Gypsum industry news

Canada: CertainTeed Canada has welcomed the Canadian International Trade Tribunal's ruling in favour of six provinces and territories' anti-dumping measures on imports of gypsum wallboard. The tribunal found that imports of gypsum wallboard from the US threatened material injury to the domestic industries of Alberta, British Columbia, Manitoba, Northwest Territories, Saskatchewan and Yukon.

CertainTeed Canada chief executive officer Julie Bonamy said "CertainTeed Canada is committed to free and fair trade; we have helped shape the Canadian building products industry for more than 80 years." Bonamy concluded "We are committed to supporting our customers and employees through our facilities in Vancouver, Calgary and Winnipeg."

North America: France-based Saint-Gobain has appointed Steve Williams president of its newly created construction chemicals North Americas unit. The unit combines GCP Applied Technology's speciality construction chemicals business and Chryso. Saint-Gobain acquired both GCP Applied Technology and Chryso in 2021.

Steve Williams previously worked as Chryso's North America president from 2019. Prior to this he was cement producer Titan America's sales and marketing director between 2012 and 2015. Williams holds a bachelor of science degree from Brigham Young University and a master’s in business administration (MBA) from the University of Florida.

UK: The European Space Agency, University of Glasgow and others are using France-based Saint-Gobain's Bantycock, Nottinghamshire, quarry to test new drill bit designs for their Drill for Extensive Exploration of Planetary Environments Using Robots (DEEPER) project. The project aims to develop tens-of-metres-long spoolable drill 'strings' to help in the search for water on Mars. Researchers will use their prototypes to drill directly into the mine's gypsum deposits. Saint-Gobain said that the hydrated mineral gypsum provides a similar geological profile to that of Mars.

Gypsum wallboard production by Saint-Gobain subsidiary British Gypsum at its nearby Barrow upon Soar, Leicestershire, and East Leake, Nottinghamshire, gypsum wallboard plants relies on Bantycock gypsum.

US: Saint-Gobain subsidiary CertainTeed's Buchanan gypsum wallboard plant in New York has successfully participated in a gypsum wallboard recycling pilot. Together with contractors Structure Tone and Cooper Recycling, it processed 20t of gypsum from waste wallboard in its gypsum wallboard production.

CertainTeed interior products vice president and general manager Jay Bachmann said "For us to achieve our sustainability goals, we must change the way we think. By partnering with organisations in the community like Cooper Recycling and Structure Tone, we can get there faster." Bachmann continued, "As the only gypsum manufacturing plant in New York, our colleagues in Buchanan were able to create a true circular economy. From the creation of drywall products to construction, to processing scraps and back into drywall production, the material is continuously used and never leaves the state. This maximises our company's positive impact while working to minimise our environmental footprint. Our Buchanan plant has increased our capacity to reuse recycled material, and we look forward to growing this successful pilot into a long-term programme, while working with builders and recyclers across the state. Partnering with CertainTeed, New York builders have the opportunity to not only reduce waste at their job sites, but also gain Leadership in Energy and Environmental Design (LEED) points on their projects."

The Buchanan plant joins CertainTeed's units at Nashville in Arkansas and Palatka in Florida in supporting the company's circular economic efforts in the US. The Nashville plant commissioned a 65,000t/yr line in May 2022, while the Palatka plant increased the recycled content of its wallboard by 18,000t/yr in August 2022. The Palatka plant plans to install a new 100t/hr Rotochopper grinding unit to replace its existing trommel machine in its reclaim processing and screening operations.

Poland: Saint-Gobain has signed a renewable electricity agreement (Power Purchase Agreement) with Tion Renewables AG (currently being renamed from Pacifico Renewables Yield AG), the German wind and solar power producer. The 15-year agreement will run from 2025 and cover around 45% of Saint-Gobain Poland's electricity needs.

"This power supply agreement is an important milestone for Saint-Gobain in Poland. It will contribute to a significant reduction in our CO₂ emissions, in line with the group's commitment to achieve carbon neutrality by 2050' said Joanna Czynsz-Piechowiak, chief executive officer of Saint-Gobain Poland. "It will enable a reduction in CO₂ emissions of 135,000t/yr, i.e. nearly 20% of Saint-Gobain's scope 1 and 2 emissions in Poland.

The PPA foresees the purchase of approximately 190GWh of wind energy annually. This is equivalent to supplying about 100,000 European homes with renewable electricity each year. The total capacity of the wind farms is equivalent to circa 52MW spread over three sites and 20 wind turbines. This announcement illustrates how Saint-Gobain is stepping up the pace on its carbon neutrality roadmap and comes in the wake of the recent endorsement by the Science Based Targets initiative of the group's commitments to reduce CO₂ emissions by 2050.

France: Saint-Gobain and the solar manufacturer Megasol, the European leader in Building Integrated Photovoltaics (BIPV), have announced a strategic partnership. As part of this partnership, Saint- Gobain has acquired a minority stake in Megasol's business unit that develops and manufactures building-integrated photovoltaics in Deitingen, Switzerland. The partnership enables Saint-Gobain to extend its sustainable solutions offer for façades and to become the leading provider for BIPV façade solutions in Europe, one of the fastest growing segments of façade construction. At the same time, it gives Megasol access to Saint-Gobain’s customer base.

BIPV's solutions contribute to sustainable construction and decarbonisation by efficiently producing energy from the surfaces of buildings. Building owners cannot only comply with today’s and future energy regulations and increase their own energy efficiency, but they can also generate additional revenue by feeding the electricity into the grid.

This investment is in line with Saint-Gobain's 'Grow & Impact' plan to further strengthen its leadership position in light and sustainable construction.

Canada: Saint-Gobain has named Julie Bonamy Racine as the chief executive officer (CEO) of its subsidiary CertainTeed Canada. She succeeds Richard Juggery, who led the company for four years before being named CEO of Saint-Gobain Benelux in July 2022. She will also be CertainTeed Canada's first female CEO.

Bonamy previously worked as the CEO of Saint-Gobain Malaysia, Singapore and Indonesia. She joined the company in 2017 in Paris as Group Vice President, Strategy & Planning. Earlier in her career, Bonamy worked in the public sector, most recently as an adviser for the budget and digital sector for the Office of the French Minister for the Economy. She is a graduate of the Paris Institute of Political Studies (IEP de Paris) and the National School of Public Administration (Ecole Nationale d'Administration).

France: SaintGobain says that the Science Based Targets initiative (SBTi) has approved its CO₂ reduction targets. The group plans to achieve net zero CO₂ emissions, both direct and indirect, along its entire value chain by 2050. This will entail a reduction in CO₂ emissions of at least 90% in the three scopes by 2050, with additional sequestration projects planned for residual emissions.

Saint-Gobain's commitments to reduce, in absolute terms, by 2030 from 2017 its direct and indirect CO₂ emissions (scopes 1 and 2) by 33% and its scope 3 emissions, mainly linked to purchasing and transport, by 16% by 2030 was already validated in 2020 by the SBTi. The group says it will continue to accelerate its roadmap, notably through improvements in energy efficiency, product weight reduction, increased recycled content and the use of green energies, in order to align its targets with the most demanding trajectory, which limits the rise in temperatures to 1.5°C.

Earlier this month the German Gypsum Association (GIPS) gave its approval for an inventory of natural gypsum deposits in Germany that was presented at the Conference of Economics Ministers that took place in early July 2022. The Federal Commission on Geosciences (BLA-GEO) had previously been given the job of taking an inventory of deposits and this was then put in front of the policy makers. The association’s stance was all about securing future supplies. In its view there will be no large-scale alternatives to natural gypsum supplies in the foreseeable future due to low recycling rates and falling production of flue gas desulfurisation (FGD) gypsum as coal power plants are shut down. So a list of where natural gypsum might be found is the start of conversations about which ones might be mined. Readers who are interested can download the inventory of German gypsum deposits here.

Security of supply of raw materials has been in the air since the end of the coronavirus lockdowns started to cause supply chain disruption around the world and the Russian invasion of Ukraine further exacerbated this and rocked energy markets. Part of the reaction to this new reality could be seen in a conference that the Federal Institute for Geosciences and Natural Resources (BGR) and the German Resource Research Institute (GERRI) ran, also in early July 2022. The state of German gypsum supplies was presented at this event too. The BGR-GERRI conference came up with a ten-point plan to strengthen the supply of raw material. Some of these recommendations were to grow domestic raw material extraction, expand recycling and the circular economy and keep supply chains closer internationally, ideally within Germany and Europe.

A focus on gypsum supplies isn’t restricted to Germany though. The issue arose in late July 2022 during an earnings call for US-based Eagle Materials’ first quarter results. These kinds of questions from analysts about supply of raw materials are common for a public company but it reinforces the general declining trend around the world of synthetic gypsum supplies. Craig Kessler, the chief financial officer of Eagle Materials, mentioned that a scarcity of synthetic gypsum might be creating cost pressures for other gypsum wallboard producers. Although he was quick to describe his company as a “natural gas or natural gypsum oriented business.” The wider picture in the US is that the ratio of natural to synthetic gypsum production has grown over the last decade. United States Geological Survey (USGS) data shows that it was 37% / 49% in 2011 compared to 53% / 32% in 2021, with the remainder imported in each year.

One more point to make here is that many of the new gypsum wallboard plant projects announced in the over the last few months have involved recycling in one form or another. For example, Siniat’s forthcoming wallboard plant in Bristol in the UK aims to achieve 30% post-consumer gypsum recycling. CertainTeed’s current upgrade plans for its Palatka plant in Florida are also recycling-based. Similarly, the subsidiary of Saint-Gobain also completed an upgrade in June 2022 to allow more recycling at its Nashville plant in Arkansas.

Finally, some of the thinking in Germany and elsewhere has been influenced by the current geopolitical situation in Ukraine. However, one potential consequence of prolonged disruption to European energy markets could be a delay to the decline of coal power plants as plant lifespans are elongated or even new ones built. This in turn could mean more synthetic gypsum supplies in Europe in the short to medium term. How all of this plays out in the placement of new gypsum wallboard plants in Europe over the next few years will be interesting to observe.

US: CertainTeed plans to spend US$1.1m towards installing recycling equipment at its Palatka gypsum wallboard plant in Florida. The upgrade will increasing the recycled content of its wallboard products manufactured at the unit by 18,000t/yr while also reducing the site’s CO₂ emissions by 2260t/yr.

The new recycling equipment at the Palatka plant will work by grinding the waste gypsum and waste paper down into fine particles, allowing the plant to capture and internally recycle the materials, which are sorted and then reintroduced to the production process at the plant. The kit will be powered by electricity and will replace older machines currently powered by diesel, lowering the plant’s Scope 1 Emissions from its operations. Additionally, by consuming more recycled gypsum, the plant will become less reliant on feedstock that is shipped to the site from external sources, allowing the unit to also reduce Scope 3 Emissions associated with transporting the feedstock.

Jay Bachmann, the Vice President and General Manager of CertainTeed Interior Products Group, said, “The new technology in Palatka will allow us to increase the recycled content in our products, reduce our carbon CO₂ at the plant, and strengthen our operations at a time of unprecedented consumer demand for gypsum wallboard in the south-eastern US.”

The investment at the Palatka plant follows similar investments that will increase the recycled content of wallboard made at CertainTeed’s wallboard plants in Silver Grove in Kentucky and Nashville in Arkansas. Parent company Saint-Gobain continues to roll out its global ‘Grow and Impact’ strategy, which includes reducing waste and increasing recycling efforts at its manufacturing sites.