Gypsum industry news

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.

India: Saint-Gobain Gyproc has launched a range of products including gypsum wallboards. The new product line includes 'Habito Standard' a gypsum wallboard made for heavy unplanned and planned loading applications, 'Rigiroc,' a multi-purpose moisture resistant board and 'Glasroc X,' a wallboard for exterior applications. Saint-Gobain Gyproc also released a ceiling tile product at the same time.

Najwa Khoury, Global Gypsum Strategy Director at parent company Saint-Gobain, said "Saint-Gobain Gyproc continues to be committed to meeting the demands of the changing preferences and environmental conditions in India. Over the last few years, we have seen a growing acceptance of drywall and modern ceiling tiles in India, and we want to stay ahead of the curve. We are delighted to introduce a new range of innovative products that are functionally superior, sustainable, affordable and customizable, redefining the future of construction.”

The products will be available in India and neighbouring countries including Nepal, Bangladesh, Sri Lanka and the Maldives.

France: Saint-Gobain’s chief executive officer (CEO) will also become the company’s chair after the next general shareholders meeting in June 2024. He will succeed Pierre-André de Chalendar in the role, who is preparing to retire. Independent director Jean-Francois Cirelli will also be appointed as vice-chair at the meeting.

The France-based company said that its board of directors have been working since 2021 to enhance the effectiveness of the group's governance and the independence of the board by restructuring the balance of power within it. A Lead Independent Director will also be appointed in June 2024 with additional powers and the proportion of independent directors on the board will be increased, subject to a vote.

France: Saint-Gobain says that its like-for-like sales were stable year-on-year during the first nine months of 2023. In real terms its sales were Euro36.5bn during the first nine months of 2023, down by 4.9% year-on-year from the corresponding period in 2022. The group partly attributed this to comparison effects from its previous divestment of assets, including its distribution division, and negative currency exchange effects. Across its businesses, Saint-Gobain’s volumes dropped by 5.9%. Geographically, a ‘resilient’ renovation market offset a slowdown in new construction projects to raise sales in Southern Europe, Middle East and Africa by 1% year-on-year, but failed to do so in Northern Europe, where sales dropped by 5%. Sales fell by 5.5% in Latin America, as Brazil experienced the impacts of macroeconomic difficulties, but rose by 5% in North America. Across the Asia-Pacific region, organic sales growth was 5.1%.

Saint-Gobain said “In a difficult macroeconomic environment, the group continued to outperform its markets thanks to the pertinence of its strategic positioning at the heart of energy and decarbonisation challenges and to the strength of its local organisation by country, which enables it to offer comprehensive solutions to its customers.” It added “The group continues to focus on developing sustainable and innovative solutions with a positive impact, supported by strong innovation and investments for growth.”

US: Saint-Gobain has acquired the remaining equity interest and assets of Seven Hills Paperboard, including a gypsum paper board liner manufacturing plant in Lynchburg, Virginia, from its joint venture partner WestRock. The purchase adds to the gypsum wallboard operations of Saint-Gobain’s CertainTeed Interior Products Group. The company said that the internal integration of gypsum paper board liner production represented a “significant” step in strengthening the supply chain for this material.

Mark Rayfield, President and Chief Executive Officer of Saint-Gobain North America and CertainTeed Canada said “The acquisition of these assets represents our continued commitment to our customers to provide quality gypsum wallboard products.” He added, “I would like to welcome our 80 new team members in Lynchburg and look forward to your contributions to our purpose, ‘To Make the World a Better Home.”

India: The Directorate General of Trade Remedies (DGTR) has recommended a five-year anti-dumping duty on gypsum tiles imported from China and Oman. Saint-Gobain India initiated the investigation that started in late 2022. It considered gypsum tiles laminated on one side with polyvinyl chloride (PVC) or wax paper that are typically used in ceilings. The study concluded that the product had been “exported to India at a price below the normal value, resulting in dumping.”

India: Saint-Gobain plans to invest over US$400m in its different businesses, including gypsum wallboard, in Tamil Nadu. Company chair Pierre-Andre de Chalendar and chief executive officer Benoit Bazin met the Chief Minister MK Stalin, senior ministers and officials of the government of Tamil Nadu as part of the announcement. The new funding brings the company’s total investment in the state to over US$950m.

Austria: Saint-Gobain Austria, waste management company Saubermacher and construction firm PORR have secured permission to build a new gypsum-to-gypsum recycling plant in Stockerau. The plant will cost Euro7m. Saint-Gobain Austria said that the facility will support the government’s Raw Materials 2030 circular economic development plan.

CEO Peter Giffinger said "Gypsum is endlessly recyclable, but special quality criteria must be met in order for recycled gypsum to be used again to produce new panels.”

Canada/US: Saint-Gobain has signed a 15-year renewable electricity supply agreement (PPA) with TotalEnergies for the purchase of solar power for its 125 industrial sites in the US and Canada. This 100MW PPA, known as the Danish Fields Solar Project (Danish Fields), is expected to offset Saint-Gobain’s North American CO₂ emissions from electricity (scope 2 emissions) by 90,000t/yr. The project is expected to come online by the end of 2024.

Danish Fields is the third PPA signed in North America by Saint-Gobain. The first PPA, with the Blooming Grove Wind Farm in Illinois, was signed in 2020, and the second, with TotalEnergies’ Cottonwood Bayou Solar Project in Texas, was signed in 2022. All three projects have been supported by Edison Energy, a leading energy and sustainability advisory that consults with the largest commercial, industrial and institutional energy users.

Mark Rayfield, the chief executive officer of Saint-Gobain North America, said “With this agreement, Saint-Gobain North America will further reduce its CO₂ emissions, demonstrating how fast the manufacturing industry can transform when long term solutions are at hand. This renewable energy project is a new milestone on the way to meeting Saint-Gobain’s commitment to reduce scope 1 and 2 CO₂ emissions by 33% by 2030 - compared to 2017 - and to reach carbon neutrality by 2050.”

The three projects combined are expected to represent a reduction of more than 70% in Saint-Gobain North America’s scope 2 emissions, compared to 2017 levels.

UK: British Gypsum’s non-loadbearing metal stud plasterboard partition systems, including shaft walls, have become one of the first products on the local market to carry the Code for Construction Product Information (CCPI) mark. The scheme is intended to provide assurance to end users that the product information for these products is clear, accurate, accessible, up-to-date and unambiguous.

The CCPI was initiated by the Construction Product Association (CPA) as a direct response to Judith Hackitt’s review of Building Regulations and Fire Safety set up in the wake of the Grenfell Tower fire in 2017. The CPA is a UK-based construction industry trade association.