2/13/2026 at 8:17:55 AM
A huge share of the gypsum used in drywall is *synthetic gypsum* — a byproduct of flue-gas desulfurization (FGD) at coal-fired power plants. When SO₂ is scrubbed from exhaust using limestone, the reaction produces calcium sulfate dihydrate, chemically identical to mined gypsum. In the US, FGD gypsum has accounted for roughly half of all gypsum consumed by the wallboard industry at its peak.The "cheap, uniform, and free of defects" story is partly a story about coal. The drywall industry scaled on the back of an abundant, nearly free waste stream from the energy sector. It's a classic example of industrial symbiosis — one industry's pollution abatement becomes another's feedstock.
And it cuts the other way now: as coal plants shut down across Europe and North America, synthetic gypsum supply is shrinking. The drywall industry is facing a real raw material squeeze, with manufacturers having to shift back toward mined gypsum or find alternative sources. There's ongoing work on using phosphogypsum (from fertilizer production) but that comes with its own radioactivity concerns.
For someone in your position this is particularly relevant — the "wonder" of drywall is entangled with the fossil fuel economy in a way that makes earth-based construction methods look increasingly attractive as that supply chain unwinds.
by jf___
2/14/2026 at 1:32:26 AM
This reminds me a bit of Hank Green's recent video on why we don't recycle plastic. The answer is we frack a lot of methane for electricity and ethane is a byporoduct of that. You can flare it off or use it as a negative cost ingredient for polyethane / many other plastics. As long as we're using lots of fossil fuels the byproducts will be cheap. Anyone who has played gregtech or factorio or similar already has an intuition for this. The answer then becomes simple: if you want less plastic you must use less fossil fuel. They are one and the same.by willis936
2/14/2026 at 3:02:27 AM
Isn't that common knowledge, that plastics aren't feasible without fossil fuels?by glitchc
2/14/2026 at 3:28:35 AM
This is different—the cost of plastic goes up if fossil fuel consumption goes down because currently it uses a waste stream. Not sure if it’s true, but it’s different than my prior intuition about fossil fuel and plastic.by _alternator_
2/14/2026 at 6:38:13 AM
Exactly - a common understanding of fossil fuels is that we could just "use them for planes and plastics" but there would be an unexpected cost there - because the plastics are basically "free" waste products of processing for other needs.It's similar to how car heaters work on waste heat from ICE and have to be accounted for in electric cars.
by bombcar
2/14/2026 at 11:26:02 AM
[flagged]by anonymousDan
2/14/2026 at 12:20:38 AM
I used to work for a drywall manufacturer who still owned their own mines despite efforts to divest from them by some. They always viewed it as a structural advantage to still own them and not be wholly dependent on the coal plants (which effectively have conveyor belts going from the coal plants to the wallboard plants). I imagine as time goes on it'll become even more of an advantage for them to still own those mines as their competitors are forced to buy at highly inflated prices (or even from them) as coal shuts down.by driscoll42
2/14/2026 at 1:28:17 AM
Or AI’s thirst for power will bring coal back.by trollbridge
2/14/2026 at 1:34:15 AM
Why would heightened electricity demand increase the use of the most expensive energy source?by willis936
2/14/2026 at 2:01:50 AM
Potentially due to a shortage of electricity from cheaper searches. There is also political pressure to keep certain coal fired power plants open.https://apnews.com/article/tennessee-valley-authority-coal-p...
by nradov
2/14/2026 at 6:26:32 AM
Coal is expensive, but it's still cheaper than nuke and peaker thermal. If you want power fast and your state and federal government aren't worried about a few pesky environmental regulations you might see coal come back. Part of coals attraction is that it takes a lot of people to run a coal plant, and people need jobs. Those people vote and politicians like votes.by idiotsecant
2/14/2026 at 9:37:56 AM
Then you would plunk down a gas turbine like everyone else. It's so much cheaper than coal to operate and uses mostly the same high capex / long-lead machinery. I could see the jobs program angle, but these are shitty jobs. It's not like working in an air conditioned mcdonald's. Workers die in mines a lot and when they don't they live shorter, less comfortable lives with disease.I'm fine with arguing against coal for environmental reasons, but that won't convince anyone who isn't already convinced. It's always worth pointing out that gas turbines put out a lot less pollutants than coal.
by willis936
2/14/2026 at 5:51:39 PM
Modern coal mining isn't that bad of a gig, especially surface mining (which a lot of coal is). I would certainly rather make a decent middle class wage hauling coal and support my family than work in an 'Air conditioned mcdonalds' and barely subsist in poverty.You can make all the technical and environmental point you want. They are valid and they are largely irrelevant, at least for the purpose of achieving your stated outcome.
People want to be able to live a life with some amount of dignity and we've been so diligently eroding their ability to do so for the last 50 years that it's becoming an existential issue.
Jobs matter. If you want social progress, environmental progress, any kind of progress people need to be able to build a life where their children are better off than they were. Full stop.
by idiotsecant
2/14/2026 at 12:29:15 PM
Gas turbines require infrastructure the may not exist in the area yet, and significant capital outlays.Like coal mining jobs or the like, if you’re stuck in Appalachia with 5 kids and it’s the only thing keeping you afloat, you’ll get pretty worked up if someone tells you ‘just don’t do that, duh’.
Even if it’s probably correct in a macro sense.
by lazide
2/14/2026 at 6:15:33 PM
Isn't the entire coal industry like 50,000 jobs? I've never seen such a small industry so specially treated.by _DeadFred_
2/14/2026 at 1:51:50 PM
Coal, the most expensive energy source?That's funny, is marginally more expensive than natural gas because natural gas is a byproduct of oil extraction.
Coal is vastly cheaper as a 24x365 source of power than anything but hydro and natural gas.
by buckle8017
2/14/2026 at 2:36:19 PM
Batteries make that less true today than in the past. Solar/wind + batteries are becoming cost-competitive with coal for energy on most days (24x7).24x7 every day of the year is much harder, though. Solar/wind + batteries are nowhere near cost competitive for reliability, though. You'd have to build a ridiculous (read: very uneconomical) multiple of typical battery capacity to make it through the long, cloudy, low-wind periods in the winter.
On the bright side, enhanced geothermal is starting to look like it may be economically competitive in the near future. If it pans out, it could repurpose a lot of the technology and labor force from the oil and gas industry to instead produce clean power. And who knows—maybe the current nuclear push will pan out and we'll have another option for reliable base load.
by bruckie
2/14/2026 at 10:58:17 AM
Solar is cheap and abundant during daytime. It has zero power at night. Coal/gas/nukes are more expensive, but runs 24/7. Batteries are getting cheaper, but are still not that cheap.AI/Data centers need power 24/7.
by lazide
2/14/2026 at 12:10:36 PM
Yes so use the cheaper methane gas turbine combined cycle power plant. Coal can't compete with higher efficiency, cheaper fuel options.by willis936
2/14/2026 at 12:19:28 PM
In areas where there are gas transmission lines, sure. Large portions of the country don’t have that infrastructure built out yet, but do have rail lines which provide coal.It’s also a timing/capital issue.
It will change eventually, but in the meantime people need their kWh.
by lazide
2/14/2026 at 12:50:45 PM
Rail lines also provides logistics for methane, which produces many more usable joules per kg of fuel.by willis936
2/14/2026 at 4:48:31 PM
I’ve never seem any analysis of feasibility for LNG (probably what you’re referring too) vs pipeline NG for things like power plants. Do we even have sufficient liquifaction facilities for that type of volume? When I hear of that kind of thing, it’s almost always liquifying for export to places like Europe.by lazide
2/14/2026 at 8:19:15 PM
Batteries exist and are already deployed, with solar-plus-battery being cheaper than coal.by UncleMeat
2/14/2026 at 1:23:34 AM
> the "wonder" of drywall is entangled with the fossil fuel economy in a way that makes earth-based construction methods look increasingly attractive as that supply chain unwinds.I keep thinking of that scene in Brazil where the hero, Harry Tuttle, opens a modular wall panel in Sam's apartment.
We standardized on 16 inch stud spacing here in the US a long time ago when we likely still used cement with a plaster skim coat on wood lath. Cutting up a board of nearly the same stuff feels primitive. You have to break open the wall to fix things.
To me the next logical step is a standard for modular walls that are laid out on a grid structure. I get that no one wants exposed screw holes but I can think of ways to hide them or make them part of a decorative pattern to blend them in. The coverings would be made to be cut to size as well. Wall panels would have to be environmentally friendly so wood is a first choice in natural and/or composite forms.
If you think this will look boxy then look up the passive house and notes on home building. Homes with a winding structure are difficult to seal reliably and roof so a boxy home is actually more economically friendly in terms of insulation to reduce HVAC energy consumption.
by MisterTea
2/14/2026 at 6:45:46 AM
We have exactly what you want - it's called shiplap or car siding.It's wood that is nailed up in such a way that you can pretty easily remove and repair something and replace it.
However, inside wall things get done so rarely that the cost savings by using drywall more than covers paying someone to patch the drywall after a repair.
A middle ground is to run all utilities at the bottom or top of the wall, and use large baseboards/crown molding to cover it up.
by bombcar
2/14/2026 at 1:36:27 AM
> You have to break open the wall to fix thingsThe best is to build in such a way as to not have to fix them in the first place. European standards mandate passing all wiring through corrugated tubes. Builders add spare empty ones for future expansion, which makes it unnecessary to open the walls in most cases.
by ragall
2/14/2026 at 12:35:26 PM
Having owned a couple European houses they’re horrible to alter and mediocre on energy. I miss nice adaptable wood structures. Bizarrely Europeans seem to think their cinderblock homes are nicer…by CalRobert
2/14/2026 at 1:00:04 PM
I've never wanted to adapt a house that significantly. But yeah, I much prefer the cinderblock homes and miss them. Something about the wood and drywall houses just feels incredibly cheap, and I don't like the aesthetic (de gustibus et coloribus..)by Insanity
2/14/2026 at 2:45:44 PM
Houses change over time. A house could have been build in 1920 without a toilet or central heating. Then over time it got a fireplace on the second floor, an indoor toilet, indoor bathroom, then central heating with gas, extra insulation, a couple decades later double paned windows, hybrid heating with a heat pump, then full electric heating, underfloor heating, solar panels, home battery.Houses change a lot over time, it is nice to be adaptable and not need to carve out stone and concrete every time you add a feature to a home.
The most beautiful homes I have been inside in Europe were wooden cabins in Sweden. The exposed wood ceiling beams, the unpainted wooden panels everywhere, the little details. I never had that with stone or brick buildings. Mainly because they got plastered and painted over, you almost never see the raw materials on the inside.
by retired
2/14/2026 at 4:03:36 PM
What you call "carving out" concrete or brick is not a big deal. You hire workers that will do it, period.by ragall
2/14/2026 at 1:58:47 PM
Ultimately houses are built in the way that works for the region they're built in.Europe has few trees and few earthquakes (outside of Romania, Italy, etc). Masonry houses make sense.
In California unreinforced masonry is illegal and trees are plentiful. Making houses out of sticks is rational even if it's unsightly.
Those asphalt roofs though...
by zarzavat
2/14/2026 at 2:33:33 PM
It's not the unavailability of trees. European countries have wisely decides that cities built of wooden houses are prone to massive fires. USians haven't learned that lesson and the Los Angeles fire isn't going to be the last one.by ragall
2/14/2026 at 2:55:35 PM
A yes, the wise Europeans like the Dutch who have homes in Amsterdam that are sinking into the ground due to rotting wooden beams sinking in swamp ground and homes in Groningen with cracks all over due to the earthquakes that came with pumping gas out of the ground.Or the dozens of structures in Italy that came crashing down, like the various bridges over the past twenty years (250 bridge collapse events in Italy between January 2000 and July 2025).
Yes us Europeans are indeed superior and we never pick the wrong building material ever.
by retired
2/14/2026 at 4:04:14 PM
[flagged]by ragall
2/14/2026 at 1:53:45 PM
To each their own I guess. I’ll happily move walls, add or remove a bathroom, add windows, etc.Terrible carbon footprint for concrete too.
I know modern structures are better but I also don’t entirely trust block in an earthquake. Obviously less of a concern in most (not all!) of Europe.
by CalRobert
2/14/2026 at 6:01:14 PM
> To each their own I guess. I’ll happily move walls, add or remove a bathroom, add windows, etc.A sign of the restlesness. Once you find a house to settle in, why would you need to change it ? European houses are typically versatile, US houses aren't due to having closets (which make a room's layout very inflexible) as well as electrical outlets being mandated exactly in the middle of the wall precisely where one would like to place furniture. US building codes are beyond stupid.
> Terrible carbon footprint for concrete too.
Carbon footprint is not that important. I want comfort. More specifically: if you are somewhat wealthy (in the top 10% of incomes, like most of the people here), in the continental Europe you can nowadays easily buy an apartment in a Passivhaus (or almost if renovated) building, with underfloor heating throughout the place, supplied by a geothermal heat pump, with triple-glazed windows and external covers that give you the utmost quietness even when there's traffic just outside. You can't get that in the US because even if you were willing to pay, there exist only a handful of construction companies that know how to build that, and they're all booked for years.
> I know modern structures are better but I also don’t entirely trust block in an earthquake. Obviously less of a concern in most (not all!) of Europe.
You can take a look at Japan. Modern buildings can withstand earthquakes. The issue in the US is that developers are allowed to just build without a civil engineer or architect designing the building. I wouldn't trust that either.
by ragall
2/14/2026 at 9:38:28 AM
>European standards mandate passing all wiring through corrugated tubes.Incorrect. It's usually done, because it's a good idea, but nobody says you have to.
by encom
2/15/2026 at 7:26:50 PM
There are residential jurisdictions within USA that require metal conduit between jboxes (e.g. Chicagoland) — initially more expensive, but much easier to modify/update. Flexible plastic conduit doesn't seem to offer barely any more protection than a standard US NM sheathed cable.As an electrician of two decades, my commonest USA gripes are these:
•) grounding wires should always have insulation, too (instead of just bare)
•) modern NM isn't protected enough (neither physically nor chemically)
•) jboxes should have better wire anchoring inside, and bigger in general
•) oldwork cut-in jboxes aren't substantial enough even perfectly installed for long-term use (if you screw them to an adjacent stud they're great, but this is against code for grounding reasons).
by ProllyInfamous
2/17/2026 at 12:27:26 AM
The main usefulness of plastic conduits is not protection, but being able to pass new wires without opening the walls.by ragall
2/14/2026 at 2:35:10 PM
Maybe in your country. In Italy it's illegal not to use appropriate corrugated tubes.by ragall
2/14/2026 at 2:53:07 PM
Bribery and tax fraud is also illegal in Italy but that didn't stop Berlusconi.by retired
2/14/2026 at 4:06:19 PM
[flagged]by ragall
2/14/2026 at 12:35:47 PM
That means everything in your house is literally set in stone. Sometimes people want to redecorate, have plumbing in a different location or a TV on a different wall.by retired
2/14/2026 at 2:36:45 PM
Sometimes people want stupid things. It's not difficult to hire masons that will redo internal walls. It's just a bit more expensive.by ragall
2/14/2026 at 2:51:34 PM
My father grew up in a home without central heating or an indoor toilet. Last time that home was listed on the market it had underfloor heating, two bathrooms, triple paned glass, an extension on the roof and various other modern amenities. Times change, houses should too. We are not longer pooping in an outhouse anymore.I guess at one point people would wonder why you would want to poop inside the home, and call it "sometimes people want stupid things".
by retired
2/14/2026 at 4:06:28 PM
[flagged]by ragall
2/14/2026 at 12:31:22 PM
Eh, people have a terrible time renovating or adding anything in housing in Europe. A lot of construction doesn’t have those tubes.It’s hard to articulate how wildly different habits are in Europe vs US around things like ‘what electrical appliances I have’ partially because of this.
Housing tends to be a lot smaller too, largely due to population density differences, but also overall differences in economic earning power and ease of buying things.
by lazide
2/14/2026 at 2:40:18 PM
It's not any different from having to renovate a 40's house in the US. You'll have to redo all the plumbing and electrical system to current code. Corrugated tubes have been common since the 90s and mandatory shortly thereafter.by ragall
2/14/2026 at 3:36:16 PM
Most European housing is made of concrete, stone, or brick.It absolutely is different from typical US housing, because unless you want to run surface mount everything (which most people don’t in residential), it’s an insane amount of work to run new anything.
‘40’s homes in the US, you typically just tear down to the studs, re-run new stuff, and throw up new drywall. Boom, done.
Unless you’re in a place that did block/brick etc like some of the big cities, then yeah it’s a nightmare there too.
by lazide
2/14/2026 at 4:18:48 PM
To properly redo an old house, you'll have to redo the siding and probably the roof too.by ragall
2/14/2026 at 4:26:26 PM
Yes, if they weren’t redone separately. Each of them has their own lifecycles, so it’s rare they all get done at once.At that point, most people will just do a full teardown.
by lazide
2/14/2026 at 4:39:03 PM
A properly built house doesn't need a teardown for centuries.by ragall
2/14/2026 at 8:14:30 PM
‘Need’ vs ‘if you’re going to redo literally everything, why not make it more modern’.by lazide
2/14/2026 at 1:37:13 AM
> no one wants exposed screw holesWouldn't bother me. But I'm an engineer. But I think the holes can be plugged with removable plugs.
by intrasight
2/14/2026 at 2:09:35 AM
I love exposed everything in construction. Every plumbing and electrical problem that required me to call someone involved the thing being hidden for aesthetic reasons.I'm currently in an old house in Vietnam and I had to add exposed PVC piping to route around a leak inside a wall that was also feeding mold.
Half of the work involved each time I call someone is understanding the hidden stuff + getting stuff out of the way to see the hidden stuff.
"Engineering types" have built much of the world most of us actually live in. Yet a core piece of engineering——maintainability——is pathologically persistent.
by yowayb
2/14/2026 at 10:43:33 AM
My dad, who has been a carpenter for over 50 years used to rail against boxing in pipes."Once upon a time people were just glad to have running water, now it has to arrive by magic"
In his house there is a duct behind the skirting boards upstairs. You can fish a wire to most places from there.
His other pet hate was glued down cupboard flooring. Squeaky floors were a common complaint in new houses. It was normally caused by not levelling the first floor joists properly (levelling the tops is the correct way), and just dropping them on the walls. The solution industry came up with was to glue the tounges and grooves together, and later to glue the boards to the joists as well. This is a big problem if you need to take up the floor for a leaking pipe. Whereas before you just cut the tongue of a board with a circular saw, pulled it up, and put a noggin under the joint, now you have to destroy a board, and try and buy a similar one
by jimnotgym
2/14/2026 at 11:39:38 PM
"glue and screw" is the norm now. I just can't - having struggled to remove glued down stuff.by intrasight
2/14/2026 at 1:52:18 PM
Interesting comment with worthwhile content, but the writing style strongly smells of ChatGPT, and the phrase "For someone in your position" is incongruous (who is being addressed?). Did you use it, and if so, would you mind sharing the prompt?by dTal
2/14/2026 at 3:25:51 PM
They're a founder of a startup doing this kind of thing, realistically they probably copied blurb per-prepared marketing blurb or something they sent to someone else.by some_random
2/14/2026 at 2:08:04 PM
“Terrestrial develops a robotic approach to earthen construction”. person you replied to claims to be a founder of this company, according to LinkedInOther “tells” in the comment are the subscript “2” and the full spelling of the chemical. Also 3 emdashes
by 46493168
2/14/2026 at 4:57:32 PM
yeah, so the turn in EU towards renewable energy is driving fwd the business of earthen construction. our core (validated) product is printing earthen acoustic barriers at ~4-5m3/hr. panels from loam are a great alternative to gypsum; due to the hygrothermic characteristics of earth the moisture content is stabilised (constant in a ~50-55% bandwidth) which is a massive advantage in view of traditional materials. and fully circular. I'm a developer of pythonocc and tesseract-nanobind, and take pleasure in augmenting my thinking with a dash of ai.by jf___
2/14/2026 at 3:17:47 PM
I use subscript 2s and emdashes. Your "tells" seem to be based on the assumption that humans will not bother to learn key combinations.by graemep
2/14/2026 at 3:24:46 PM
There are 4 paragraphs and three of them have emdashes. You may use emdashes, but you use them orders of magnitude less frequently than current AI models.by some_random
2/13/2026 at 9:20:51 AM
Fascinating. I wonder if supply constraints will make drywall recycling profitable.by xnx
2/13/2026 at 10:59:51 PM
I don’t know about other countries, but in New Zealand there’s already recycling of leftover bits of drywall (we call it ‘gib board’ after a brand name). All the big building companies will accept leftover bits of gib board, but small bits can be thrown directly in your garden beds to help break up clay.The gypsum used in New Zealand is mined locally.
by PlunderBunny
2/14/2026 at 6:09:59 AM
I was just wondering where our gypsum came from, I always assumed it was mined. Thank you for the information.by teruakohatu
2/14/2026 at 7:13:32 AM
Question: Would this process of creating synthethic gypsum leave any toxic chemicals from the scrubbing process at the coal power plant exhaust?by hettygreen