Gypsum industry news

US: According to Charlotte Business Journal, Duke Energy has proposed excavating 12 more of its 36 coal ash ponds in North and South Carolina and burying the waste in a fully-lined landfills or structural fill projects.

To date, Duke has proposed closure plans for 24 of the 36 ash ponds. In every case, it has proposed excavation and reburial. However, Garry Miller, head of closure engineering for Duke, said that might not be the case for the remaining 12 ponds. He said that the engineering work that remains to be done at those plants could yet show that a 'cap in place' process, which critics have said would be insufficient to protect against further contamination of groundwater, can effectively close them.

Miller said that none of the waste ash from Duke's 36 ash ponds would undergo beneficial reuse, the process of using the ash for commercial products such as a replacement for Portland cement in concrete and gypsum board. However, he added that Duke does send a portion of the dry ash it is currently producing at its largest plants for reuse. However, the time constraints imposed by North Carolina's Coal Ash Management Act of 2014 make it impossible for the existing ash ponds. "As we close these basins, the quantity in them is such that the market cannot handle it in a timely manner," said Miller.

Duke's current cost estimate for closing the ponds is US$3.4bn, although this is subject to revision.

US: According to local media, NB Power has paid J D Irving more than US$12.3m in penalties and contract renegotiation fees since 2009.

"The revelation that NB Power has a contract with J D Irving to provide gypsum from the oil-burning Coleson Cove plant until 2026 for Irving's wallboard plant and pay J D Irving when they can't deliver stunned many New Brunswickers," said David Coon, New Brunswick Green Party leader. "It reminds me of the contract this government currently has with J D Irving to supply an unsustainable volume of softwood from the Crown lands for years into the future or pay up if they can't deliver."

The 2005 contract commits NB Power's Coleson Cove generating station to provide a minimum amount of synthetic gypsum to Atlantic Wallboard every year until 2026. NB Power currently produces 20,000 - 30,000t/yr of gypsum. According to NB Power, the contract states that in the event of a production shortfall, NB Power must pay for the difference between the actual gypsum supplied and the minimum amount of gypsum agreed to in the contract. NB Power has paid US$5.33m in shortfall penalties since the 2009 - 2010 fiscal year. NB Power paid Atlantic Wallboard another US$5m in 2010 - 2011 so that it could reduce the annual cap that it is required to meet, thereby reducing the penalties it has to pay in the future.

Brent Staeben, director of marketing and communications for NB Power, said that the contract was again renegotiated recently, costing another US$2m. "The contract has evolved over time to reflect the fact that the production at Coleson is changing. We have been in constant talks and negotiations over the course of this contract with the buyer to ensure that it better reflects the production at the facility, said Staeben. NB Power has budgeted another US$829,000 for a penalty payment for 2015 - 2016.

Despite the fact that Coleson Cove is producing less gypsum than anticipated, Staeben sid that the contract still makes economic sense because the gypsum needs to be disposed of one way or another. "Originally we committed because we had some sense of how much we would be producing over time. We estimated that, at that time, when we looked into the future, we would need to landfill this," said Staeben. "The cost of landfilling would be significant, in the tens-of-millions of dollars. Even with the changing nature of production there, it's still a very, very good deal for New Brunswickers," he added.

"Without the synthetic gypsum from Coleson Cove, the project would not proceed as the economics to run a gypsum plant in Saint John, relying solely on natural gypsum rock, would not be viable," said Atlantic Wallboard's franchise application to the New Brunswick Energy and Utilities Board in 2006. The document also stated that, "Over time, however, synthetic gypsum from NB Power's generating stations will be supplemented by natural gypsum planned to be imported from out-of-province sources to produce wallboard products."

US: Oklahoma-based ACG Materials has appointed Paul Harrington as its new CEO. ACG Materials is a national provider of minerals, aggregates and related downstream products including gypsum, limestone, sand, gravel and anhydrite.

Paul Harrington joined ACG Materials in July 2014 as president and COO. Prior to July 2014, Harrington was executive vice president at Rain for Rent. Before that, he spent 24 years working for Holcim.

US: Continental Building Products has announced the appointment of Dennis Schemm as chief financial officer, effective from 11 May 2015.

"We are excited to welcome Schemm to our leadership team," said Jay Bachmann, Continental's CEO. "He has a proven history of experience, with more than 20 years in finance, including 16 years in senior management roles at publicly-traded industrial companies. His extensive and broad leadership capabilities will be instrumental to supporting our efforts as we further strengthen our low-cost position and generate additional cash flow as our end markets improve."

Schemm most recently served from 2013 to 2015 as vice president of global finance for Armstrong Flooring, a division of Armstrong Worldwide, where he oversaw the division's financial and accounting functions. From 2011 to 2013, Schemm served as director of global financial planning and analysis at Gilbarco Veeder Root, a Danaher Corporation, where he was responsible for operational and strategic planning and provided financial leadership for global operations and research and development.

US: Eagle Materials Inc has reported its financial results for its 2015 fiscal year that ended on 31 March 2015.

Earnings before interest and income taxes increased by 32% year-on-year to US$265m, reflecting improved sales volumes across nearly all business lines, with cement sales volumes setting an annual record of 4.8Mt. Net sales prices also strengthened across all businesses. Fourth quarter earnings before interest and income taxes increased by 31% to US$44.4m, as fourth quarter sales volumes improved across nearly all businesses, reflecting improving construction fundamentals in the US.

On 3 March 2015, Eagle entered into a definitive agreement with Holcim (US) to purchase its 600,000t/yr granulated ground blast furnace slag (GGBFS) plant in South Chicago. The purchase price of US$30m is subject to customary post-closing adjustments and will be funded from operating cashflow. The transaction is expected to close in the second quarter of its 2016 fiscal year and is conditioned upon the closing of the Lafarge-Holcim global merger.

Operating earnings from gypsum wallboard and paperboard grew by 28% year-on-year to US$177m in the 2015 financial year. Revenues from gypsum wallboard and paperboard grew by 13% year-on-year to US$525m. Gypsum wallboard and paperboard fourth quarter operating earnings grew by 32% year-on-year to US$38.3m. The increase in operating earnings was primarily due to higher net wallboard and paperboard sales prices and higher wallboard sales volumes. Gypsum wallboard and paperboard revenues for the fourth quarter grew by 5% year-on-year to US$112m. The average gypsum wallboard net sales price for the quarter grew by 4% year-on-year to US$168.97/Mft². Gypsum wallboard sales volumes grew by 5% year-on-year to 464Mft² in the fourth quarter.

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.

US: Gypsum Management and Supply Inc (GMS) has launched its newly-redesigned website. The company has said that new website was established to 'capture the essence of the brand today,' as well as to digitally facilitate its core competencies in servicing customers and connecting them to local markets.

"GMS has a long-standing commitment to offering customers a better experience," said Michelle Leader, marketing director of GMS. "Our goal continues to be to connect with our customers on a local level and provide the best possible service. This new website helps support this effort, but more importantly equips our customers for success on the job."

US: USG's sales for the first quarter of 2015 have risen by 7% year-on-year to US$909m. The company's operating profit rose by 15% to US$76m in the same period. The positive results were driven by its gypsum and ceilings divisions.

"USG is off to a great start in 2015, led by the performance of our US Gypsum and US Ceilings businesses... We generated operating margin improvement in these businesses by achieving price increases, focusing on manufacturing cost control, and tailoring our spending on investments in these businesses," said James S Metcalf, Chairman, President, and CEO.

USG also announced that it has entered into agreements to sell the two ships in its non-core shipping business, Gypsum Transportation Limited (GTL), for US$42m. The sales of the ships are expected to close in April 2015.

US: Al Mueller has joined the PABCO Building Products LLC board of managers with effect from 1 April 2015. Following Mueller's retirement as PABCO's president, he served on the Basalite Concrete Products LLC board of managers and will continue to do so going forward. Mueller gained a wealth of experience in the gypsum, roofing and paper industries, while providing leadership during his tenure as PABCO's president. His knowledge and expertise of both the industry and the operations will be a very valuable addition to the board.

US: Gypsum Management and Supply Inc (GMS) has made a strategic entrance into the California and Hawaii markets by acquiring San Diego-based J&B Materials Inc and its affiliated Hawaiian operation, Pono Building Materials LLC.

"We are pleased to bring J&B Materials and Pono Building Materials into the GMS family," said Mike Callahan, president of GMS. "Their commitment to delivering exceptional service, knowledgeable personnel and an expansive product suite with a focus on safety fits well within our culture. This partnership provides us with an excellent opportunity to expand our service area into California and Hawaii while enhancing our West Coast coverage."

J&B Materials has locations in El Cajon, Escondido, Riverside and El Centro in California and one in Honolulu, Hawaii. J&B offers a wide variety of building products including wallboard, stucco, lath and plaster and fasteners among others.

Don Taylor, the GMS vice president of operations for the western region, sees the acquisition as a key step in growing the GMS footprint in California and the whole southwestern US. "We feel that J&B, with its exceptional customer relationships and strong brand name, will be a key component to further expansion. With Bob and Jeff Young joining our team, this will give us the additional management depth to continue our growth," said Taylor.