Gypsum industry news

Belgium: Etex reported sales of €3.81bn in 2023, up by 2.5% from 2022 levels. The company's recurring earnings before interest, taxation, depreciation and amortisation (REBITDA) rose by 10% to €712m. It also raised its capital expenditure for the year, to €371m. Etex says that it was Europe’s leading gypsum recycling performer, with a recycling rate of 8.6% of all gypsum used. The group is ‘actively preparing’ to help rebuild Ukraine as soon as conditions permit.

CEO Bernard Delvaux said “Even more so than 2022, 2023 was a challenging year marked by volatility, uncertainty and severe drops in demand across the world, as we observed the continued impacts of increased energy prices and interest rates. Combined with tougher financing possibilities by banks, all these circumstances meant that both renovation and new construction levels dropped globally. Devaluation of some foreign currencies and hyperinflation accounting also had significant effects on our results. Despite all these challenges, I am extremely proud to share that Etex navigated these difficult waters very well and delivered yet again another record year. This includes our highest ever revenue and REBITDA, among others. This strong performance stems from our anticipation in making strategic decisions and changes at global, regional and local levels, ensuring continued proximity with our customers. This is also a result of even tighter cost monitoring in 2023, without ever losing sight of our long-term ambitions and continuing to improve our strong industrial footprint.”

North America: Market research firm IMARC Group has forecast a composite annual growth rate (CAGR) of 2.6% in the North American gypsum wallboard market between 2024 and 2032. It attributed the anticipated growth to rising regional levels of construction activity, amid increasing urbanisation. Additionally, it expects gypsum wallboard to remain its market share within the building materials segment, as a cost-effective, easy-to-use product for both residential and commercial construction applications.

US: National consumption of gypsum wallboard dropped by 4.3% year-on-year to 2.51Mm² in 2023, according to United States Geological Survey (USGS) data. Demand for natural gypsum was 45Mt, up by 3% from 43.7Mt in 2022. The market imported 8.1Mt of gypsum throughout the year, up by 18% year-on-year.

Domestic production of crude gypsum in the US dropped by 1.3% year-on-year in 2023, to 22Mt. Exports grew by 15% to 45,000t.

US: Eagle Materials recorded sales of US$1.78bn in the first nine months of the 2024 financial year. This corresponds to a rise of 6.2% year-on-year from the corresponding period of the 2023 financial year. The producer’s light materials sales fell by 4.6% to US$703m, and its gypsum wallboard sales volumes fell by 4% to 206Mm². The group raised its net earnings by 11% to US$401m.

Morocco: Compagnie Marocaine de Plâtre et d’Enduit (CMPE), a joint venture of Knauf and Groupe Safari Maroc, has announced plans for a new gypsum wallboard production facility in Sidi-Tiji, Marrakech–Asfi Region. CMPE expects that the plant will generate 100 direct and over 500 indirect jobs.

Groupe Safari Maroc CEO Saïda Lamrani Karim and Knauf general partner Jörg Kampmeyer said "Our investment decision in a new plasterboard plant shows our trust in the growth of the Moroccan market and will strengthen the leading position of CMPE.” They added “This investment aligns with the Moroccan government's guidance to reduce imports and develop a competitive local industry of excellence. With our new production, we will supply the Moroccan market and export to Sub-Saharan markets."

US: Georgia-Pacific made total investments worth US$2bn throughout 2023. Major capital expenditure (CAPEX) investments include its US$325m construction of its second Sweetwater gypsum wallboard plant in Texas.

Georgia-Pacific Gypsum president David Neal said "Georgia-Pacific is keenly focused on the future and committed to innovation and meeting the needs of our customers. The two [Sweetwater gypsum wallboard plant] operations combined will supply customers and distribution partners with more than 93Mm²/yr of gypsum wallboard each year and create more than 100 new jobs. This investment strengthens Georgia-Pacific's capacity to meet growing customer needs in Texas' residential, commercial and industrial construction markets."

Georgia-Pacific officially opened its new gypsum wallboard plant at Sweetwater in Texas earlier this month. The US$325m project is situated next to the company’s existing plant at the site, Sweetwater West, on the other side of a road. Canada-based Gyptech said in 2021 that it was supplying the equipment for the new high-speed line at the site.

When Georgia-Pacific first announced the new project in 2020, it mentioned that it would be able to keep its logistics costs low, use raw gypsum reserves and the existing workforce. Despite this, the plant has still created over 100 new jobs. The company also said that it anticipated closing its 60Mm²/yr Quanah plant, also in Texas, depending upon market conditions. This came to pass in March 2023. Altogether, both plants at Sweetwater will have a production capacity of around 93Mm²/yr. This implies that the new plant has a production capacity of around 60Mm²/yr, given that the existing plant’s capacity is 30Mm²/yr. Funnily enough this is the same as the Quanah plant.

The new plant at Sweetwater may be a sign that the US wallboard market is picking up again. Georgia-Pacific has invested some serious money and it is targeting Texas, a leading area for construction nationally. However, it does come with a few caveats. Firstly, the new plant at Sweetwater is replacing existing capacity at Quanah. Secondly, it is using some of the advantages of the existing plant such as its trucks and its proximity to its customers. This suggests that the company may be wary of building a new plant in a greenfield location with all the potential risks that might involve.

US wallboard sales have regularly peaked and troughed over the decades, like many other commodity markets, as demand and production capacity race each other. Sales of wallboard peaked around the year 2000 and then again in the mid 2000s before tailing off following the 2007 recession. They have been recovering ever since and started to get close to the levels seen in the first half of the 2000s in 2022 when the United States Geological Survey (USGS) reported wallboard sales of 2.6Bnm².

Generally, the last tranche of new wallboard plants in the US were built or approved in the late 2000s before the financial downturn. These new sites included CertainTeed’s Roxboro plant in North Carolina and the Moundsville plant in West Virginia, Gold Bond Building Products’ Mount Holly plant in North Carolina and American Gypsum’s Georgetown plant in South Carolina. From this point though various plants were either closed or mothballed. Some of the latter have been restarted as the market slowly recovered. New plant projects in the 2010s tended to be upgrades or replacements. One example of this was USG’s plan to rebuild a production line at its Jacksonville plant in Florida, which was announced in late 2017 before Knauf took over the company in 2018. Another was National Gypsum’s scheme to reopen its Wilmington plant in North Carolina in 2019. At the same time in the 2010s there were a number of mergers and acquisitions including Lafarge’s sale of its gypsum business in North America in 2013, Knauf’s takeover of USG in 2019 and Saint-Gobain’s acquisition of Continental Building Products in 2020.

When Georgia-Pacific started building the new plant at Sweetwater in 2020 this marked the start of a new phase of US wallboard plant projects. American Gypsum announced plans for an upgrade to its Albuquerque gypsum wallboard plant in 2021, Gold Bond Building Products started building its long-delayed Eloy plant in Arizona in 2022 and it said it was spending US$90m on an upgrade to its Mount Holly gypsum wallboard plant in North Carolina in 2023, and CertainTeed revealed it wanted to build a second production line at its Palatka gypsum wallboard plant in Florida also in 2023.

Congratulations are due to Georgia-Pacific for the achievement at Sweetwater. Optimism for the US market in general may also be in order given the slow but steady stream of projects that have been announced and completed since 2020. The next step, when a company builds a new wallboard plant at a greenfield site in the US, looks set to happen when Gold Bond Building Products completes its Eloy plant.

US: Beneficial Reuse Management (BRM) has acquired Pennsylvania-based gypsum wallboard recycling firm USA Gypsum (USAG).

BRM board chair Dave Schuurman said “The acquisition of USAG gives BRM an opportunity to further diversify our sources of gypsum to include recycled scrap wallboard, as well as to grow our geographic footprint. USAG’s operations will complement our existing gypsum processing operations, which provide gypsum in pelletised form to agricultural and other markets. This acquisition aligns perfectly with our mission of providing sustainable solutions for the management of industrial byproducts to divert materials away from landfills.”

Australia/New Zealand: Belgium-based Etex has signed an agreement with building materials company BGC to acquire the latter’s gypsum and fibre cement businesses. The gypsum business consists of wallboard, plasters, compounds and cornice production units, and includes the Perth gypsum wallboard plant in Western Australia. BGC also operates nine warehouses across Australia and New Zealand. Etex says that the deal expands its activities in the ‘attractive’ local market, with significant growth opportunities. Finalisation is expected in early 2024.

Etex CEO Bernard Delvaux said “This deal is a strategic opportunity for Etex to complement our footprint in Australia and further increase the accessibility of our products and services for customers. This will both reinforce our gypsum wallboard offering and position us well in the growing fibre cement activities through a broad product range and good channel access.”

US: Xeriant has hired the National Fire Protection Association (NFPA) and another accreditation agency to test its NEXBOARD waste plastic-based wallboard for the construction market. The producer says that tests will include the NFPA 286 and the ASTM E84 fire safety tests, as well as tests of tensile strength, hardness, water resistance, acoustic and thermal insulating performance, and volatile organic compound emissions.