of crude gypsum, up by 35% year-on-year. Spain supplied 2.4Mt (41%) of imports, followed by Mexico with 1.7Mt (29 %) and Canada with 1.56Mt (26%).
Time for new gypsum wallboard plants in the US
26 October 2023Georgia-Pacific officially opened its new gypsum wallboard plant at Sweetwater in Texas earlier this month. The US$325m project is situated next to the company’s existing plant at the site, Sweetwater West, on the other side of a road. Canada-based Gyptech said in 2021 that it was supplying the equipment for the new high-speed line at the site.
When Georgia-Pacific first announced the new project in 2020, it mentioned that it would be able to keep its logistics costs low, use raw gypsum reserves and the existing workforce. Despite this, the plant has still created over 100 new jobs. The company also said that it anticipated closing its 60Mm2/yr Quanah plant, also in Texas, depending upon market conditions. This came to pass in March 2023. Altogether, both plants at Sweetwater will have a production capacity of around 93Mm2/yr. This implies that the new plant has a production capacity of around 60Mm2/yr, given that the existing plant’s capacity is 30Mm2/yr. Funnily enough this is the same as the Quanah plant.
The new plant at Sweetwater may be a sign that the US wallboard market is picking up again. Georgia-Pacific has invested some serious money and it is targeting Texas, a leading area for construction nationally. However, it does come with a few caveats. Firstly, the new plant at Sweetwater is replacing existing capacity at Quanah. Secondly, it is using some of the advantages of the existing plant such as its trucks and its proximity to its customers. This suggests that the company may be wary of building a new plant in a greenfield location with all the potential risks that might involve.
US wallboard sales have regularly peaked and troughed over the decades, like many other commodity markets, as demand and production capacity race each other. Sales of wallboard peaked around the year 2000 and then again in the mid 2000s before tailing off following the 2007 recession. They have been recovering ever since and started to get close to the levels seen in the first half of the 2000s in 2022 when the United States Geological Survey (USGS) reported wallboard sales of 2.6Bnm2.
Generally, the last tranche of new wallboard plants in the US were built or approved in the late 2000s before the financial downturn. These new sites included CertainTeed’s Roxboro plant in North Carolina and the Moundsville plant in West Virginia, Gold Bond Building Products’ Mount Holly plant in North Carolina and American Gypsum’s Georgetown plant in South Carolina. From this point though various plants were either closed or mothballed. Some of the latter have been restarted as the market slowly recovered. New plant projects in the 2010s tended to be upgrades or replacements. One example of this was USG’s plan to rebuild a production line at its Jacksonville plant in Florida, which was announced in late 2017 before Knauf took over the company in 2018. Another was National Gypsum’s scheme to reopen its Wilmington plant in North Carolina in 2019. At the same time in the 2010s there were a number of mergers and acquisitions including Lafarge’s sale of its gypsum business in North America in 2013, Knauf’s takeover of USG in 2019 and Saint-Gobain’s acquisition of Continental Building Products in 2020.
When Georgia-Pacific started building the new plant at Sweetwater in 2020 this marked the start of a new phase of US wallboard plant projects. American Gypsum announced plans for an upgrade to its Albuquerque gypsum wallboard plant in 2021, Gold Bond Building Products started building its long-delayed Eloy plant in Arizona in 2022 and it said it was spending US$90m on an upgrade to its Mount Holly gypsum wallboard plant in North Carolina in 2023, and CertainTeed revealed it wanted to build a second production line at its Palatka gypsum wallboard plant in Florida also in 2023.
Congratulations are due to Georgia-Pacific for the achievement at Sweetwater. Optimism for the US market in general may also be in order given the slow but steady stream of projects that have been announced and completed since 2020. The next step, when a company builds a new wallboard plant at a greenfield site in the US, looks set to happen when Gold Bond Building Products completes its Eloy plant.
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."
Beneficial Reuse Management acquires USA Gypsum
16 October 2023US: 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.
Saint-Gobain buys remaining share of Seven Hills Paperboard
11 October 2023US: 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.”