Gypsum industry news

Belgium: Christoph Dorn has been elected as the new president of Eurogypsum, the Brussels-based European association representing the gypsum supply and processing industry. Dorn, a member of the Group Management Committee for Knauf Central Europe, takes over from Dr. Jörg Ertle of the Etex Group.

Dorn said "Taking over the presidency of Eurogypsum in 2024 is a great honour, as the gypsum industry has much to offer, sourcing domestic and multi-recyclable materials to decarbonise Europe’s buildings."

Securing sustainable energy sources has been the priority for some of Spain’s gypsum wallboard producers in recent weeks.

In late November 2023 Pladur revealed that it plans to use green hydrogen at its production plants from the second half of 2024 onwards. It will start at its Valdemoro plant near Madrid before rolling usage out elsewhere afterwards. The subsidiary of Belgium-based Etex is also considering trials with biomethane and biogas. Then a few weeks later in early December 2023 Knauf Ibérica announced that it is planning to build a 7.5MW biomass unit at its Guixers plant in Lleida. Commissioning is currently scheduled for late 2024. This follows the installation of solar panels at the site earlier in 2023. Along similar lines, Saint-Gobain Placo signed an 11-year power purchase agreement (PPA) with electricity company Endesa at the end of 2022 to supply 150GWh/yr of renewable energy. Together with a previous renewable energy deal this was expected to cover up to 65% of the group’s electricity requirements in Spain.

Wallboard plants all over the world have been embarking on sustainable energy drives in recent years but the particular drivers in Spain are worth mentioning. The country’s high electricity prices have frequently been raised by large-scale industrial users in the past, often in terms of competitiveness of exports. However, the situation worsened following the start of the war in Ukraine in early 2022 as the wholesale price of coal and gas jumped. The high price of gas in particular pushed the electricity prices up in Spain and wallboard plants typically use both sources of energy. The government eventually capped the price of gas and coal for power generation. It then offered an aid scheme for large-scale gas users but missed the gypsum sector out, much to the chagrin of the Asociación Técnica y Empresarial del Yeso (ATEDY), which complained about it at the end of 2022. The gypsum industry was later included in July 2023 when a funding scheme was announced. It’s unknown how much this initiative has helped wallboard manufacturers but the shift to renewables by the three main companies mentioned above tells its own story.

Despite the energy supply problems a new entrant to the wallboard market in Spain announced itself in March 2023. Italy-based Fassa Bortolo said it was going to spend Euro90m on building a wallboard plant at Tarancón in Cuenca. No commissioning date or main supplier name has been disclosed, but Italy-based Bedeschi did say in late November 2023 that it was providing raw bulk material handling equipment including an apron feeder, stacker, excavator and conveyor belt line. There has also been no word on how the new plant will power itself.

On the topic of exports, Spain has long been one of the world’s larger shippers of natural gypsum. Data from the Geological and Mining Institute of Spain (IGME) shows that the country exported 9.2Mt of gypsum in 2021 with a value of Euro60m. Whether this changed in 2022 when the energy prices increased is unknown at the time of writing. In 2021 Almería was the epicentre of the country, accounting for 70% of the 13Mt total volume of gypsum extracted that year with a quarry at Sorbas, operated by Saint-Gobain Placo, reportedly being the second largest in the world. Most of the gypsum extracted at Sorbas was then driven by truck to the Port of Garrucha, making it the busiest gypsum port in Europe by volume.

Eurogypsum, the European federation of national associations of producers of gypsum products, launched its industry roadmap to net-zero by 2050 on 9 November 2023 at the Global Gypsum Conference 2023, which took place in Chicago, US. Various actions and technologies were unveiled as part of the plan including some of the approaches being taken in Spain such as using ‘green’ electricity, biomass and green hydrogen. All of these suggestions were split into short, mid and final term feasibility categories. So, for example, using renewable sourced electricity is dependent on it being affordable and available. It was placed in the immediate category. Yet, using biofuels or green hydrogen is flagged as requiring investment, so deemed as short-to-mid term.

Spain presents a case where the cost of energy for industrial users may be aligning with sustainability goals. How this translates onto balance sheets remains to be seen though. These kinds of sustainable energy projects may only be slowing the inevitable as raw material and energy costs mount anyway leading to tighter margins, increased competition and potential consolidation. The gypsum sector in Spain may well be testing out slightly earlier than elsewhere how much a more sustainable world will actually cost.

Europe/US: Tristan Suffys, secretary general of Eurogypsum, the European gypsum association, presented the association’s net zero roadmap at the Global Gypsum Conference 2023 in Chicago, US, on 9 November 2023. Live and online audiences heard Eurogypsum’s full life cycle-based carbon footprint analysis, according to which European gypsum wallboard currently generates CO₂ emissions of 2kg/m², 14% lower than 2008 levels. On its pathway to net zero by a deadline of 2050, Eurogypsum plans to reduce wallboard’s CO₂ emissions from raw materials by 13%, from transport by 12%, from production by 69% and from end-of-life processes by 6%.

Suffys said “Presenting our roadmap today in Chicago is a clear signal that global warming requires global action. We want to engage with other regional actors along the way to climate neutrality.”

Eurogypsum president Jörg Ertle added “We are committed to making this transition a reality. First examples show that we can move towards net-zero emission production if we have access to low-carbon energy at affordable costs and optimal raw material supply, but this will require significant investment from our sector.”

Eurogypsum added its views on the European Union’s (EU) proposed Critical Raw Materials Act (CRMA) last month. It wants gypsum to be added to the bill’s list of critical and strategic raw materials. It is not surprising that the European federation of national associations of producers of gypsum products might want to do this. However, when compared to rare earth minerals of the sort required to manufacture batteries for electric vehicles (EV), gypsum doesn’t seem all that, well, rare.

What may be rare though is people’s patience with new gypsum mines. The association’s argument is that gypsum is indeed abundant in the EU but that accessing it is increasingly becoming difficult. The EU’s sustainability agenda has made the energy efficiency of buildings as important as reducing CO₂ emissions from the transportation sector. Gypsum and other materials used to make lightweight building materials are a way of renovating existing buildings and improving energy efficiency. Therefore it suggests that the act should either recognise gypsum as strategic or introduce a new ‘essential’ category. This would then make the process of extracting gypsum more easy.

This approach ties back to initiatives such as one by the Federal Commission on Geosciences (BLA-GEO) in Germany, which previously started to compile an inventory of the nation’s gypsum deposits with the intention of putting this in front of policy makers. Nor is the gypsum sector alone in targeting the potentially lucrative retrofit market. In May 2023 Daikin, Danfoss, Knauf Insulation, Rockwool, Saint-Gobain, Signify and Velux signed an agreement to promote building energy efficiency in Central and Eastern Europe (CEE). Radek Bedrna, Knauf Insulation’s managing director for Eastern Europe and Middle East, noted that two thirds of the 43.6m homes in single- and multi-family houses in the CEE region were reportedly built before 1989 and are energy inefficient. The European Commission places transport-related greenhouse gas emissions at about 25% of the region’s total. Renovating buildings fully, by contrast, could save up to 5% of the EU’s emissions. Targeting transport emissions may be a higher priority for the EU but the savings from retrofitting are not trivial either.

Then - on cue in mid-June 2023 - there was an example of the difficulties gypsum product producers can face with building new quarries or enlarging old ones when expansion plans for a gypsum quarry supporting Placoplatre’s wallboard plant in Chambéry in France were scaled back from local opposition. The subsidiary of Saint-Gobain met similar issues in late 2022 when a public enquiry started examining its plans to build a new quarry at Fort Vaujours, Seine-Saint-Denis. This site is intended to serve the Vaujours gypsum wallboard plant as a replacement for its Bernouille quarry after the latter closes in 2026. This one has a happier ending, for the gypsum sector at least, since the project received an environmental permit in late May 2023. One of the key issues that came up in the enquiry was a disagreement over the means of extraction. A local environmental group favoured underground mining but an open-cast approach was preferred by the producer as it would yield much more gypsum. The latter was eventually approved.

What this suggests is that making gypsum an ‘essential’ raw material in Europe requires engagement with the general public as much as legislators. Some people may not like having a wind farm built near where they live but the chances are that there will be less opposition than building a new coal mine. Digging up new gypsum deposits should be presented as more like the former than the latter. Whizzing around in a new EV is generally seen as being more fun than bragging about how great the lamba factor is for one’s house. However, this may change if energy prices keep ticking upwards. Gypsum may not be rare but Eurogypsum and others can make a strong case for it being essential.

Belgium: Eurogypsum, the European federation of national associations of producers of gypsum products, is lobbying for building materials such as gypsum to be included in a list of critical and strategic raw materials as part of the European Union’s (EU) proposed Critical Raw Materials Act (CRMA). The organisation welcomes the CRMA but wants it to also consider the energy renovation of the building stock in addition to raw earth minerals such as those required to build batteries. It has suggested either amending the proposed act to include certain building materials as strategic or introducing a new category of ‘essential’ raw materials, with streamlined permitting processes and access to finance.

It noted that Europe was, in principle, self sufficient in gypsum due to abundant deposits. However, it said that, “increasing difficulties in the access to extractive permits, combined with the foreseen reduction of alternative gypsum sources from the flue gas desulphurisation of coal power plants in the energy transition, are raising serious concerns about the future supply of this mineral essential for the construction and renovation of buildings.”

The CRMA was originally announced by EU President Ursula von der Leyen in September 2022 before being formally proposed in March 2023. It is now being considered by the European Parliament and the Council of the European Union.

Belgium: Eurogypsum, the European federation of national associations of producers of gypsum products, has welcomed proposed changes to the European Union’s (EU) Construction Products Regulation (CPR). It said that it welcomed “…the proposal presented by the European Commission (EC) on 30 March 2022 as an ambitious basis to strengthen and modernise the existing rules, as well as to speed up the uptake of sustainable and circular practices in the construction product manufacturing industry.”

In preliminary feedback comments the association said that it supports a European Committee for Standardisation (CEN) driven system as opposed to increased regulatory powers for construction material manufacturing that the new proposals might create. For the assessment of the environmental performance of products the association wants more clarity about any potential new digital approach. It reiterated that it supports the continued use of Life-Cycle Assessments (LCA) and Environmental Product Decelerations (EPD). It also called for product labelling to be provided in an electronic format with easy-to-understand pictograms as the norm. However it suggested that any consumer should be able to request a paper version if required.

The CPR regulations were originally introduced in 2011 and are recognisable to consumers through the use of the CE (Communauté Européenne) markings on certain products. The EC has since decided to revise the regulations to fit with newer policy priorities including the European Green Deal.

Members of Eurogypsum, the European Gypsum Association, gathered at the Les Atelier des Tanneurs in Brussels on 27 - 28 April 2022 to formally celebrate the 60th Anniversary of their association, despite a delay of 12 months due to Covid restrictions. Over two days, they participated in meetings and panel sessions reminiscent of pre-pandemic times. Attending the Open Congress session on 28 April 2022, Global Gypsum found the event to be very dynamic and surprisingly open.

The Open Congress began with welcomes from the moderator, Knauf Insulation’s Sian Hughes and outgoing Eurogypsum President Emmanuel Normant, of Saint-Gobain. He introduced the past 60 years as one of ‘enormous change’ for the sector, but this was not meant to be a retrospective. Turning to the next 60 years, Normant said that gypsum’s inherent benefits, including its low embodied CO₂ emissions, recyclability, high degree of safety and ease of use, would make it even more crucial to global development in the future than in the past.

A series of quick-fire presentations from the industry’s big hitters then highlighted a wide range of ways to increase the sustainability of our sector.

Saint-Gobain’s Klaus Birk introduced Gyproc's project to switch its Fredrikstad wallboard plant in Norway to use a 100% electric wallboard production process by 2023. This will use renewable energy, predominantly sourced from hydroelectric power, and lead to a 70% drop in CO₂ emissions. This approach could be applicable to any wallboard plant with access to sufficient renewable power.

Knauf's Jörg Demmich then spoke about a project to extract gypsum from the ‘waste’ from the lithium production process. Even the best lithium ores only contain 3 - 6% lithium by mass, leaving 94 - 97% currently unused. As electric mobility grows, by-product gypsum from the lithium sector could partly offset the expected fall in flue-gas desulphurisation (FGD) gypsum supplies.

Iryna Yermakova introduced the Etex Group's approach to the wallboard plant of the future. One area she highlighted was the potential for prefabrication at the wallboard plant before panels reach the job site. This has the potential, on some projects, to save up to 10% of the wallboard cost, transport cost and CO₂ emissions of the board used. Surely a quick win for contractors.

Nikolai Halle from Cobuilder introduced the Define tool, freely-available to the construction sector. Define will act like the Swift payment system, but for sustainability data instead of financial data. This would unify different sustainability metrics to cut through the confusing terms used by producers and reveal the 'real' performance of different products, rather than how effectively their attributes are marketed.

The keynote presentation, from the former European Commissioner for the Environment Janez Potočnik – ‘The Father of the Circular Economy’ - then highlighted why innovation is key, not only to the future of the gypsum sector, but to the planet itself. At current rates, the mass of man-made material will be three times larger than all biomass by 2040.

To avoid this, Potočnik argued that the entire economy needs to become service-based, rather than product-based. Under such a model, wallboard producers would become part of the ‘building envelope services sector’ rather than selling wallboard. The desire is then to sell wallboard with a long service life, that can be repurposed and recycled, rather than selling ever-increasing volumes of board.Taking this approach across the entire economy would help society to maximise gross domestic product while reducing environmental impacts, eventually decoupling them from each other entirely. Potočnik concluded that nature is already the 'perfect' circular economy. Humans just need to reintegrate into it.

To say that the panel discussion that followed was ‘lively’ would be an understatement. Member of the European Parliament Iskra Mihaylova, speaking the day after Russia halted gas supplies to her native Bulgaria, said that talk of energy independence and solidarity was 'not enough' and that Europe needed to act on the European Union Green Deal, particularly with a view to energy and resource efficiency and security.

Josefina Lindblom, the European Commission’s Policy Officer for Sustainable Buildings for Circular Economy, introduced what she hoped would become the next buzzword: ‘sufficiency’ - properly taking pause to consider what is truly required of new buildings. This includes the need to apply full circularity to renovation projects.

Adrian Joyce, from the European Alliance of Companies for Energy Efficiency in Buildings, asked the audience to think not in terms of 'energy efficiency,' but 'conservation of energy.' The two terms are subtly different, with the latter akin to ‘sufficiency.' Both point to the need to reduce the use of resources, not just the effectiveness which we use increasing amounts of resources.

Tristan Suffys, Secretary General of Eurogypsum, said that gypsum is well suited to fit into the low-CO₂, low-resource-use sector of the future. He called for re-use of derelict buildings, re-purposing and optimising the use of space by building above existing buildings.

The Open Congress drew to a close with a speech by the incoming President of Eurogypsum (and Head of Corporate Social Responsibility at Etex) Jörg Ertle. He told Eurogypsum members that the 'doors' marked 'Green Deal,' 'Decarbonisation,' and 'Recycling' were all 'open' and that they should be making the most of the opportunities behind each. From Global Gypsum’s perspective, it seems that they have burst through each of the doors into the rooms behind. Some are even measuring up for wallboard.

In conclusion, it appears that the European wallboard sector is at the start of a major increase in sustainability efforts. This will be backed by politicians who are keen to decouple their economies from Russia’s and a public that is increasingly asking for change. And, with three major global producers - Knauf, Saint-Gobain and Etex - based in Europe, between them sharing 47% of the world’s wallboard capacity, we can expect to see these innovations spread to other regions rapidly.

Here’s to the next 60 years!

Belgium: Eurogypsum’s board of directors has elected Jörg Ertle president of the association. The Etex head of corporate social responsibility will succeed Saint-Gobain Group vice-president for sustainable development Emmanuel Normant, who now takes over the position of Eurogypsum vice-president. Knauf Group Central Europe managing director and Knauf Gips chair Christoph Dorn will serve as the association’ new treasurer.

Ertle studied mining and mineral engineering at RWTH University Aachen and holds a Ph.D in environment technology from Berlin Technical University. He has over 20 years’ gypsum industry experience, including time spent in management roles Lafarge before and after its acquisition by Etex. Having previously headed Etex’s worldwide gypsum sourcing, Ertle took on his current role in the group in 2019. He has also participated in different Eurogypsum working groups concerning raw material policy, and has chaired the association’s Environment and Sustainability Committee since 2018.

Ertle said “I am taking over Eurogypsum’s presidency at a challenging time for Europe, with a global climate and environmental challenge, as well as a particularly unstable international environment. Economic actors are working under increased regulatory and financial pressure.” He added “I am convinced that gypsum solutions are a strong enabler to facilitate this transition, supporting the ambitions of the European Green Deal.”

Belgium: Eurogypsum will celebrate its 60th anniversary at an event in Brussels to be held on 28 April 2022. The event will include a keynote speech by Janez Potočnik, a former European Commissioner for the Environment and architect of the commission’s circularity agenda. There will also be a panel discussion, bringing together leading policymakers to discuss opportunities to advance the European Union’s sustainability agenda in the built environment, the official launch of association’s EG60 guide and a photo exhibition. The full programme will be announced in due course. The European federation of national associations of gypsum product manufacturers was founded in 1961.

Belgium: During its General Assembly held in Brussels, Belgium on 21 May 2014, Eurogypsum elected the president of Saint-Gobain Gypsum Claude-Alain Tardy as president of Eurogypsum for the period of 2014 - 2016. Tardy succeeds Dott Maurizio Casalini, managing director of Knauf Italy, on the expiry of his statutory term of office.

Tardy is a civil engineer graduate of the École Centrale de Paris. He also has an MS in Industrial Engineering & Engineering Management from the University of Stanford, US. Tardy joined Saint-Gobain in 1981 and between 2005 and 2009 he was chief operating officer of Saint-Gobain Insulation, before being appointed as president of Saint-Gobain Gypsum in 2009.

"I am convinced that wallboard and plaster solutions will play a growing role in the future," said Tardy. "The unique attributes of our products; recyclability, ease of installation, fire resistance, acoustics and thermal properties make our systems inescapable for the construction and renovation of buildings. During my presidency I will concentrate my efforts on the promotion of gypsum industry solutions as the best option to create safe and comfortable interior spaces."