Gypsum industry news

China: BNBM says that despite issues with the domestic real estate sector demand for wallboard had ‘remained relatively stable’ in the first half of 2024. It attributed this to retrofit activity, government changes to the housing market and infrastructure projects. Its operating income grew by 19% year-on-year from US$1.60bn in the first half of 2023 to US$1.91bn in the first half of 2024. Sales volumes of gypsum wallboard rose by 7% from 1092Mm² to 1168Mm². The company added that overseas sales had grown in the reporting period and its Thailand Gypsum Board project had started construction.

CNBM’s New Materials business division, comprising BNBM and other subsidiaries, saw its sales grow slightly but profit fell. However, CNBM’s group revenue and gross profit fell significantly due to the poor performance of its heavy building materials division.

China: Beijing New Building Materials’ (BNBM) operating revenue increased by 11% year-on-year to US$3.10bn in 2023 from US$2.79bn in 2022. Its net profit rose by 32% to US$483m from US$367m. Its sales volumes of gypsum wallboard rose by 4% to 2.17Bnm² from 2.09Bnm². This compares to total national sales of 3.21Bnm2. The company is the largest seller of wallboard in China.

The subsidiary of CNBM reported that the country has a wallboard production capacity of 4.95Bnm²/yr, using data from Gypsum Building Materials Branch of the China Building Materials Federation, although 280Mm²/yr of this is classified as ‘backward and uncompetitive.’ It also added that the National Development and Reform Commission proposed in February 2024 that China phase out wallboard production lines with a capacity below 10Mm²/yr as part of the country’s plans to become net zero by 2060.

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.

China: Beijing New Building Materials (BNBM)’s operating income grew by 9% year-on-year to US$1.57bn in the first half of 2023, from US$1.44bn in the same period in 2022. Its net profit increased by 19% to US$251m from US$211m. The company said that it had a total gypsum wallboard production capacity of 3.4Bnm²/yr and that it was the world’s largest gypsum board group.

Parent company China National Building Material (CNBM) reported separately that its total sales of gypsum wallboard remained stable in the first half of 2023, at 1.09Bnm². It said “The supply of gypsum board is stable, but affected by the weak operation of the real estate market. The demand is insufficient and the operation of the industry is under pressure.” It added that BNBM built four “nearly zero emission” gypsum board production lines in the reporting period.

China: BNBM has held a high level discussion and information exchange with the China Construction Eighth Engineering Division Corporation (CSCEC 8). Senior representatives of both companies attended the event. Dong Zhanbo, assistant general manager and chief engineer at BNBM, commented that both companies have a good relationship and they share ambitions for low-carbon future. He hoped that further high-level communication between the companies and future meetings could lead to more extensive and in-depth cooperation. Zhang Guangtao, general manager of the Procurement Management Department of CSCEC 8, expressed the hope that the two companies could work together more closely.

CSCEC 8 is a subsidiary of the China State Construction Engineering, one of the world’s largest construction companies, both within China and worldwide.

Bosnia & Herzegovina: The shareholders assembly of state-owned power company RiTE Ugljevik has approved the signing of contracts for the sale of gypsum and coal with Beijing New Building Materials (BNBM) Ugljevik. The project intends to build a 40Mm²/yr gypsum wallboard plant and it has a budget of Euro50m, according to the Sarajevo Times. RiTE Ugljevik previously agreed to supply 250,000t/yr of flue gas desulfurisation (FGD) to the proposed wallboard plant.

China: BNBM’s operating income fell by 6% year-on-year to US$2.90bn in 2022 from US$3.07bn in 2021. Its net profit dropped by 11% to US$457m from US$511m. Parent company China New Building Material (CNBM) reported that its sales volumes of gypsum wallboard declined by 12% to 2.09Bnm² from 2.38Bnm². It noted that, despite prices for raw materials and energy increasing in 2022, the poor local real estate market had led to a decline in demand for wallboard. It added that performance in Tanzania had grown in the reporting year and that new projects in Uzbekistan and Thailand remained on track. The group said that its 50 gypsum wallboard production lines had achieved “nearly zero emissions” in 2022.

China: BNBM’s operating revenue grew by 2.4% year-on-year to US$1.50bn in the first half of 2022 from US$1.46bn in the same period in 2021. Its net profit fell by 11% to US$237m from US$266m. Parent company CNBM reported that its sales volumes of gypsum wallboard fell by 5.8% to 1.09Bnm² from 1.16Bnm2. It said that continued coronavirus lockdowns and problems in the real estate market had affected market demand. It added that the price of raw materials and energy had also risen, leading to increased production costs and mounting product prices.

China: BNBM’s operating income grew by 25% to US$3.33bn in 2021 from US$2.66bn in 2020. Its net profit rose by 23% to US$554m from US$451m. Its production and sales volumes of gypsum wallboard increased by 19% to 2.43Bnm² and 18% to 2.38Bnm² respectively. It reported a gypsum wallboard production capacity utilisation rate of 78%. The group added that data from the Gypsum Building Materials Branch of China Building Materials Federation showed that national wallboard production capacity was 4.90Bnm²/yr and that production and sales were 3.51Bnm² in 2021.

Parent company CNBM separately reported that the group raised its average wallboard selling prices by 7%. It said it put up its prices in the reporting period due to high prices of coal, gypsum, paper and other raw materials. Internationally, the group said that a new wallboard plant in Tanzania had started operation in 2021 and that a new plant in Uzbekistan is still being built.

BNBM has announced two overseas gypsum wallboard plants since the start of 2022. In Early January 2022 the China-based producer said it was going to build a 40Mm²/yr plant in Thailand as part of a joint-venture with Sinoma International Engineering and its subsidiary Sinoma (Thailand). Notably the unit is also to be equipped with a decorative gypsum line. The estimated project investment is US$55m. Then, in February 2022 BNBM revealed plans to build a 40Mm²/yr gypsum wallboard plant in Bosnia & Herzegovina. This one is a joint venture with Rudnik i Termoelektrana Ugljevik (RiTE Ugljevik), a subsidiary of the local state-run power company. The project will be situated next to the coal-fired power plant at Ugljevik. No surprises then for what source of raw gypsum the wallboard plant is likely to be using! The estimated project cost is Euro50m.

These two projects join a pair of other plants the producer is also cooking up internationally. In mid-2019 it revealed new wallboard plants in Tanzania and Uzbekistan. The former is a 15Mm²/yr plant to be run via a subsidiary. It was reported to be in a construction phase in mid-2021. The latter is a 40Mm²/yr gypsum wallboard plant to be built in the Kokand Free Economic Zone, Fergana Region in Uzbekistan via a wholly-owned subsidiary. So far it is reportedly in the preparation stage. The company also has a number of wallboard plant projects in development at home in China, including plants currently being built at Shuozhou in Shanxi province and Yichang in Hubei province.

During the first half of 2021, BNBM’s operating income rose by 46% year-on-year to US$1.59bn from US$1.09bn. 65% of this was generated from its gypsum wallboard business sales. Overall, parent company CNBM reported gypsum wallboard sales of 2.01Bm2 in 2020 from BNBM and Taishan Gypsum.

A subsidiary of CNBM building production capacity outside of China will sound familiar to those readers who follow the cement industry. The industry has been using the Belt and Road Initiative to move redundant domestic capacity abroad as the local market has become saturated and environmental measures bite. Chinese cement production capacity per capita has seemed extraordinarily high by international norms over the last 20 years. Yet, gypsum wallboard production capacity per capita is a wildly different story. Global Gypsum Directory 2021 data suggests that the US had a rate of 12.7m²/capita compared to 2.4m²/capita in China.

With this in mind it makes one wonder why BNBM is bothering internationally given the market scope at home as China meets its climate commitments. As the move by some western multinational building material companies over the last year or so suggests, the future may lie in light building materials. On the other hand BNBM/CNBM may simply have its eye on the bigger picture. Just like its international competitors, it doesn’t want to miss out on the opportunity for market enlargement or being left behind if the ratio between heavy and light building materials switches. If it really means business, then the next steps could be wallboard plants in Western Europe or even the US. A US-based joint-venture for BNBM might help to make everyone forget the unending legal debacle with Taishan’s imports.