Following a three-year electrification and upgrading project, Saint-Gobain Canada opened the first zero-carbon gypsum wallboard facility in North America in Sainte-Catherine, Quebec. The location, which is also the biggest of its sort in the world, demonstrates the company’s efforts to combine sustainability and growth.

The project, which was announced in 2022, includes significant facility-wide upgrades. Insulation systems were improved, smart energy meters were implemented, and electric heating elements were used in place of natural gas burners. These actions increase manufacturing capacity by 40% while reducing energy use by up to 30%.

Today, the plant prevents 44,000 tonnes of carbon dioxide emissions each year, which is the same amount of carbon dioxide produced by 14,000 cars annually. Additionally, the increased capacity will assist Saint-Gobain in meeting Canada’s growing demand for gypsum wallboard. Additionally, the project was the first time Infinaé, a range of gypsum wallboards with a lower climate impact, was introduced in Canada. CarbonLow is predicted to have 60% less embodied carbon from cradle to gate than the range.

The CEO of Saint-Gobain Canada, Jean-Claude Lasserre, stated that “productivity and sustainability can work together to improve the future for all Canadians.” The development, he continued, demonstrates how green investment can boost company expansion and alleviate Canada’s housing scarcity.

The EcoPerformance program in Quebec provided funds for the C$40 million ($28.7 million) project, while Hydro-Québec provided technical assistance. The factory is “a great example” of industrial decarbonisation, according to Christine Fréchette, the minister of business, innovation, and energy for Quebec.

Saint-Gobain collaborated with Hydro-Québec from the beginning to the end. According to Caroline DeVit, senior director of business growth and performance at the utility, “This is an inspiring model for the entire industry.” Approximately 80% of the Sainte-Catherine plant’s machinery has been updated. Improved compressed air design, real-time monitoring sensors, and new heat recovery systems are among the improvements. Further actions will increase recycled content and lower transportation-related emissions associated with the supply of gypsum.

The endeavour aligns with Saint-Gobain’s worldwide goal of achieving net zero carbon emissions by 2050. In Canada, the team is creating novel insulation using bio-sourced binders, improving gypsum recovery, and testing waste diversion initiatives in Quebec.

According to Saint-Gobain North America CEO Mark Rayfield, the facility enhances the business’s standing as a pioneer in environmentally friendly plasterboard production. “With our continued commitment to expansion, this significant investment will advance our operations in Canada,” he stated.

In 2024, Saint-Gobain recorded sales of €46.6 billion and employed over 161,000 people in 80 countries. The company is focusing its future strategy on innovation, circularity, and sustainability in building materials as it commemorates its 360th anniversary this year.