Gypsum industry news

Winstone Wallboards has been in the spotlight in recent months over ongoing supply issues of gypsum wallboard in New Zealand. Many places around the world have suffered from similar shortages of building materials following the coronavirus lockdowns. However, the shortages in New Zealand have started to generate a considerable response, as we detail below.

Rightly or wrongly, Winstone Wallboards’ dominance in the market locally has been perceived as part of the problem. It operates the country’s only two wallboard plants and it is frequently reported to hold around a 95% share of the market. It is also currently building a new 10Mm²/yr gypsum wallboard plant at Tauriko near Auckland. Commissioning is planned for mid-2023. Once completed the company will have a total national wallboard production capacity of around 40Mm²/yr.

The current problems date back to the start of the coronavirus pandemic when New Zealand started implementing its lockdowns and residential renovation work increased. The issue then gained prominence in September 2021 when Winstone Wallboards started issuing regular supply updates on its website as the government began to relax the lockdown at that time. It says that order volumes more than doubled from November 2021 to February 2022 as customers started to bring forward their orders to cope with general building material shortages. It coped for a while by using its inventory stock and by bringing in imports from Australia but the latter stopped in November 2021 due to shortages there also. So it proposed introducing an allocation model from July 2022 whereby customers could place orders no more than one month in advance. It then says it worked on increased output through plant and process upgrades with the installation of a heat exchange system for its Auckland plant planned for July 2022 and by securing further imports from an Australian producer for the second half of 2022. As of late June 2022 it expected the market to return to equilibrium by October 2022.

Unfortunately, some consumers have been vocal about their unhappiness with the supply situation. Rental property developer Simplicity Living took to the press to complain about the delays in June 2022. It added that it had started importing its own wallboard from Thailand instead. The story then became nastier when Simplicity Living alleged that Winstone Wallboards’s parent company, Australia-based Fletcher Building, was blocking imports of certain colours of wallboard. Fletcher Building clarified in the same article that it had trademarked “specific” shades of blue, green, mauve and pink to differentiate its products in the marketplace. This, of course, will be familiar to insulation sector readers of Global Gypsum as Owens Corning is arguably the world’s most famous and successful example of how to copyright a colour. It’s unclear how much of an impediment Fletcher Building’s colour trademarks have been to imports to New Zealand. The company did say in an investor presentation in late June 2022 that it had granted 10 trademark royalty-free licenses so far to allow other companies to import wallboard. To give readers an idea of the amount of attention being focused on Winstone Wallboards and its connected companies, when a shipment of wallboard was delivered early to a construction subsidiary of Fletcher Building, apparently breaking the company’s own supply rules, a video of the incident started circulating on social media before being picked up by national news channels.

Government oversight then stepped up a notch in late June 2022 with the formation of a ministerial taskforce to tackle the wallboard shortage. It plans to troubleshoot the regulation of alternative plasterboard products, look at ways to streamline the use of products that are currently untested in the New Zealand market, provide advice on building consent and explore new distribution models, amongst other goals. Alongside all of this, the New Zealand Commerce Commission started a market study into residential building supplies in November 2021. Its aim is to look into any factors that may affect competition for the supply or acquisition of key building supplies. A draft report for consultation was scheduled for release in July 2022 and the final report should be due in December 2022.

Winstone Wallboards’ woes are clearly down to the disruption caused to supply chains by the coronavirus pandemic. However, fairly or unfairly, its local market dominance has exposed it to most of the blame for the situation in the eyes of some of the New Zealand public. Its products are so integrated into the usage of wallboard in the country, for example, that the Gib brand is specified by name in many of the region’s building consent application documents. The government has now become involved adding further to the public scrutiny. Structural changes may or may not be required at some or multiple levels of the New Zealand wallboard market to fix the current crisis. Yet, funnily enough, in one interview Fletcher Building chief executive officer Ross Taylor raised the issue of customers developing the ‘fear factor’ in response to hearing about shortages and then buying more than they might need. This may sound familiar because it is exactly what happened at the start of the worldwide coronavirus lockdowns when people started panic buying toilet-roll. Whatever else is happening in New Zealand, human nature can’t be helping either.

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.

Australia: BGC has started a second attempt to sell the company and has appointed Macquarie Capital to run the process. An indicative bidding round is planned for June 2022, according to the Australian Financial Review newspaper. The process is expected to take up to one year. BGC previously tried to find a buyer in 2018 but legal issues following the death of the company founder Len Buckeridge and a slowdown in the construction market in Western Australia made this difficult.

The company is presenting itself as a major presence in the West Australia cement market, with a 47% share, and the only organisation with a vertically integrated quarry, cement and concrete business. Macquarie Capital says that the company has an annual revenue of around US$740m and earnings before interest, taxation, depreciation and amortisation (EBITDA) of US$74m. Group earnings are reportedly mostly generated by heavy building materials, brick and masonry divisions. BGC assets include a cement grinding plant, concrete plants and a gypsum wallboard plant in Perth.

Belgium: ETEX recorded consolidated net sales of Euro2.97bn in 2021, up by 14% year-on-year from Euro2.62bn in 2020. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 12% to Euro522m from Euro468m, while its profit for the year dropped by 1.4% to Euro198m from Euro201m. The group’s building performance recorded like-for-like sales growth of 21% from 2020 levels and of 15% from 2019 levels. Its gypsum wallboard volumes grew year-on-year, while strong demand in all regions except South Africa impacted some export businesses through supply chain issues and increased shipping costs. The company adapted its prices to offset a sharp rise in raw material and energy cost prices.

During the year, ETEX acquired a top-three Australian gypsum wallboard producer and completed its rebranding as Siniat. It also diversified with the launch of a fourth group division, new ways, which includes light steel framing production operations.

Oman: Oman exported 8.74Mt of gypsum in 2021. Data from Oman-based Zawawi Minerals shows that the country had a 44% share of the gypsum export market to Asian, the Middle East and south-east Africa. Its main destination was India, followed by Bangladesh. Thailand followed with exports of 4.91Mt for both gypsum and anhydrite (32%) and then Iran with 4.2Mt (21%). Other exporting nations included Australia, Mexico and Bhutan. Total recorded exports to the region were 19.8Mt.

Australia: Cohiba Minerals has received notification that it has successfully secured a 5-year extension of its exploration licence for its Pyramid Lake gypsum mine in south-western Western Australia. The new lease will expire on 4 July 2026.

The company says that it has recommenced its application for a mining lease for the high-grade area of the Pyramid Lake mine, which is not covered by its present lease. It says that it had previously delayed the process due to a change in its application conditions.

Cohiba Minerals previously announced the planned expansion in December 2020 as part of a countrywide expansion of its extraction activities, towards which it was raising US$1.5m through a share purchase plan.

Australia: Boral recorded consolidated sales of US$3.87bn in the 2021 financial year, down by 6.7% from US$4.14bn in the 2020 financial year. It recorded a net profit of US$463m, compared to a loss of US$828m in the 2020 financial year.

CEO and managing director Zlatko Todorcevski said “Our full-year 2021 financial year results reflect the mixed market conditions we are continuing to experience in Australia during the pandemic. The value of total construction work was lower than the prior year, including in multi-residential, non-residential and infrastructure construction. Several major projects were completed during the period, with others delayed before new projects come on-line and reach materials intensity. While a lift in detached housing provided a boost to activity during the year, Boral’s earnings are predominantly exposed to construction activity outside of residential.”

He added “We have made substantial progress in our strategy to transform Boral into a stronger, better performing, more customer-focused organisation, with a core portfolio of businesses that deliver value throughout the cycle. Over the past year, we have progressed the divestments of several non-core assets, including completing the divestment of our interest in the USG Boral joint venture and announcing the sale of North America Building Products, achieving sale prices well above expectation. With total proceeds of almost US$3.25bn from completed and announced divestments to date, our strategy to focus Boral on the core Australian construction materials business is well advanced. And following a detailed assessment of strategic options for our North American Fly Ash business, we are now entering the final stages of a divestment of this business.”

Australia: Boral has rejected a proposed US$5/share takeover bid by Seven Group Holdings. The building materials producer received the bid on 10 May 2021 and then rejected it the following day, according to the Financial Review newspaper. Seven Group Holdings started buying shares in Boral in March 2020 and reached a 23% stake in the company by April 2021. Boral has continued a share buy-back programme it commenced in April 2021 as part of its response to the takeover attempt. Sources quoted by the newspaper also expect Boral to work with investment bank Jarden Australia in retaliation to Seven Group Holdings’ actions.

Australia: Boral has sold its 50% stake in USG Boral to Germany-based Knauf for US$1.02bn. The profit on sale after tax will go towards reducing the group’s net debt by 21% to US$1.15bn from US$1.45bn. This will leave a US$763,000 surplus for reinvestment or return to investors.

Following on from the sale, Boral has launched a share buy-back, ending in April 2022. It intends to purchase 10% of shares on issue. The group says that the USG Boral sale proceeds will fund the investment.

Chief executive officer and managing director Zlatko Todorcevski said “The sale of our 50% interest in USG Boral to Knauf for an attractive premium creates substantial value for Boral’s shareholders. The sale enables Boral to reduce net debt to our current target and create surplus capital available for return to shareholders, which is consistent with Boral’s financial framework.” He added “We believe that an on-market buy-back is the most effective method of returning this surplus capital to our shareholders.”

Belgium: Etex’s full-year consolidated net sales were Euro2.62bn, down by 11% year-on-year from Euro2.94bn. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 16% to Euro468m from Euro557m. The group called its bottom-line performance ‘stunning.’ It reduced its debt by 95% to Euro15.0m from Euro331m.

The coronavirus outbreak impacted performance across all regions. At the peak of the outbreak’s impact on the group’s operations in April 2020, it had suspended operations at 48% of its facilities globally. In Europe, sales increased year-on-year in Germany and Romania. This, a dynamic plasterboard market in the Netherlands and ‘good’ group performance in Eastern Europe failed to offset the regional decline. The impact was notably severe in the Benelux countries and the UK in the second quarter of 2020. In Latin America, sales were comparable with 2019 levels on a like-for-like basis. Asian and African sales experienced a decline, partly offset by the opening of new markets in Australia prior to the acquisition of Knauf Plasterboard in February 2021.

Chief executive officer Paul Van Oyen and chair Jean-Louis de Cartier de Marchienne said, “Although our order book for the first half of 2021 is positive, we expect our revenue to be affected by Covid-19-related volatility this year and the next. Despite this forecast, the performance culture that we have invested in over the last year is firmly in place and delivering results. In addition, our strategic acceleration of sustainability and customer experience initiatives will continue to bear fruit moving forward.” They added, “The acquisitions we made in 2020 will fuel our future growth in high-potential markets. In 2021, we will continue to identify new opportunities, as we are currently in an excellent position to make significant additional investments.”