Recycling construction and demolition waste is a growing priority in the industry and gypsum panels play a role in that effort. As sustainability efforts across the building sector intensify, so too does the drive to find effective, attainable, and scalable solutions for gypsum recycling. Here we highlight the current practices, benefits and challenges associated with recycling gypsum panels.
Current Practices and Benefits of Gypsum Panel Recycling
Gypsum panel recycling offers environmental and economic advantages:
- Recycled Content in Manufacturing: Gypsum panels already contain recycled materials. The paper facers have incorporated
recycled paper for over 75 years. - Use of FGD Gypsum: Flue gas desulfurization (FGD) gypsum, a non-hazardous byproduct of coal-fired power generation, is widely used in gypsum panels. The EPA recognizes this as a key contribution to sustainable materials management, helping to reduce reliance on virgin gypsum.
- Recycling Plant Scrap: Manufacturing scrap and dunnage are routinely returned to production, reducing landfill waste and increasing efficiency.
- Construction Site Recycling: New construction generates significant amounts of scrap, estimated at roughly 12% of all gypsum board used. This material can be source-separated on-site, kept free from contamination, and processed for reuse.
- Reuse in Other Applications: Once paper facers are removed, the gypsum core can be used in a variety of ways, such as a concrete additive, soil amendment, water treatment medium, or even animal bedding. Ongoing research explores additional uses, including large-scale composting.
Challenges in Gypsum Panel Recycling
Despite its benefits, gypsum panel recycling faces a number of challenges:
- Strict Quality Standards: To maintain the fire-resistant properties of gypsum panels, manufacturers must ensure high purity of recycled gypsum. Residual paper fibers can compromise performance, especially in fire-rated assemblies.
- Transportation: Recycling drywall can be environmentally challenging due to the long distances between construction sites and recycling facilities, especially in rural areas. Drywall is bulky, which can lead to inefficient transport and multiple trips resulting in higher diesel fuel use and CO₂ emissions that may reduce or negate the environmental benefits of recycling.
- Contamination Risks: Clean separation of gypsum board scrap from paper and other construction materials is critical. Contaminants, such as joint compound, adhesives, or even dirt, can limit the recyclability of gypsum.
- Demolition Waste Complexity: Recycling gypsum from demolition or renovation projects is significantly more difficult than from new construction. Mixed materials, fasteners, wood, plaster, paint, and potentially hazardous substances such as lead paint (in buildings pre-dating 1978) are common.
- Closed-Loop Limitations: While “clean scrap” gypsum from new construction is more viable for closed-loop recycling into new panels, demolition waste often ends up being downcycled or landfilled due to contamination.
Industry Commitment and Innovation
The gypsum industry continues to invest in research, technology, and best practices to overcome these barriers.
After three years of research, the GA produced a report in early 2025 titled California Gypsum Material Flows for Life Cycle Impact Analysis and Recycling Assessment: Emerging Research for California Policy Makers to address challenges and knowledge gaps regarding closed-loop recycling in the state of California and to fuel future conversations around the manufacture, distribution, use and recycling of this common building product.
Gypsum Association staff and member companies also helped develop the ASTM C1881 – 20 Standard Guide for Closed-Loop Recycling of Scrap Gypsum Panel Products to provide essential guidance for safe and effective recycling practices.
While recycling gypsum board remains complex, GA members are committed to environmental stewardship and the advancement of circular economy principles in the building materials sector.