Gypsum industry news

Australia: Building materials supplier Boral says that its prospects are improving as government infrastructure spending increases and industrial turmoil recedes. "After reporting lower earnings for two years running, we have clearly turned the corner," said Boral's chief executive Mike Kane.

Boral swung to an annual net profit after tax of US$161m in the financial year ending 30 June 2014, bouncing back from a US$192m net loss in the financial year ending 30 June 2013. The full-year result showed market conditions had improved across all of its divisions in Australia, the US and Asia.

Kane also expressed confidence in the American USG-Boral joint venture, which will soon launch a new lightweight gypsum board into 12 markets across Australia, Asia and the Middle East.

US: Continental Building Products (CBP) has announced its results for the second quarter of 2014, which ended on 30 June 2014. Net sales increased by 3.2% to US$103m and adjusted earnings before interest, taxes, depreciation and amortisation (EBITDA) fell to US$26.7m from US$27.4m for the same period of 2013.

"During the second quarter we continued to grow our net sales, generate significant cash flow and strengthen our balance sheet," said Ike Preston, CBP's CEO. "Excluding the impact of higher freight costs, our average mill net pricing remained firm compared to the first quarter 2014, as expected. Our overall modest wallboard demand was supported by higher shipments in our US operations that grew by 3.1% compared to 2013. As we look to the remainder of 2014, we remain confident in our ability to maintain disciplined cost control and generate additional cash flow as demand improves."

Average gypsum wallboard prices rose by 4.1% during the quarter. Wallboard volumes rose slightly to 525Mft² compared to 523Mft² in the same quarter of 2013, with a 3.1% increase in US volumes mostly offset by lower volumes in Canada. The second quarter gross profit was significantly impacted by purchase accounting from the acquisition by Lone Star. Gross profit was US$20.9m, down compared to US$25.7m in the same quarter of 2013, primarily as a result of US$7.8m in higher depreciation and amortisation costs from the acquisition.

Operating income was US$12.8m in the second quarter of 2014, down from US$17.2m in the prior year quarter, largely attributable to the impact of higher depreciation and amortisation resulting from the Lone Star acquisition. Net income was US$4.7m for the second quarter of 2014, compared to US$16.7m in the prior year quarter.

Europe: Microban International has secured a European patent relating to treated wallboard, increasing its portfolio of wallboard technology patents that include the United States, Canada, Mexico, China, Hong Kong, Australia and Brazil. The patent covers the incorporation of an antimicrobial additive package into the wallboard to resist the growth of mould and mildew. The patented wallboard employs a two-part anti-microbial system and an innovative targeting approach to provide protection against mould, mildew and fungus.

"These types of product patents help us to develop new specific formulations for dealing with microbial issues that wallboard may have, especially in humid or damp areas," said Ivan Ong, VP of research and development. "In wallboard, fungal issues typically occur at the interface between the paper and the gypsum core. Fungal infiltration of this nature can occur without visual cues until it becomes extensive and damaging. The patent provides an effective and manufacturing-friendly method to deliver a combinatorial package of antimicrobial agents to specifically target microbial issues this interface."

US: Stephen H Meima has been named as the executive director of the Gypsum Association. In this position, he leads the organisation's day-to-day operations, oversees its significant contributions to model building codes and standards and ensures that Association member companies and their customers receive vital services, including technical information on the proper selection and installation of gypsum panel products. The Gypsum Association represents all of the active gypsum wallboard manufacturers in the United States and Canada.

"The Gypsum Association has a lengthy history of service to both the gypsum community and the public in North America," said Meima. "I am proud to represent a building materials industry with a tradition of innovation and sustainability and an established commitment to safety and consumer satisfaction."

In addition to serving as the Gypsum Association's director of promotion from 1996 to 1999, Meima returned as CEO in 2013. During the interim, he served within a Gypsum Association member company for over a decade, taking on various marketing and communications leadership roles. Meima also headed marketing and membership at the Design-Build Institute of America.

A LEED Green Associate credential has enhanced Meima's ability to serve building professionals at a time when sustainability has taken on new and growing significance within the industry. In addition, Meima holds an Accreditation in Public Relations from the Public Relations Society of America.

US: USG Corporation has reported its strongest quarterly net income since 2007. Second quarter 2014 net sales of US$948m were up by 3% from second quarter 2013 net sales of US$916m. USG's second quarter 2014 operating profit was US$98m compared to US$74m in the second quarter of 2013. Second quarter 2014 net income was US$57m. This compares to a net income of US$25m in the second quarter of 2013.

"I'm pleased to report our best quarterly results in seven years," said James S Metcalf, chairman, president, and CEO of USG. "Despite slower than expected acceleration in industry opportunity, most of our businesses and products improved their performance from a year ago and we also recorded our first full quarter of operations in our USG Boral joint venture."

The corporation's adjusted operating profit was US$93m in the second quarter of 2014, which includes adjusted equity method investment income of US$6m from USG Boral Building Products, compared to an adjusted operating profit of US$76m in the second quarter of 2013. Adjusted net income was US$48m in the second quarter of 2014 compared to an adjusted net income of US$26m in the second quarter of 2013. Adjusted net income in the second quarter of 2014 excluded, among other items, a US$12m gain on the sale of its New Jersey paper mill, which has been idled since 2009.

"We remain confident in the recovery, but challenges in the macro-economic environment still exist," said Metcalf. "However, we believe that the second half of the year will be better than the first half and we are well positioned to capitalise on the improving opportunity."

US: Eagle Materials has reported financial results for the first quarter of fiscal 2015, which ended on 30 June 2014. First quarter earnings before interest and income taxes increased by 21% year-on-year to US$59.8m, as first quarter sales volumes improved across nearly all businesses areas and sales prices improved in all businesses.

Gypsum wallboard and paperboard reported first quarter operating earnings were US$45.0m, up by 27% from the same quarter of its 2014 fiscal year. Improved wallboard sales prices and increased wallboard and paperboard sales volumes were the primary drivers of the earnings increase. Wallboard and paperboard revenues totalled US$136m, an 18% year-on-year increase. The revenue increase reflects higher average wallboard sales prices and higher wallboard and paperboard sales volumes. The average wallboard sales price grew by 11% year-on-year. Wallboard sales volumes of 569Mft² represent a 7% year-on-year increase.

Thailand: Siam Gypsum Industry (SGI), a subsidiary of Siam Cement Group, expects sales of gypsum products to rise by 10% in its 2015 fiscal year, which started on 1 July 2014, to nearly US$182m due to the rebounding property market. SGI's managing director Soraphong Channarukul said that the property market was set to recover rapidly in the second half of 2014 after delays in the development of many projects.

SGI is launching its new gypsum wall product to spur sales growth in the second half of 2014. The country's overall gypsum demand should expand by 7% in the next 12 months, but SGI expects its sales will surge slightly beyond that thanks to its innovative gypsum product, Zolidwall.

Soraphong said that Zolidwall would save developers on costs, as it is stronger and lighter, requiring less time to install and decorate. Zolidwall costs 5 - 10% more than traditional wall materials such as cement, brisk and standard gypsum wallboard, but the cost will be offset by faster installation and decoration, plus it does not require the same level of skill as is required to build a traditional wall.

Yuthasak Naruchaipramote, SGI's innovation director, said that it took a year to develop a product that would satisfy the needs of customers seeking materials that save time but meet international standards. The development of Zolidwall followed close consultation from gypsum wallboard users and Pruksa Real Estate plc, Thailand's largest housing developer. Pruksa's housing projects and high-rise buildings will be among the first groups to use Zolidwall, according to Naruchaipramote.

SGI expects sales of 300,000Mm² of Zolidwall in the first year, with 30% growth within three to five years. It also plans to launch Zolidwall in Myanmar and Cambodia soon to tap their booming property markets. Zolidwall was developed at SGI's new US$627,550 product and system testing centre at the gypsum plant in Saraburi Province. The centre, which opened earlier in 2014, helps to ensure new products meet international standards. In the past only tailor-made products were launched.

Vietnam: Knauf Vietnam has commenced construction of its first gypsum wallboard plant in the northern port city of Hai Phong on 16 July 2014. Located in Dinh Vu Industrial Zone, the plant has been one of the largest foreign direct investment projects in the city. Covering an area of 63,000m², the plant has a total investment of US$40m. When the plant is operational it will have a wallboard production capacity 12Mm²/yr.

"We have just launched two distributors in Vietnam, one in the south and one in the north and now we are starting the construction of our plant," said David Thomas, Knauf's general director. "We believe that, once completed by mid-2015, the plant will help us to gain a considerable market share in Vietnam in general and in the north in particular."

Thomas said that Knauf plans to expand its relationship with key partners such as distributors, architects, developers and government authorities, with an aim to widely introduce its products to the Vietnamese market.

"Dinh Vu Industrial Zone is a strategic location in terms of transportation and manufacturing that would provide the market with high quality products at competitive prices and improve the standards of the whole industry," said Thomas.