Gypsum industry news

UK: Adaptavate has partnered with British Land, Royal London Asset Management Property and office refurbishment company Overbury to test its Breathaboard 50% reduced-CO₂ alternative wallboard at the 1 Triton Square mixed-use development in Camden, London. This is the product’s first large-scale commercial application.

Adaptavate produces Breathaboard from renewable agricultural feedstocks as a scalable, CO₂-sequestering alternative to conventional gypsum wallboard. It offers net reduction of 4kg/m³ of CO₂.

Japan: Sumitomo Osaka Cement has applied for a patent for a method of combining alkali metal hydroxide solutions with CO₂ to produce alkali metal salts that react with gypsum to produce calcium carbonate. Energy Weekly News has reported that the developers used gypsum from recycled gypsum wallboard to demonstrate the process.

Spain: Paper products specialist Alier has begun construction of a new €40m gypsum wallboard recycling plant in Zaragoza’s López Soriano Recycling Technology Park. The plant will recycle gypsum wallboards powered by a solar plant and biomass plant, generating net zero CO₂ emissions. The Heraldo de Aragón newspaper has reported that the plant will create 130 direct jobs and an estimated 390 indirect jobs.

Spain: Knauf España has successfully achieved Cradle to Cradle (C2C) Silver certification for all gypsum wallboard and metal profiles produced at its Escúzar and Guixers plants. Corresponsables News has reported that the company is the first gypsum wallboard producer to do so globally. Its products achieved C2C Gold certification in the Material Reutilisation category.

Canada: CertainTeed Canada will begin to sell its new CarbonLow range of reduced-CO₂ gypsum wallboard in 2025. The range includes Easi-Lite, Type X and M2Tech boards and GlasRoc sheathing. The products offer 60% lower emissions cradle-to-gate than the company’s ‘traditional’ gypsum wallboard.

France: Saint-Gobain Placo has installed a heat and water recovery system in its Val-de-Cognac gypsum wallboard plant. In a post to LinkedIn, the company said that the new system has reduced the plant’s CO₂ emissions by 14%, its energy consumption by 11% and its water consumption by 10% compared to 2019 levels.

France: Knauf France aims to use 35% recycled gypsum at its Fos-sur-Mer gypsum wallboard plant in Bouches-du-Rhône, with an interim target of 10% by 2025. The company inaugurated the 30Mm²/yr plant in March 2024. It is currently using its own offcuts in production, but has a dedicated silo in which to also store gypsum from other sources in future. The plant’s wallboard requires 15 – 20% less energy than is used at a ‘traditional’ Knauf plant through the use of a vertical mill and high-efficiency driers. Its water use is optimised by drawing it in batches.

Les Cahiers Techniques News has reported that general manager Christine Muscat said "The ramp-up is gradual and we are at a third of production capacity, which we plan to reach fully in the second half of 2025."

Canada: Saint-Gobain subsidiary CertainTeed Canada has announced the upcoming launch of BasCarbone, a new range of 60% reduced-CO₂ gypsum wallboard. The company will produce BasCarbone wallboard at its carbon-neutral Montreal plant in Quebec.

Romania: Saint-Gobain Romania has completed construction of a new 1730-panel solar power plant at its Turda gypsum wallboard plant in Cluj County. Electronics retailer Visual Fan supported the project, which will contribute ‘significantly’ to meeting the plant’s energy consumption. When commissioned, it will reduce the Turda plant’s CO₂ emissions by 238t/yr. Romania’s government partly funded the installation under its National Recovery and Resilience Plan.

Saint-Gobain Romania CEO Ovidiu Păscuțiu said “This project represents an important step for Saint-Gobain in the direction of adopting renewable energy and reinforcing our commitment to the environment. It is a concrete example of investments made to optimise our production processes by reducing internal energy consumption. We have an ambitious sustainability goal – net zero carbon emissions by 2050. We will achieve this by investing in innovation, new technologies and a portfolio of solutions that pave the way for lightweight and sustainable construction.”

US: Xeriant will begin to produce its Nexboard alternative wallboard for sale at some time in the near-term future after making further recipe adjustments focused on ensuring fire safety. The company has contracted large-scale production to a ‘well-established’ producer, with which it is currently in the setup stage. It is also in talks with a bank about finance.

CEO Keith Duffy said "After initial fire testing at a national certification laboratory in June 2024, we engaged a polymer chemist to refine Nexboard's composition with a focus on passing the rigorous NFPA 286 fire safety test. This step followed several modifications in the base material and fire-retardant compositions and the finalisation of a production method that ensures the highest-volume, best quality and lowest-cost output. This extensive research and testing over many months has led us to believe that the additional changes will enable Nexboard to meet or even surpass the existing code requirements for building materials used in our targeted applications."