Gypsum industry news

Norway: France-based Saint-Gobain plans to upgrade its 13Mm²/yr Fredrikstad gypsum wallboard plant in partnership with state-owned sustainable energy agency Enova. The Euro25m upgrade will expand the plant’s production capacity by 40% and make it, what the producer says, is the world's first carbon-neutral plasterboard plant. One feature of the plan is electrification of the currently gas-powered production process. The upgrade will be completed in early 2021.

Saint-Gobain is considering implementing the net-zero CO₂ plant project across others of its gypsum wallboard plants.

Romania: Saint-Gobain has begun construction of a new line at its Turda gypsum wallboard plant in Cluj county. The company plans to invest Euro45.0m in the project. The scheduled completion date is April 2023. The group says that the expansion aims to meet ‘rapidly growing’ local needs as well as those of the wider Central and Eastern European market, and to secure Saint-Gobain's leadership position within light construction.

Spain: France-based Saint-Gobain has announced plans for a new Euro40m production line at its Quinto gypsum wallboard plant near Zaragosa, Aragon. The line will integrate recycled raw materials use and an Industry 4.0 digitisation programme to increase production, warehousing, transport and delivery automation.The scheduled commissioning date for the expanded facility is in 2022. When operational, the line will generate 70 new direct jobs. The government of Aragon has declared the work a project of regional interest.

The group says that the new line will enable it to capture the growth of the Spanish market and its rapid shift towards more complex needs and especially more lightweight construction systems.

Switzerland: Sika’s 2020 full-year sales were Euro7.29m, up by 3% year-on-year when adjusted for currency variations. Sales grew in the Europe, Middle East and Africa region by 4.4%, in the Americas regions by 1% and in the Asia/Pacific region by 13%. The group recorded market share gains in all regions. During the year it acquired Romania-based Adeplast, US-based CIDRA Concrete Systems and Egypt-based Modern Waterproofing Group. The acquisitions span concrete, mortars and insulation production. The company established new plants in China and Colombia. It upgraded plants in France, Switzerland and the UAE.

Chief executive officer (CEO) Paul Schuler said "The 2020 fiscal year was overshadowed by the global coronavirus pandemic, which had a number of serious repercussions for the construction and automotive sectors. Thanks to the strong motivation of our employees and their pronounced customer focus, Sika managed to perform successfully in this highly challenging market environment and achieve above-average results. We remain very well positioned in what is still a difficult environment – thanks to our innovative products and solutions, as well as to our employees, who continue to deliver their utmost even in times such as these. On behalf of group management, I would like to thank our global workforce of 25,000 people for the tremendous dedication they have shown and for the unique way they identify with our company."

The group confirmed its 2023 targets, saying “The company remains aligned for long-term success and profitable growth. With its focus on the six strategic pillars – market penetration, innovation, operational efficiency, acquisitions, strong corporate values, and sustainability – Sika is seeking to grow by 6 – 8% a year in local currencies up to 2023. From 2021, the company is aiming for a higher earnings before interest and taxation (EBIT) margin of 15 – 18%. Projects in the areas of operations, logistics, procurement, and product formulation should result in an annual improvement in operating costs equivalent to 0.5% of sales.”

UK: Etex Building Performance recycled 14% its Siniat gypsum wallboard products in 2019, a UK gypsum wallboard recycling record. The company says that the figure exceeds both the UK average of 8% in 2019 and the industry target of 10% in 2020. It attributed the achievement to its “substantial investments in operational improvements to reuse waste gypsum, which can also be recycled.”

The improvements consisted of an upgrade to gypsum wallboard production at the company’s Ferrybridge plant in West Yorkshire and the addition of a new recycling facility at the site. Its planned new gypsum wallboard plant in Bristol will be able to produce wallboard using a higher proportion of recycled gypsum and source part of its water intake from rain. The producer has additionally secured a dedicated supply of post-consumer gypsum from construction sites across England and Wales via its subsidiary Crucible Gypsum Recycling. It said it decided to form the subsidiary after taking part in the European Commission’s Gypsum to Gypsum research project, which “showed the importance of controlling the quality of post-consumer material and re-orientating the industry for the recovery of waste at the end of a building's lifecycle.”

Head of environment and sustainability Steve Hemmings said, "Recovering waste gypsum makes business as well as environmental sense. The plasterboard industry traditionally relied on quarried gypsum or desulphurised gypsum – the latter is becoming less available as the UK switches to alternative energy sources. Recycling offers a greener future for construction, but it requires investment and coordination across the supply chain. We're investing early to make sure we have the capability and capacity to continue leading the UK's gypsum wallboard sector and to provide more sustainable solutions for our clients.”

US: Georgia-Pacific has begun construction of a 65Mm²/yr gypsum wallboard plant adjacent to its existing 30Mm²/yr Sweetwater gypsum wallboard plant in Nolan County, Texas. The company says that the plant will start production in late 2022, following a total investment of US$285m and it will employ 120 people.

President Brent Paugh said, “The demand for our diverse gypsum products continues to be strong, especially in Texas. By having two production lines in Nolan County, Georgia-Pacific can strengthen its capacity to meet our growing customer needs in Texas’ residential, commercial and industrial construction.”

US: The Bureau of Land Management has approved American Gypsum’s proposal to expand its gypsum mine at Eagle, Colorado by around 40 hectares. The current quarry has been in operation since 1984. The mine and associated Eagle gypsum wallboard plant near Gypsum produce around 60Mm2/yr of wallboard and employ nearly 100 people. American Gypsum is the fifth largest producer of gypsum wallboard in North America, operating four wallboard plants.

Uzbekistan: Knauf has announced plans for a second gypsum wallboard production line in Bukhara, Bukhara region. The plans also include an investment of Euro2.2m in an additional gypsum mixture line at its Bukharagips plant, also in Bukhara, which produces dry building mixes. Trend News has reported that Knauf is currently Uzbekistan’s leading producer of gypsum wallboard, which it sells on the Uzbek, Afghan and Turkmen markets.

Canada: Cabot Gypsum is investing just under US$5m on upgrade to its Port Tupper gypsum wallboard plant in Nova Scotia. Company president Marcel Girouard said demand for rented residential properties was driving the expansion, according to the Canadian Broadcasting Corporation. The project is expected to create up to 40 new jobs.

The wallboard producer has benefited from the building materials distribution network operated by its parent company, Acadian Drywall. It acquired the Port Tupper plant in 2011 following its closure in 2008.

Bosnia & Herzegovina: A three-month test run of hot flue gas desulphurisation at RiTE’s Ugljevik coal-fired power station in the Republika Srpska region began on 13 December 2019. The Euro80m installation will reduce sulphur dioxide (SO₂) emissions to 200ppm from 16,000ppm, in accordance with European Union standards, and produce an unspecified quantity of gypsum. Ugljevik manager Čedomir Stojanović said, “we are considering the construction of a second plant.”