Global Gypsum levels its gaze on... the entire world, for a review of global gypsum wallboard production in , on a producer-by-producer basis. This report combines data from the Global Gypsum Directory with the latest industry news from the columns of Global Gypsum Magazine.
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In mid-, the world has a gypsum wallboard capacity of 14.3Bnm2/yr across 435 plants. Gypsum wallboard is produced in a total of 72 countries. Figure 1 maps the distribution of gypsum wallboard production capacity around the world. Figure 2, meanwhile, divides national capacities by population size, to map the distribution of capacity per capita.
The leading gypsum wallboard-producing nation, with an installed capacity of Mm2/yr (25% of the global total) across 63 plants, is the US. This is followed by China, with Mm2/yr (22%) across 85 plants - as many as the next seven countries combined. Of these, Japan leads with 775Mm2/yr (5.4%), followed by Russia with 483Mm2/yr (3.4%) and South Korea with 413Mm2/yr (2.9%).
Ownership of global gypsum wallboard production capacity is also unequally distributed. 96 different companies range in the scope of their control from 25% of global capacity (Knauf - 3.63Bnm2/yr) down to less than 0.1% (Crystal Group, FACT-RCF and Perfectum - 1Mm2/yr). Figure 3 (below) compares their relative shares, including between each of the Top 10 producers.
Recent years have brought an increasing share of gypsum wallboard capacity ownership under control of a smaller number of large, mostly multinational, producers. Four are based in North America, three in Asia and three in Europe.
Knauf&#;s light blue branding is synonymous with gypsum wallboard across many of the 90 markets in which it markets its products globally.1 Perhaps strikingly for a company of its scale, Knauf is a private limited partnership. It has remained Knauf family-owned over nine decades of existence.
Founded:
HQ: Iphofen, Germany
Wallboard capacity: 3.63Bnm2/yr
Turnover ():1US$16.8bn
Knauf subsidiary Knauf Gypsum Tanzania is in the process of almost tripling its 15Mm2/yr Mkuranga gypsum wallboard plant in Tanzania&#; Pwani Region to 43Mm2/yr. The US$49.3m project aims to raise the producer&#;s Tanzanian export volumes by 170%.
In April , Knauf had concluded preliminary negotiations for the construction of a new gypsum plant in southern Kyrgyzstan, and was studying gypsum deposits in the area.
Romania was the location of Knauf&#;s previous announcement of a new gypsum wallboard plant. It told press that it planned to invest US$82.8m in an upcoming plant in Huedin, Cluj County, in October . Older plans for a Knauf gypsum wallboard plant at Huedin, first delayed in , consisted of a planned investment of US$76.2m in a 35Mm2/yr-capacity plant.
Knauf has launched its 17Mm2/yr Fergana gypsum wallboard plant, in the region of the same name, in Uzbekistan in mid-, investing Euro19m. The plant is also equipped with a dry building mixes line.
The government of Kazakhstan claimed in April that Knauf will choose Kazakhstan for the future relocation of its Russian business. German press reported that Knauf &#;did not confirm&#; any plan to withdraw from the sanctioned state. Investments in the business have been frozen since March . Chair Alexander Knauf accounted for the group&#;s decision to stay in Russia as a refusal to abandon its employees there to &#;an uncertain future.&#; Knauf derived 10% of its turnover from Russia in .2
Beijing New Building Materials (BNBM) operates at a similar scale to Knauf, across a smaller geographical footprint. 2.75Bnm2/yr (97%) of its installed capacity is in China, 40Mm2/yr (1.4%) in Uzbekistan, 35Mm2/yr (1.2%) in Egypt and 3Mm2/yr (0.1%) in Tanzania.
Founded:
HQ: Beijing, China
Wallboard capacity: 2.83Bnm2/yr
Wallboard sales, : 2.09Bnm2/yr (-12%)
BNBM is set to increase its total number of gypsum wallboard plants to 73 from 71 with the commissioning of upcoming new plants in Thailand and Uzbekistan. A third, 40Mm2/yr, gypsum wallboard plant, belonging to a joint venture of BNBM and Bosnian state-owned energy provider RiTE Ugljevik, is planned for construction in Bosnia-Herzegovina, with a budget of Euro50m.
During , BNBM reported an operating income of US$2.9bn, down by 6% from US$3.07bn in . The producer&#;s net profit fell by 11% to US$457m from US$511m. It said that domestic demand fell throughout the year due to a contraction in residential construction activity. At the same time, the prices of raw materials and energy rose. BNBM recorded &#;nearly zero emissions&#; from all of its gypsum wallboard plants in .
BNBM maintains multiple outright subsidiaries, including Guangdong Province-based Taishan Gypsum, which operates 100Mm2/yr plants at Louyang, Henan Province, and Zouping, Shandong Province, along with 55 other smaller-scale units across 23 provinces of China and in Egypt.
Saint-Gobain made its start in glass production in Paris in , but today operates as the quintessential modern building materials conglomerate across a diversity of mostly lightweight products.
Founded:
HQ: Paris, France
Wallboard capacity: 2.72Bnm2/yr
Sales, : US$45.4bn (+23%)
Saint-Gobain India plans to make capital expenditure (CAPEX) investments worth US$215m throughout . In the medium term, in addition to CAPEX, it forecast total new acquisitions worth US$144 &#; 150m between and . The company aims to achieve sales of US$3.7bn in . The company is expanding all its businesses in the country, including gypsum wallboard, glass, construction chemicals and ceramics.
Saint-Gobain commenced net zero-CO2 gypsum wallboard production at its Fredrikstad plant in Norway in April . The world-first achievement in the gypsum industry followed a Euro27.2m upgrade, which also expanded the plant&#;s capacity by 40%. The project also switched the plant from natural gas to hydroelectric power and reduced its energy consumption by 30%. The producer says that it will eliminate 23,000t/yr of CO2 emissions. Throughout , Saint-Gobain will continue to launch new gypsum wallboard products at the plant with the lowest carbon footprint on the market. Saint-Gobain is committed to achieving net zero CO2 emissions by , with an interim target of a 33% reduction between and .
In China, Saint-Gobain is set to commence a capacity expansion project at its Yangzhou gypsum wallboard plant in Jiangsu Province in mid-late , for completion and commissioning in .
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Turkish competition authorities approved Saint-Gobain&#;s merger of local subsidiary Saint-Gobain Rigips with Dalsan Alçi. The companies have a combined gypsum wallboard capacity of
100Mm2/yr. Dalsan Alçi is in the process of acquiring another local gypsum wallboard producer, Manisa Turgutlu.
Saint-Gobain Poland will supply 45% of its power consumption with renewable electricity from under a wind energy supply contract with Germany-based Tion Renewables. The producer expects the deal to eliminate 135,000t/yr of CO2 emissions from its operations.
National Gypsum is the first of three US-focused gypsum wallboard in the Global Gypsum Top 50 - and Top 10. It is the first of two Top 50 producers named National Gypsum, with the other ranked at number 16 and operating from headquarters in Riyadh, Saudi Arabia. All-American National Gypsum (US) is a private company and is owned by the Spangler family.
Founded:
HQ: Charlotte, US
Wallboard capacity: 793Mm2/yr
National Gypsum affiliate Gold Bond Building Products announced US$90m plans for an upgrade to its Mount Holly gypsum wallboard plant in North Carolina in April . The project includes the installation of a railway line and related infrastructure. Once completed in , the expansion will create 11 new jobs.
Georgia-Pacific&#;s name signifies its geographical expansion westward during the first half of the 21st century, from its beginnings as a lumber producer in the Southeastern US state
of Georgia.
Founded:
HQ: Atlanta, US
Wallboard capacity: 742Mm2/yr
Georgia-Pacific began building a new 65Mm2/yr gypsum wallboard plant at the site of its existing 30Mm2/yr Sweetwater gypsum wallboard plant in Texas in late . The producer opened a new 0.73Mt/yr gypsum quarry to serve the upcoming plant in June .
On 1 March , Georgia-Pacific completed the shutdown of its Quanah gypsum wallboard plant, also in Texas. 166 people had been employed at
the facility before the closure.
A quote featured in Etex&#;s marketing materials draws on the image of &#;A tree with a strong trunk, which grows new branches every year and where existing branches are becoming stronger.&#; The metaphor captures Etex&#;s expansive activities in recent years, especially in its home continent, Europe, where it is building a new US$187m wallboard plant in Portbury, UK.
Founded:
HQ: Brussels, Belgium
Wallboard capacity:731Mm2/yr
Sales, :US$4.07bn (+25%)
Yoshino Gypsum shares its name with a grove of red-leaved cherry trees on Mount Yoshino, Nara Prefecture, regarded as sacred since ancient times. While Yoshino Gypsum&#;s corporate logo is a cherry blossom, consumers in Japan will be more familiar with the Tiger Brand image under which the company sells its gypsum wallboard. Tiger Brand celebrated its centenary in .
Founded:
HQ: Tokyo, Japan
Wallboard capacity: 300Mm2/yr
American Gypsum is growing its operations, with a US$22m upgrade to its Albuquerque gypsum wallboard plant in New Mexico. The producer secured a licence to expand its 336 hectare Eagle gypsum quarry near Gypsum, Colorado, to 376 hectares in late . The expansion will secure its Eagle wallboard plant&#;s gypsum supply until .
Founded:
Headquarters: Dallas, US
Wallboard capacity: 300Mm2/yr
South Korea&#;s leading building materials supplier, KCC, is the larger of two gypsum wallboard producers active in its home country, where it competes with Knauf subsidiary Knauf Korea.
Founded:
HQ: Seoul, South Korea
Wallboard capacity: 263Mm2/yr
PABCO Gypsum was founded as Pacific Coast Building Products in . It moved into gypsum wallboard production in through the acquisition of the Newark gypsum wallboard plant
in California.
Founded:
Headquarters: Tacoma, US
Wallboard capacity: 147Mm2/yr
Table 3 breaks down global gypsum wallboard capacity for the remainder of the Global Gypsum Top 50 producers (for the Top 10 breakdown, see Figure 3.
Table 1: Global Gypsum Top 50 gypsum wallboard producers, 11 - 50. For the Top 10, see Figure 1. Source: Global Gypsum Directory . Note: Data includes Global Gypsum estimates.
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Producer HQ Capacity (Mm2/yr) Global share (%) No. of plants 11 Jason Plasterboard China 120 0.8 3 12 Panel Rey Mexico 86 0.6 3 13 Volma Corporation Russia 85 0.6 3 14 CSR Gyprock Australia 80 0.6 4 15 Holcim Switzerland 66 0.5 3 16 National Gypsum Saudi Arabia 54 0.4 2 17 Irving Wallboard Canada 46 0.3 1 18 Mada Gypsum Saudi Arabia 42 0.3 1 19 Gypsemna Canada 34 0.2 1 = Fletcher Building New Zeland 34 0.2 2 21 Fassa Bortolo Italy 30 0.2 1 = Magma Mordovcement Russia 30 0.2 1 = Pingyi Baier Building Materials China 30 0.2 1 = TAOUEB Algeria 30 0.2 1 = United Mining Industries Saudi Arabia 30 0.2 1 26 Technogips Bulgaria 27 0.2 2 27 Cabot Gypsum Canada 25 0.2 1 28 Tanzania Gypsum Tanzania 24 0.2 3 29 Gulf Gypsum Board Saudi Arabia 23 0.2 2 30 Aplus Pacific Indonesia 21 0.1 2 31 ABS Alçı Türkiye 20 0.1 1 = Akçansa Çimento Türkiye 20 0.1 1 = Aytaş Alçı Türkiye 20 0.1 1 = Fibran Italy 20 0.1 1 = Global Gypsum Board Saudi Arabia 20 0.1 1 = Highcity Building Saudi Arabia 20 0.1 1 = Linyi Feipang China 20 0.1 1 = Siam-Indo Gypsum Indonesia 20 0.1 1 = Universal Cement Taiwan ROC 20 0.1 1 40 Aswell Argentina 16 0.1 1 = Trevo Industrial de Gesso Brazil 16 0.1 1 42 Aksolit Russia 15 0.1 1 = Al-Qaseem Gypsum Saudi Arabia 15 0.1 1 = Atışkan Yapı Ürünleri Türkiye 15 0.1 1 = BGC Group Australia 15 0.1 1 = El-Khayyat Gypsum Saudi Arabia 15 0.1 1 = Gypfor, Gessos Laminados Portugal 15 0.1 1 = Gyptec Ibérica Portugal 15 0.1 1 = Interplac Spain 15 0.1 1 = Onat Alçı Türkiye 15 0.1 1 Producers 51 - 97 297 2 45