Gypsum industry news

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."

Australia: Saint-Gobain subsidiary CSR plans to expand its Welshpool gypsum wallboard plant in Western Australia. The producer plans to upgrade the plant’s production line and expand warehouses that serve it and the neighbouring Bradford building materials plant. CSR said that the upgrade to the Welshpool wallboard plant will reduce its consumption of natural gas and electricity and facilitate its transition to alternative fuels or electricity.

CEO Paul Dalton said "This significant investment will make Welshpool safer and more sustainable, increase capacity and improve productivity and cost efficiency, all while removing risk from our supply chain.”

US: The Oregon Department of Environmental Quality is receiving public comment on its revised 2021 Climate Protection Program, under which natural gas users, including gypsum wallboard producers, will face tighter emissions regulations. The programme will enable plants to buy credits for emissions above regulation level, with the money raised primarily going to fund community-based projects. Local press has reported that the revised rules aim to help realise a 50% reduction in CO₂ emissions by 2035 and a 90% reduction by 2050. The latest revision also shortens companies’ compliance period from three years to two.

Germany: Chemicals company BASF's sales fell by 19% year-on-year to €37.3bn in the first half of the 2024 financial year (FY2024). Its earnings before interest, taxation, depreciation and amortisation (EBITDA) declined by 34% to €4.72bn. As a result, the company now anticipates full-year sales of €73 – 76bn in FY2024, down from the previously forecast €84 – 87bn. It revised its earnings forecast to €4 – 4.4bn, from €4.8 – €5.4bn previously. At the same time, it increased its anticipated reduction in CO₂ emissions for the year. It now expects to generate 17 – 17.6Mt of CO₂ from its operations, down from its previously forecast 18.1 – 19.1Mt.

Germany: A working group of gypsum producers in the Harz region has supported the Mission: Urban Forest Rescue 2024 reforestation initiative in Osterode, Lower Saxony. The group, including CASEA, Saint-Gobain, Rump & Salzmann and VG Orth, donated €12,500 to the initiative.

The Mayor of Osterode, Jens Augat, said "We are pleased about the companies' commitment to conservation, which goes far beyond the required level.”

Belgium: Etex says that it ‘considerably’ progressed its Road to Sustainability 2030 plan during 2023. That year, safety intensity increased by 7%, and Etex established a global diversity, equity and inclusion ambassador community of 110 volunteers across 26 countries. In Europe, the company achieved 70% Environmental Product Declaration coverage as a percentage of its turnover, up from 58% in 2022. Etex raised its total use of recycled materials to 7.6%, and achieved a 23% reduction in Scopes 1 and 2 CO₂ compared to 2018 levels, in line with its 2030 target of 35%.

CEO Bernard Delvaux said “In the EU, more than 40% of energy consumed is used in buildings and more than 30% of energy-related greenhouse gasses emissions come from buildings. Next to new building activities, and according to current high energy standards, renovating old building stock should hence be a top priority. With our portfolio of building materials such as glass wool and extruded polystyrene insulation, gypsum wallboard, fibre cement boards and fire protection materials, Etex has the solutions to reach the ambitious targets. But in view of the huge challenge, a holistic and effective plan to boost renovation is needed, to finance and simplify the renovation process, in each of the EU countries.”