Gypsum industry news

New Zealand: Fletcher Building Materials recorded consolidated sales of US$5.37bn during its 2022 financial year, up by 4.7% year-on-year from US$5.13bn in the previous year. Its net earnings also rose by 42%, to US$273m from US$193m.

The group's building materials division, which includes Winstone Wallboards, contributed US$1.02bn-worth (17%) of group sales. The business delivered 'strong' volumes, with pricing initiatives effectively offsetting cost inflation. The latter particularly impacted imports of raw materials. The business made capital expenditure investments of US$129m, of which US$98.4m went towards the construction of Winstone Wallboards' upcoming Tauriko gypsum wallboard plant in the Bay of Plenty region. The plant's commissioning in 2023 will increase the company's production capacity by 30% and reduce its CO₂ emissions and waste generation.

Fletcher Building Materials chief executive officer Ross Taylor said "The 2022 financial year has not been without its challenges. Global and national supply chain disruptions have continued into the third year of the Covid-19 pandemic. In New Zealand, surging plasterboard orders following the first quarter lockdown outstripped our ability to supply, despite our manufacturing facilities running at record levels. In recognition of our key role as a local manufacturer in keeping the market supplied, we carried out a range of measures to address the shortage including operating production lines 24/7, running down inventory, importing additional product, and establishing an emergency supply pool." Taylor added "The New Zealand Commerce Commission recently published its interim market study report into residential building supplies. The final report and recommendations will be published in December 2022 and in the meantime we will continue to work collaboratively with both the commission and the government."

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: The government has established a taskforce to tackle the on-going national gypsum wallboard shortage. Scoop News has reported that the taskforce consists of industry experts. The body says that it will renew the focus on competition in the building materials sector. Minister for Building and Construction Megan Woods has written a letter to Winstone Wallboards' parent company Fletcher Building regarding trademark protections, specifically urging it not to take action on its product colour trademarks. The taskforce also plans to explore new distribution models and investigate the potential of new products in the New Zealand market.

Megan Woods said "The taskforce has a very clear aim: to increase sector productivity as quickly as possible, and to remove any unnecessary barriers, including around certification, to facilitate the use of different types of plasterboard."

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.

New Zealand: Revenue from Fletcher Building’s Building Products division rose by 9% year-on-year to US$514m in the first half to 31 December 2021 from US$471m in the same period in 2020. Earnings before interest and taxation (EBIT) fell by 6% to US$68.6m from US$64.6m. The building materials producer, distributor and construction company blamed the declining earnings on a coronavirus-related lockdown in the summer of 2021, although it noted improved performance in the following quarter. Overall group revenue and earnings grew in the reporting period.

“With improved operational performance and cost disciplines now embedded across the business, we were able to deliver a strong performance. This was despite the first quarter being heavily impacted by the up to five week-long Covid-19 stringent lockdown in New Zealand and local lockdowns in Australia which impacted EBIT,” said Fletcher Building’s chief executive officer Ross Taylor.

Fletcher Building’s subsidiary Winstone Wallboards is currently building a new 10Mm²/yr gypsum wallboard plant at Tauriko near Auckland. Commissioning is planned for the group’s 2023 financial year that starts in June 2023. Once completed the company says it will have a total national wallboard production capacity of 40Mm²/yr.

New Zealand: Winstone Wallboards has decided to move to an allocation model of supplying its GIB plasterboard products from July 2022 due to mounting lead times in manufacture. It said it would, effective immediately, not be accepting or processing new GIB plasterboard orders for July 2022 deliveries onwards. Instead it plans to assess the situation in the coming months and it anticipates moving to a process where customers order plasterboard products one month in advance.

The gypsum wallboard producer blamed the situation on significant disruption across the building industry caused by local-coronavirus-related lockdowns in August and September 2021. It said that this caused a backlog of orders. Subsequent record manufacturing output and imports were insufficient to alleviate the situation.

New Zealand: Fletcher Building has appointed Martin Brydon as a non-executive director with effect from 1 September 2018. Brydon, who is currently the chief executive officer (CEO) and managing director of Adelaide Brighton, is scheduled to retire from the Australian company later in 2018. Chairman Ralph Norris said that Fletcher Building is focusing on the New Zealand and Australian markets and that an Australian director who will help this strategy.

Brydon has worked for over 40 years in the Australian building products sector. He started his career as an indentured engineering cadet with BHP, before progressing to general management roles with Cockburn Cement, where he then served as CEO from 1998 - 1999. Brydon joined Adelaide Brighton in 1999 and held a number of general management roles before his appointment as CEO and managing director in 2014.

New Zealand: Fletcher Building has appointed Michele Kernahan as Chief Executive Building Products. His former position of Chief Executive Construction will be taken by Peter Reidy, currently Chief Executive KiwiRail. Both appointments are effective from early November 2018. David Thomas, currently serving as the Interim Chief Executive Building Products, will return to his role as General Manager Winstone Wallboards once the appointments are effective.

New Zealand: Fletcher Building’s subsidiary Winstone Wallboards plans to build a US$181m gypsum wallboard plant in Auckland. The new unit is expected to create around 200 new jobs, according to the New Zealand Herald newspaper. Negotiations at the Drury site have not yet been concluded yet. The company hopes that the new plant will be operational in 2021 or 2022. The new development is planned to meet local demands and upgrade the existing capacity at Winstone Wallboards’ Penrose plant in Auckland.

New Zealand: Fletcher Building has reported that its net profit rose by 51% year-on-year to US$114m in the half year that ended on 31 December 2015 from US$75.6m in the same period in 2014. Its sales rose by 2.5% to US$2.94bn from US$2.87bn. It attributed this to growth in its building products and distribution businesses making up for weaker earnings from Formica and New Zealand housing developments.

Fletcher Building reported that gypsum wallboard volumes via its Building Products division rose by 9% in the half year. Volumes of performance board rose by 12%. Sales volumes of insulation rose by 12% in New Zealand and 9% in Australia. It noted that its market share has also improved in both insulation markets due to competitive pricing following the strengthening of the US Dollar.