Gypsum industry news
SGK unifies USG Boral brand across 12 countries
07 February 2017US: SGK, a division of Matthews International Corporation, has created a global, unified packaging system for USG Boral. USG Boral hired SGK to brand its varied processes and brands packaging into one core and consistent master brand. The common goal was to unify 14 categories across 12 markets and 13 businesses into one cohesive efficient packaging system.
To prepare for the branding exercise, the USG Boral and SGK teams conducted audit sessions within the different markets and spoke to a range of stakeholders, architects, builders, contractors, distributors and end users. The aim was to create a unified portfolio architecture that allows for future 'premiumization,' whilst optimising brand recognition and product navigation. The new packaging design is intended to allow easy navigation of product types through vivid colours and bold typography. It also includes anti-counterfeiting measures.
"Our partnership with SGK has been a fascinating journey in designing a new, cohesive packaging system for our diverse portfolio across the Asia-Pacific and Middle East markets. The system manages to convey the union of USG Boral's premium positioning and best-in-class building products technology, manufacturing and distribution footprint. We are now becoming one USG Boral across 12 different markets and cultures throughout Asia, Australia and the Middle East," said Jeremy Verstraete, Marketing Director, USG Boral.
USG Boral to upgrade wallboard plant in South Korea
09 June 2016South Korea: USG Boral plans to increases production at its Dangjin, South Chungcheong wallboard plant by at least 30Mm2. Currently the plant, operated by USG Boral Korea, has a production capacity of 70Mm2. Work on the upgrade will start in the fourth quarter of 2016 and the extra manufacturing lines are expected to be fully operational by the end of 2018, according to the Korea Times.
US: USG's net sales have risen by 7% year-on-year to US$970m in the first quarter of 2016 from US$909m in the same period in 2015. Its operating profit rose by 67% to US$127m from US$76m. The building products company reported sales growth across its gypsum wallboard, ceilings and distribution businesses.
"We're off to a strong start in 2016, with arguably the best quarter we've had in almost a decade," said James S Metcalf, Chairman, President, and CEO. "We realised significant operating margin expansion in all of our US operations, led by our ceilings business which turned in an all-time record quarter."
The corporation's gypsum business saw its net sales rise by 10% to US$635m from US$577m. Its operating profit rose by 63% to US$111m from US$68m.
Wallboard sales volumes rose by 20% while the wallboard price was down roughly 2% on differences in mix and the timing of price increases. The corporation reported that a 28 March 2016 wallboard price increase has driven price improvement in wallboard through the first three weeks of the second quarter of 2016.
The USG Boral business generated US$7m of equity method income in the first quarter of 2016, down US$1m from the first quarter of 2015 due to poor exchange rates.
USG Boral starts local gypsum wallboard production
06 November 2015Oman: USG Boral Middle East has started manufacturing its Sheetrock wallboard brand and wall solutions at its production unit in Salalah, Oman.
The local production will cater to its customers in the Gulf and the wider Middle East region. USG Boral Zawawi Drywall is the first to produce the Sheetrock brand in the Gulf Cooperation Council (GCC).
"Here in the Gulf region and around the world, our focus is on delivering innovation that helps our customers work smarter, do more and build better projects," said Fares Saghbini, the Managing Director at USG Boral Middle East. "That is exactly what the launch of our locally-produced Sheetrock brand wallboard products in the GCC enables us to do. We are delighted to bring our manufacturing facility and premium products closer to our customers without compromising on quality, dependability and, most importantly, the safety standards upon which Sheetrock's reputation has been built."
USG's Sheetrock production line in Oman has been fully certified by UL to produce fire rated products and will continue to undergo quarterly inspections according to UL's standards testing for quality, uniformity and safety including fire resistance.
USG to shift focus to Asia
03 November 2015Asia: USG has expanded its business in the Asian region with a joint venture with Australia's Boral to strengthen its foothold in the wallboard market.
"Korea is our second-largest market and is one of the big elephants along with Australia, Thailand and Indonesia," said James Metcalf, USG President and CEO.
USG Boral, a 50-50 joint venture formed in 2014, entered the building materials business with sales and operations across Asia, Australasia and the Middle East with a goal to grow earnings from the regions and to transform the business over the longer term through its product and manufacturing solutions, which include ceilings, cement board, fibreboard and lightweight wallboard.
Metcalf said that USG Boral has a five-year capital plan of investment in the areas and facility expansion, as well as transfer of technological know-how. He declined to disclose the exact amount of investment, citing confidentiality. "With strong GDP growth, Asian countries' adoption rate is expected to increase. The critical mass happening in Korea and the rest of Asian countries will continue to round out our portfolio," said Metcalf.
Metcalf said that the marriage between USG's building supply technologies and Boral's wallboard distribution footprint in the Asian and Australian markets is expected to create greater synergies in the next decade. "I wouldn't be surprised if this part of the business becomes larger than what we have in North America in the next 10 years," he said.
USG Corporation Reports Third Quarter 2015 Results
23 October 2015US: USG Corporation has reported that, on a consolidated basis in the third quarter of 2015, its net sales were US$972m, consistent with the third quarter of 2014.
On an adjusted basis, USG's net sales increased by US$20m or 2%. Operating profit improved by US$80m to US$102m. USG's adjusted operating profit was US$115m in the third quarter of 2015, an US$8m increase from the third quarter of 2014. USG generated US$76m in net income in the third quarter of 2015, compared to a net loss of US$12m in the third quarter of 2014. On an adjusted basis, net income of US$76m increased by US$14m from the third quarter of 2014. Foreign currency unfavourably impacted consolidated net income by US$8m in the third quarter of 2015. Adjusted results exclude results from Gypsum Transportation Limited (GTL) a shipping operation which USG has exited, litigation settlement charges and impairment charges were all recorded in the third quarter of 2014.
USG's gypsum segment generated US$89m of operating profit in the third quarter of 2015. On an adjusted basis, operating profit of US$89m improved by US$4m over the third quarter of 2014, led by the US gypsum business. Wallboard provided US$7m of improved operating profit, while the surfaces and substrates businesses contributed US$6m in incremental profit. These improvements were offset by US$5m of increased selling, general and administrative spending due to the timing of projects and costs incurred, as well as a US$4m unfavourable foreign currency impact.
The USG Boral business generated US$12m of equity income in the third quarter of 2015, consistent with the amount earned in the third quarter of 2014. On a currency-neutral basis, the USG Boral business earned US$15m of equity income, a US$3m improvement over the 2014 quarter.
"We saw margin expansion in our gypsum, distribution and USG Boral businesses, notwithstanding softer than expected demand," said James S Metcalf, Chairman, President, and CEO. "In the third quarter we saw improvements in wallboard, strong contributions from our surfaces and substrates businesses, organic margin growth in distribution and continued expansion in USG Boral. With our focus on controlling costs, we are well positioned to take advantage of an improving demand environment going forward."
Oman: USG Zawawi Drywall SFZ 's US$37m state-of-the-art gypsum plant in Oman's Salalah Free Zone (SFZ) was inaugurated on 6 May 2015 marking the formal start of commercial production of a range of Sheetrock brand gypsum wallboard products earmarked primarily for export across the Middle East and Indian subcontinent. USG Zawawi Drywall SFZ is a 50:50 partnership between USG Corporation, Boral and Zawawi Minerals.
"We are pleased to see the opening of this successful US-Omani venture. Building relations between the US and Oman is a top priority of the US Embassy and this work is a shining example of the strategic coordination that benefits both our countries," said Ann Mason, economic-commercial officer from the US Embassy. "We applaud USG Boral and Zawawi Minerals for taking full advantage of the potential of Salalah Port and Free Zone and the US Oman Free Trade Agreement."
Commissioning of the Salalah plant, which has 8Mm2/yr of gypsum wallboard production capacity, began in March 2015. It was designed to enable future expansion to double wallboard production capacity or add new products like construction plaster. The plant will produce a wide range of Sheetrock gypsum boards, including products resistant to water, fire, sound, impact and mould. According to Curt Loring, general manager of USG Zawawi Drywall SFZ, it will produce products with special certifications not currently manufactured or available in the GCC. These products are specially engineered for custom wall systems in demand by architects for commercial construction.
The products will be marketed across the Gulf and Indian Subcontinent. Uptake is expected to be robust around the Gulf Cooperation Council (GCC), where a commercial construction boom is already underway. The raw gypsum is sourced entirely from a major gypsum quarry located in the Thamrait area of Dhofar Governorate. The quarry is operated by Zawawi Gypsum and is jointly-owned by USG-Boral and Zawawi Minerals.
"USG Zawawi Drywall's investment is in keeping with the Omani government's economic policies advocating the sustainable commercialisation of natural resources to diversify the economy, create employment for Omanis and facilitate inflows of investment and know-how. The Salalah facility operates to the same stringent safety and environmental standards applied by USG at its facilities in the US," said Alawi Al Zawawi, chairman of USG Zawawi Drywall SFZ.
Awadh Al Shanfari, CEO of Salalah Free Zone explained that the project is a re-enforcement of the Free Zone's commitment to maximise the Sultanate's mineral wealth through national and foreign partnership. "In the past, we have been focusing on projects that can create new industries linked to the available raw materials in the Sultanate. As a result of our endeavours, we will be announcing more investments during 2015," said Al Shanfari.
USG’s fourth quarter sales up by 4%
06 February 2015US: USG Corporation has reported fourth quarter 2014 net sales of US$954m, up by 4% from the fourth quarter of 2013, when net sales were US$915m. Its fourth quarter 2014 operating loss was US$24m compared to US$60m of operating profit in the fourth quarter of 2013, primarily due to US$75m of charges for impairments and other related costs associated with its non-core shipping business and US$13m of charges to permanently settle a pension plan in the UK. During the fourth quarter of 2014, net loss attributable to USG was US$53m compared to US$3m in the fourth quarter of 2013.
"I'm pleased with the progress we made towards our 'Plan to Win' during the quarter, delivering strong adjusted operating profit from our operations," said James S. Metcalf, chairman, president, and CEO. "All of our businesses are heading in the right direction and we are well positioned for profitable growth in all of our improving end markets."
USG's adjusted operating profit was US$79m in the fourth quarter of 2014, which includes, among other items, adjusted equity method investment income of US$14m from USG Boral Building Products, compared to an adjusted operating profit of US$75m in the fourth quarter of 2013. Adjusted net income was US$35m in the fourth quarter of 2014 compared to US$22m in the fourth quarter of 2013. Adjusted net income and adjusted operating profit in the fourth quarter of 2014 excluded long-lived asset impairment charges of US$60m and contract termination and loss on receivable charges of US$15m related to the corporation's non-core shipping business, as well as a pension settlement charge of US$13m related to the wind-up of its pension plan in the UK.
USG recorded full year 2014 net sales of US$3.7bn and an operating profit of US$162m, with a net income of US$37m. On an adjusted basis for the full year of 2014, adjusted operating profit was US$353m and adjusted net income was US$168m. For the full year of 2013, net sales were US$3.6bn, operating profit was US$258m and net income was US$47m. On an adjusted basis for the full year of 2013, adjusted operating profit was US$278m and adjusted net income of US$73m.
"In 2014 our adjusted net income of US$168m more than doubled relative to what we generated in 2013, with our USG Boral joint venture contributing significantly to our success," said Metcalf. "While the pace of the recovery is clearly more shallow than what we were anticipating, our trajectory continues to be positive and we are confident that 2015 will outperform 2014."
Boral concerned that wet winter will affect results
06 November 2014Australia: A wet winter has delayed construction activity in key east coast markets as New South Wales experienced its wettest August in 16 years. Boral's CEO Mike Kane has told shareholders that more heavy rain could buffet earnings in its construction, materials and cement division during the rest of 2014 and 2015.
"Expectations could be dampened if we are unable to realise potential property sales and some level of price increase in this very competitive market and if we experience extended periods of adverse weather," said Kane. However, he added that Boral expected to more than double earnings in its building products division in 2014 and 2015, which made US$8m in earnings before interest and tax in the 2013 – 2014 financial year. Kane said that rising energy and labour costs remained a concern across the group.
Chairman Bob Every said that Boral expects a resources industry slowdown, particularly in Queensland. "We are expecting continued softening in roads and infrastructure activity for most of fiscal 2015 before a solid multi-year pick-up from fiscal year 2016," said Every.
"In our 2015 financial year we continue to expect ongoing strong results from construction materials and cement, improvements from both the building products and Boral USA divisions and improvements in the underlying USG Boral business," said Kane. "We anticipate return on funds employed to improve, despite the shift to equity accounting on Boral's 50% interest in the Gypsum joint venture." Boral made a net profit of US$173m in ist 2014 financial year, an improvement on a US$212m loss suffered during the previous financial year.
Every also announced his intention to stand down in 2016: "I was re-elected by shareholders at Boral's annual general meeting last year and at the time I intended that, if I was re-elected, that this would be my last term on the board. My intentions are unchanged. Therefore, I will not stand for re-election in 2016. I will work with the board to identify the best possible candidate for a successor for the role of chairman and I will help to ensure an orderly transition process."