Global Gypsum Top 50

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• A gypsum quarry in Mochios, Greece. Source: Peter Titmuss.

• Figure 1: Global gypsum wallboard capacity by country. Source: Global Gypsum

• Figure 2: Global gypsum wallboard capacity per capita by country. Source: Global Gypsum Directory .

• Figure 3: Global gypsum wallboard production capacity by producer. For the remainder of the Top 50, see Table 1.

Global Gypsum levels its gaze on... the entire world, for a review of global gypsum wallboard production in 2023, 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.

As of mid-2023, 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, mapping the distribution of capacity per capita.

The leading gypsum wallboard-producing nation, with an installed capacity of 3.63Bnm2/yr (25% of the global total) across 63 plants, is the US. This is followed by China, with 2.83Bnm2/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%).

Gypsum wallboard producers

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.

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.

1. Knauf

Knauf's light blue branding is synonymous with gypsum wallboard across many of the 90 markets in which it markets its products globally. 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 (2022): US$16.8bn

News

Knauf subsidiary Knauf Gypsum Tanzania is in the process of almost tripling its 15Mm2/yr Mkuranga gypsum wallboard plant in Tanzania's Pwani Region to 43Mm2/yr. The US$49.3m project aims to raise the producer's Tanzanian export volumes by 170%.

In April 2023, Knauf concluded preliminary negotiations for the construction of a new gypsum plant in southern Kyrgyzstan and is studying gypsum deposits in the area.

Romania was the location of Knauf's previous announcement of a new gypsum wallboard plant. The company stated it planned to invest US$82.8m in an upcoming plant in Huedin, Cluj County, in October 2023. Older plans for a Knauf gypsum wallboard plant at Huedin, first delayed in 2021, included a planned investment of US$76.2m in a 35Mm2/yr-capacity plant.

Knauf has launched its 17Mm2/yr Fergana gypsum wallboard plant in Uzbekistan in mid-2023, investing Euro19m. This plant is also equipped with a dry building mix line.

The government of Kazakhstan claimed in April 2023 that Knauf would 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 2023. Chair Alexander Knauf stated their decision to stay in Russia is to avoid leaving employees there in an uncertain future. Knauf derived 10% of its turnover from Russia in 2022.

2. Beijing New Building Materials

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, 2022: 2.09Bnm2/yr (-12%)

News

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 2022, BNBM reported an operating income of US$2.9bn, down by 6% from US$3.07bn in 2021. The producer's net profit fell by 11% to US$457m from US$511m. The company stated that domestic demand fell throughout the year due to a contraction in residential construction activity while raw material and energy prices rose. BNBM recorded 'nearly zero emissions' from all of its gypsum wallboard plants in 2022.

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.

3. Saint-Gobain

Saint-Gobain made its start in glass production in Paris in 1665, but today operates as the quintessential modern building materials conglomerate, offering a diversity of mostly lightweight products.

Founded:
HQ: Paris, France
Wallboard capacity: 2.72Bnm2/yr
Sales, 2022: US$45.4bn (+23%)

News

Saint-Gobain India plans to invest US$215m throughout 2023 in capital expenditure (CAPEX). The company forecasts total new acquisitions worth US$144 - 150m between 2023 and 2025. It aims to achieve sales of US$3.7bn in 2023. 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 2023. This world-first milestone in the gypsum industry followed a Euro27.2m upgrade, expanding the plant's capacity by 40% and switching it from natural gas to hydroelectric power and reducing its energy consumption by 30%. The producer states it will eliminate 23,000t/yr of CO2 emissions. Throughout 2023, Saint-Gobain will continue to launch new gypsum wallboard products with the lowest carbon footprint on the market. It is committed to achieving net zero CO2 emissions by 2050, with an interim target of a 33% reduction from 2020 to 2025.

In China, Saint-Gobain is set to begin a capacity expansion project at its Yangzhou gypsum wallboard plant in Jiangsu Province in mid-late 2023, with completion and commissioning expected in 2024.

Turkish competition authorities approved Saint-Gobain's merger of local subsidiary Saint-Gobain Rigips with Dalsan Alçı. The companies have a combined gypsum wallboard capacity of 100Mm2/yr. Dalsan Alçı 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 2024 under a wind energy supply contract with Germany-based Tion Renewables, which is expected to eliminate 135,000t/yr of CO2 emissions from its operations.

4. National Gypsum

National Gypsum is the first of three US-focused gypsum wallboard producers in the Global Gypsum Top 50 - and Top 10. It is actually 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 owned by the Spangler family.

Founded:
HQ: Charlotte, US
Wallboard capacity: 793Mm2/yr

News

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 2023. The project includes the installation of a railway line and related infrastructure. Once completed in late 2024, the expansion will create 11 new jobs.

5. Georgia-Pacific

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

News

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 2022. The producer opened a new 0.73Mt/yr gypsum quarry to serve the upcoming plant in June 2023.

On 1 March 2023, 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.

6. Etex

A quote featured in Etex’s marketing materials captures the image of 'A tree with a strong trunk, which grows new branches every year and where existing branches are becoming stronger.' This metaphor reflects Etex's expansive activities in recent years, especially in Europe, where it is constructing a new US$187m wallboard plant in Portbury, UK.

Founded:
HQ: Brussels, Belgium
Wallboard capacity: 731Mm2/yr
Sales, 2022: US$4.07bn (+25%)

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7. Yoshino Gypsum

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 2023.

Founded:
HQ: Tokyo, Japan
Wallboard capacity: 300Mm2/yr

8. American Gypsum

American Gypsum is growing its operations, with a US$22m upgrade to its Albuquerque gypsum wallboard plant in New Mexico. The producer secured a license to expand its 336-hectare Eagle gypsum quarry near Gypsum, Colorado, to 376 hectares in late 2023. The expansion will secure its Eagle wallboard plant's gypsum supply until 2026.

Founded:
HQ: Dallas, US
Wallboard capacity: 300Mm2/yr

9. KCC

South Korea’s leading building materials supplier, KCC, is the larger of two gypsum wallboard producers active in its home country, competing with Knauf subsidiary Knauf Korea.

Founded:
HQ: Seoul, South Korea
Wallboard capacity: 263Mm2/yr

10. PABCO Gypsum

PABCO Gypsum was founded as Pacific Coast Building Products in 1968. It expanded into gypsum wallboard production in 1977 through the acquisition of the Newark gypsum wallboard plant in California.

Founded:
HQ: Tacoma, US
Wallboard capacity: 147Mm2/yr

Other players

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.

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
• 20 Fletcher Building New Zealand 34 0.2 2
• 21 Fassa Bortolo Italy 30 0.2 1
• 22 Magma Mordovcement Russia 30 0.2 1
• 23 Pingyi Baier Building Materials China 30 0.2 1
• 24 TAOUEB Algeria 30 0.2 1
• 25 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
• 32 Akçansa Çimento Türkiye 20 0.1 1
• 33 Aytaş Alçı Türkiye 20 0.1 1
• 34 Fibran Italy 20 0.1 1
• 35 Global Gypsum Board Saudi Arabia 20 0.1 1
• 36 Highcity Building Saudi Arabia 20 0.1 1
• 37 Linyi Feipang China 20 0.1 1
• 38 Siam-Indo Gypsum Indonesia 20 0.1 1
• 39 Universal Cement Taiwan ROC 20 0.1 1
• 40 Aswell Argentina 16 0.1 1
• 41 Trevo Industrial de Gesso Brazil 16 0.1 1
• 42 Aksolit Russia 15 0.1 1
• 43 Al-Qaseem Gypsum Saudi Arabia 15 0.1 1
• 44 Atışkan Yapı Ürünleri Türkiye 15 0.1 1
• 45 BGC Group Australia 15 0.1 1
• 46 El-Khayyat Gypsum Saudi Arabia 15 0.1 1
• 47 Gypfor, Gessos Laminados Portugal 15 0.1 1
• 48 Gyptec Ibérica Portugal 15 0.1 1
• 49 Interplac Spain 15 0.1 1
• 50 Onat Alçı Türkiye 15 0.1 1

Producers 51 - 97 297 2 45

References

1. Knauf, 'Start your Career with Knauf,' January 2023, career.knauf.com/pages/knauf-gypsum-worldwide
2. DW, 'Is Kazakhstan misleading world on firms fleeing Russia?' 28 March 2023, www.dw.com/en/is-kazakhstan-misleading-world-on-firms-fleeing-russia/a-

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