Gypsum industry news

US: A team from Washington State University have developed bricks made from recycled gypsum wallboard. The blocks are made from 80% drywall waste and a binder made from industrial by-products. They are waterproof and lighter than earth blocks, bricks or concrete blocks. The researchers are partnering with local contractors to get the waste, and architecture students are using a press to build the blocks, which look like masonry bricks.

The researchers, including Taiji Miyasaka, professor in the School of Design and Construction, David Drake, adjunct faculty in the School of Design and Construction, and Robert Richards, a professor in the School of Mechanical and Materials Engineering, began developing the wallboard blocks in 2017 with a grant from the American Institute of Architects. They have also received an Amazon Catalyst grant to move the project from laboratory scale to a demonstration structure. In the next year, the researchers will be testing the blocks to meet building, seismic and fire codes. They also aim to build a 15m² demonstration structure.

A prototype structure featuring the wallboard-based bricks will be displayed as part of the ‘Make/Do: A History of Creative Reuse’ exhibition that is running at the Washington State History Museum until December 2018.

Ireland: Gyproc has launched what it says is the country’s first wallboard recycling service at its Kingscourt plant in County Cavan. The subsidiary of Saint-Gobain hopes to recycle 0.5Mt of wallboard by 2028. It has spent Euro1.5m on the upgrade to the plant and it has increased the number of employees to 220.

“We’re very proud to be the first and only plasterboard manufacturer in the country to offer recycling of our products on the island,” said Brian Dolan, Managing Director of Gyproc. “As a market leader in this sector we are determined to be at the forefront of innovation in new products and services, and in the sustainability and environmental benefits of those services.” The manufacturer sources gypsum from its Drummond mine in County Monaghan.

Denmark: Environmental services company Reconor, a subsidiary of private equity firm Agilitas, has purchased Mijodan for an undisclosed sum. Mijodan, based in South Jutland, recycles a number of products, including gypsum wallboard.

UK: Mid UK Recycling plans to increase the amount of plasterboard it processes by 50% to 75,000t in 2018. The waste management company recycles gypsum wallboard at its Ancaster plant in Lincolnshire. It processes plasterboard from waste transfer stations and local governments across the UK. Subsequently, it produces several grades of gypsum products for different industries, including gypsum wallboard, cement production, cat litter and industrial absorbents.

Germany: Rigips has inaugurated its first gypsum recycling plant at Gelsenkirchen in North Rhine-Westphalia. The subsidiary of Saint-Gobain will recycle gypsum with New West Gypsum Recycling Germany. Waste material from buildings from the Rhine-Ruhr region and the northern part of Rhineland-Palatinate will be sent to a reprocessing site operated by New West Gypsum first before being despatched to the Rigips plant where it will be returned to the production process. Rigips intends to open more gypsum recycling plants following the start-up process of its new unit.

"With the start of the plant, Rigips assumes a pioneering role for the entire drywall construction industry. As the first manufacturer, we in North Rhine-Westphalia are now able to implement the idea 'from gypsum to gypsum'. Thus we cover the complete product service life cycle, from the raw material extraction via the production and installation to the demolition and the recycling," said Werner Hansmann, chairman of the management at Rigips.

Germany: Canada-based New West Gypsum Recycling (NWGR) has announced that it will invest in a new gypsum recycling facility in Hürth / Cologne, Germany. NWGR, together, with its local joint venture partner Schulz Baustoffe GmbH, will build a state-of-the-art plant with a gypsum recycling capacity of 90,000t/yr. It will begin operations in January 2017.

NWGR says that the plant location allows easy access to the main industrial areas of Cologne, Düsseldorf, Dortmund and the south west of the Netherlands. It adds that the new plant will 'set the new standard in recycled gypsum, unmatched particle size and paper content, combined with the highest care for safety and the environment.'

100% of the recycled gypsum produced by the plant will be used in the production of gypsum wallboard in the Rigips plant in Scholven, Germany.

New Zealand: Auckland's first comprehensive recycling facility for building industry waste, including wallboard, has been opened by the environment and building and housing minister Nick Smith, according to Live News.

"This new recycling facility is about greening the building industry, enabling 30,000t/yr of construction and demolition waste to be diverted from going to landfill. It will enable thousands of tonnes of wood, wallboard, steel, plastics and aggregates from the construction sector to be sorted and re-processed into a reusable form," said Smith.

The US$2.78m facility is part-funded by a government grant of US$1.39m from the Waste Minimisation Fund and has created 15 jobs in the local Onehunga community. The fund was established by the government from a US$6.6/t levy on waste going to landfill that was introduced on 1 July 2009. Over US$39.6m has been used to fund more than 100 projects in the past five years.

"The opening of this new facility is very timely with Auckland on the brink of its largest ever building boom. The house build rate has increased from 4000/yr to 8000/yr since 2011 and is expected to grow to over 12,000/yr. Each home constructed generates 4t of waste and it makes sense to recycle as much of this construction material as possible," said Smith.

Wood, plasterboard, steel, plastics, aggregates and cardboard are being targeted by CID Resource Recovery for recycling or reuse. Wood will be further processed into biofuel for industrial kilns, while old wallboard can be recycled for use as a soil conditioner. Scrap steel will be extracted by magnet and delivered to metal recyclers for processing and sale on the local or export markets. Various grades of plastic, card and paper will go to local recyclers for processing. Aggregates will be used locally for hardfill or drainage material on building or infrastructure projects.

"This sort of practical approach to recycling typifies the Government's Bluegreen approach to waste. We are partnering with business to find economically-viable ways to recycle waste and focusing on those areas where there are the biggest gains. This initiative is particularly significant as construction and demolition waste makes up half of New Zealand's total waste going to landfill," said Smith.

UK: Mid UK Recycling Limited plans to extend its Wilsford Heath waste management facility at Ancaster, South Kesteven in Lincolnshire. If its plans are approved, the plant would recycle up to 350,000t/yr of waste mattresses and plastics.

Chris Mountain, managing director, said that the investment could run into 'multiple millions' of Euros. "We are an existing business, we employ 350 people in Sleaford, Caythorpe and the Ancaster site," said Mountain. "We will put in the main planning proposal in the next three months and as soon as we get the green light we'll start straight away." He said that initially the company wants to start by the end of December 2015, although it may take three years to complete the expansion. "We have been four years developing the site next-door, which is full to capacity now," he said. "The range of products we produce is getting wider and wider. It makes no sense to export those jobs out of the county."

There would be a building for machinery that could break down mattresses into resalable parts. Leftovers would form solid recovered fuel (SRF) products, which could by cement plants and power stations. Another building would be created for packing and storing gypsum from recycled wallboard, which would be sold to supermarkets as cat litter. The business would also bring in a new way of recycling rigid plastics, breaking them down into granules to sell to Lincolnshire manufacturers of drainage pipes, water pipes and car parts.

US: Wallboard recycler USA Gypsum has opened its US$3m wallboard recycling plant and corporate headquarters in the West Cocalico Township, Pennsylvania. The company said that the new buildings and equipment will produce better quality products more efficiently and will help USA Gypsum to divert even more wallboard waste from landfills.

The recycling plant also includes renovated buildings for packaging, storage and offices. In the past 10 years, USA Gypsum has diverted more than 225,000t of wallboard from landfills, converting it to beneficial use by farmers in the form of gypsum fertiliser, soil conditioners and amendments and gypsum animal bedding. In spite of this growth, USA Gypsum has estimated that less than 10% of wallboard scraps generated in Pennsylvania are recycled. USA Gypsum ships its gypsum products across the US and Canada.

Europe: The GtoG project (The perfect loop - the path to a circular economy: A European collaborative approach between the recycling industry, the demolition sector and the gypsum industry) has developed a film that presents in detail the project objectives and results.

Gypsum products like wallboard and blocks are among the very few construction materials where closed-loop recycling is possible. The recycling process separates gypsum from paper and both materials can be re-used to repeatedly produce the same products. The overall aim of GtoG is to transform the gypsum demolition waste market to achieve higher recycling rates of gypsum waste, thereby helping to achieve a resource-efficient economy.

The newly-launched film enables the audience to gain insight on the project developments and is part of the consortium's willingness to enhance the quality and availability of information to all industry professionals and to its stakeholders. The film includes contributions from professionals covering not only the entire gypsum supply chain (demolition, recycling and production), but also the full range of organisations represented in the project (universities, consulting agencies and demolition, recycling and manufacturing companies).