Snapshots For The Crushed Stone, Construction Sand And Gravel, Industrial Sand, Cement, Lime And Gypsum Markets.
Each mineral commodity chapter of the 2021 edition of the U.S. Geological Survey (USGS) Mineral Commodity Summaries (MCS) includes information on events, trends and issues for each mineral commodity. The MCS is the earliest comprehensive source of 2020 mineral production data for the world. More than 90 individual minerals and materials are covered by two-page synopses at www.usgs.gov/centers/nmic/mineral-commodity-summaries.
Crushed Stone
Domestic Production and Use: In 2020, 1.46 billion tons of crushed stone valued at more than $17.8 billion was produced by an estimated 1,410 companies operating 3,440 quarries and 180 sales and (or) distribution yards in 50 states. Leading states were, in descending order of production, Texas, Missouri, Florida, Pennsylvania, Ohio, Georgia, Virginia, Illinois, North Carolina and Kentucky, which combined accounted for more than one-half of the total crushed stone output.
Of the total domestic crushed stone produced in 2020, about 70% was limestone and dolomite; 15%, granite; 6%, traprock; 5%, miscellaneous stone; 3%, sandstone and quartzite; and the remaining 1% was divided, in descending order of tonnage, among marble, volcanic cinder and scoria, calcareous marl, slate, and shell. It is estimated that of the 1.5 billion tons of crushed stone consumed in the United States in 2020, 72% was used as construction aggregate, mostly for road construction and maintenance; 16% for cement manufacturing; 8% for lime manufacturing; 2% for agricultural uses; and the remainder for other chemical, special, and miscellaneous uses and products.
Recycling: Road surfaces made of asphalt concrete and portland cement concrete surface layers, which contain crushed stone aggregate, were recycled on a limited but increasing basis in most states. In 2020, asphalt and portland cement concrete road surfaces were recycled in all 50 states.
Import Sources (2016–19): Mexico, 56%; Canada, 27%; The Bahamas, 11%; Honduras, 5%; and Jamaica, 1%.
Events, Trends and Issues: Crushed stone production was about 1.46 billion tons in 2020, a slight decrease compared with 1.49 billion tons in 2019. Apparent consumption also decreased slightly to about 1.52 billion tons. Consumption of crushed stone decreased in 2020 because of measures instituted to mitigate the spread of the global COVID-19 pandemic that caused disruptions in the mining and construction industries. Usually commercial and heavy industrial construction activity, infrastructure funding, new single-family housing unit starts, and weather, affect growth in crushed stone production and consumption.
Long-term increases in construction aggregates demand are influenced by activity in the public and private construction sectors, as well as by construction work related to security measures being implemented around the nation. The underlying factors that would support a rise in prices of crushed stone are expected to be present in 2021, especially in and near metropolitan areas.
The crushed stone industry continued to be concerned with environmental, health, and safety regulations. Shortages in some urban and industrialized areas are expected to continue to increase owing to local zoning regulations and land-development alternatives. These issues are expected to continue and to cause new crushed stone quarries to be located away from large population centers.
Construction Sand and Gravel
Domestic Production and Use: In 2020, 960 million tons of construction sand and gravel valued at $9.2 billion was produced by an estimated 3,870 companies operating 6,800 pits and 340 sales and distribution yards in 50 states. Leading producing states were, in order of decreasing tonnage, California, Texas, Arizona, Minnesota, Michigan, Utah, Ohio, Washington, Colorado and New York, which together accounted for about 53% of total output.
It is estimated that about 46% of construction sand and gravel was used as portland cement concrete aggregates, 21% for road base and coverings and road stabilization, 13% for construction fill, 12% for asphaltic concrete aggregate and for other bituminous mixtures, and 4% for other miscellaneous uses. The remaining 4% was used for concrete products, filtration, golf course maintenance, plaster and gunite sands, railroad ballast, road stabilization, roofing granules, and snow and ice control.
Events, Trends and Issues: Construction sand and gravel production was about 960 million tons in 2020, a slight decrease compared with that of 2019. Apparent consumption also decreased slightly to 965 million tons.
Demand for construction sand and gravel decreased in 2020 because of measures instituted to mitigate the spread of the global COVID-19 pandemic that caused disruptions in the mining and construction industries. Usually commercial and heavy-industrial construction activity, infrastructure funding, new single-family housing unit starts, and weather affect growth in sand and gravel production and consumption.
Long-term increases in construction aggregates demand will be influenced by activity in the public and private construction sectors, as well as by construction work related to security measures being implemented around the nation.
The underlying factors that would support a rise in prices of construction sand and gravel are expected to be present in 2021, especially in and near metropolitan areas.
The construction sand and gravel industry remained concerned with environmental, health, permitting, safety and zoning regulations. Movement of sand and gravel operations away from densely populated regions was expected to continue where regulations and local sentiment discouraged them. Resultant regional shortages of construction sand and gravel would result in higher-than-average price increases in industrialized and urban areas.
Industrial Sand and Gravel
Domestic Production and Use: In 2020, industrial sand and gravel valued at about $3.2 billion was produced by about 180 companies from about 280 operations in 34 states. The value of production of industrial sand and gravel in 2020 decreased by 40% compared with that of the previous year, owing primarily to reduced demand for hydraulic-fracturing sand and metallurgical uses. Demand declined as a result of restrictions put in place in response to the global COVID-19 pandemic coupled with ongoing weak demand from the oil and gas sector.
Leading producing states were Texas, Wisconsin, Illinois, Missouri, Minnesota, Oklahoma, Mississippi, North Carolina, Louisiana and Iowa, in descending order of tonnage produced. Combined production from these states accounted for about 81% of total domestic sales and use. About 58% of the U.S. tonnage was used as hydraulic-fracturing sand and well-packing and cementing sand; as glassmaking sand and as other whole-grain silica, 12% each; as foundry sand, 4%; as ceramics, whole-grain fillers for building products, and recreational sand, 3% each; and as other ground silica, 2%. Abrasives, chemicals, fillers, filtration sand, metallurgical flux, roofing granules, silica gravel, and traction sand, combined, accounted for the remaining 3% of industrial sand and gravel end uses.
Events, Trends and Issues: U.S. apparent consumption of industrial sand and gravel was estimated to be 68 million tons in 2020, a 38% decrease from that of the previous year. The primary causes of the decline were decreased natural gas and petroleum well drilling in North America and oil well completion activity.
These decreases were exacerbated by COVID-19 pandemic restrictions, which resulted in a significant decline in consumption of petroleum products, which in turn prompted a decrease in demand for hydraulic-fracturing sand in 2020 compared with that of the previous year. Imports of industrial sand and gravel in 2020 were about 380,000 tons – slightly less than those of 2019.
Imports of silica are generally of two types – small shipments of very high-purity silica or a few large shipments of lower grade silica shipped only under special circumstances (for example, very low freight rates). The United States remained a net exporter of industrial sand and gravel, although U.S. exports of industrial sand and gravel decreased by 34% in 2020 compared with those of 2019, also a result of the global pandemic.
The United States was the world’s leading producer and consumer of industrial sand and gravel based on estimated world production figures. It is difficult to collect definitive data on industrial sand and gravel (sometimes also referred to as silica sand and gravel) production in most nations because of the wide range of terminology and specifications used by different countries.
The United States remained a major exporter of industrial sand and gravel, shipping it to almost every region of the world. High global demand for U.S. industrial sand and gravel can be attributed to the high quality and advanced processing techniques used in the United States for many grades of industrial sand and gravel, meeting specifications for virtually any use.
Cement
Domestic Production and Use: In 2020, U.S. portland cement production increased slightly to an estimated 87 million tons, and masonry cement production decreased slightly to 2.3 million tons. Cement was produced at 96 plants in 34 states, and at two plants in Puerto Rico. Texas, Missouri, California and Florida were, in descending order of production, the four leading cement-producing states and accounted for nearly 45% of U.S. production.
Overall, the U.S. cement industry’s growth continued to be constrained by closed or idle plants, underutilized capacity at others, production disruptions from plant upgrades, and relatively inexpensive imports. In 2020, shipments of cement were essentially unchanged from those of 2019 and were valued at $12.7 billion. In 2020, it was estimated that 70% to 75% of sales were to ready-mixed concrete producers, 10% to concrete product manufactures, 8% to 10% to contractors, and 5% to 12% to other customer types.
Recycling: Cement is not recycled, but significant quantities of concrete are recycled for use as a construction aggregate. Cement kilns can use waste fuels, recycled cement kiln dust, and recycled raw materials such as slags and fly ash. Various secondary materials can be incorporated as supplementary cementitious materials (SCMs) in blended cements and in the cement paste in concrete.
Events, Trends and Issues: In 2020, production of cement was temporarily idled in many countries and localities in response to national lockdowns imposed to limit the spread of the global COVID-19 pandemic. The duration of the lockdowns and the return to full production following the restart of operations, varied by geographic region. Disruptions to construction activities corresponded with reduced cement demand, and some regions experienced increased fuel and freight costs. Additionally, several planned cement plant openings and expansions were delayed.
A cement plant in New York was idled in April because of decreased demand resulting from restrictions put in place to mitigate the spread of the virus. However, the U.S. cement industry has shown no prolonged or widespread negative effects from the pandemic. The leading cement-consuming states continued to be Texas, California and Florida, in descending order by tonnage. Company merger-and-acquisition activity continued in 2020, with the completion of the sale of a cement company in Kentucky. In 2019, one European cement company entered into an agreement to purchase a Mexican cement company’s plant in Pennsylvania and the transaction was still pending regulatory approval in 2020.
Cement plant upgrades were announced at cement plants in Alabama and Texas. Several minor upgrades were ongoing at some other domestic plants, and upgrades were also announced for a few cement terminals. However, one cement company delayed work on an upgrade to one of its plants in Indiana.
Another company secured its final air permit for a new cement plant in Georgia. Numerous companies made announcements aligned with the industry’s commitment to sustainability, such as new product lines, renewable energy plans, decarbonization research initiatives, and other innovations. Many plants have installed emissions-reduction equipment to comply with the 2010 National Emissions Standards for Hazardous Air Pollutants (NESHAP). It remains possible that some kilns could be shut, idled, or used in a reduced capacity to comply with NESHAP, which would constrain U.S. clinker capacity.
Lime
Domestic Production and Use: In 2020, an estimated 16 million tons of quicklime and hydrate was produced (excluding independent commercial hydrators), valued at about $2.2 billion. At year-end, 28 companies were producing lime, which included 18 companies with commercial sales and 10 companies that produced lime strictly for internal use (for example, sugar companies). These companies had 74 primary lime plants (plants operating quicklime kilns) in 28 states and Puerto Rico. One lime plant was idle in 2020. Five of the 28 companies operated only hydrating plants in nine states.
In 2020, the five leading U.S. lime companies produced quicklime or hydrate in 22 states and accounted for about 72% of U.S. lime production. Principal producing states were, in alphabetical order, Alabama, Kentucky, Missouri, Ohio and Texas. Major markets for lime were, in descending order of consumption, steelmaking, chemical and industrial applications (such as the manufacture of fertilizer, glass, paper and pulp, and precipitated calcium carbonate, and in sugar refining), flue gas treatment, construction, water treatment, and nonferrous mining.
Recycling: Large quantities of lime are regenerated by paper mills. Some municipal water-treatment plants regenerate lime from softening sludge. Quicklime is regenerated from waste hydrated lime in the carbide industry. Data for these sources were not included as production in order to avoid duplication.
Events, Trends and Issues: In 2020, domestic lime production was estimated to have decreased by 5% from that of 2019. A decline in lime production was a result of plants temporarily closing as a result of the global COVID-19 pandemic. In San Bernardino County, Calif., plans were underway to a construct a new quicklime plant using crushed limestone transported to the site from a nearby quarry.
In Texas, one company planned to expand lime production capacity at two separate plants by 2021. One plant was adding a new vertical kiln to meet increasing steel industry demand for high-purity dolomitic lime products. The other plant was adding a new energy-efficient lime kiln to produce high-calcium lime products to meet the increasing demand from the steel and construction industries.
The total number of operating quicklime plants was 73 in 2020 along with 10 hydrating plants. Hydrated lime is a dry calcium hydroxide powder made from reacting quicklime with a controlled amount of water in a hydrator. It is used in chemical and industrial, construction, and environmental applications.
Gypsum
Domestic Production and Use: In 2020, domestic production of crude gypsum was estimated to be 22 million tons with a value of about $190 million. The leading crude gypsum-producing states were estimated to be Iowa, Kansas, Nevada, Oklahoma and Texas. Overall, 47 companies produced or processed gypsum in the United States at 52 mines in 16 states.
The majority of domestic consumption, which totaled approximately 41 million tons, was used by agriculture, cement production, and manufacturers of wallboard and plaster products. Small quantities of high- purity gypsum, used in a wide range of industrial processes, accounted for the remaining tonnage. At the beginning of 2020, the production capacity of 63 operating gypsum panel manufacturing plants in the United States was about 34.1 billion sq. ft. per year. Total wallboard sales were estimated to be 26.0 billion sq. ft.
Recycling: Approximately 700,000 tons of gypsum scrap that was generated by wallboard manufacturing was recycled onsite. The recycling of wallboard from new construction and demolition sources also took place, although those amounts are unknown. Recycled gypsum was used primarily for agricultural purposes and feedstock for the manufacture of new wallboard. Other potential markets for recycled gypsum include athletic field marking, cement production (as a stucco additive), grease absorption, sludge drying, and water treatment.
Events, Trends and Issues: U.S. gypsum production increased by 4% compared with that of 2019. Apparent consumption decreased slightly compared with that of 2019. U.S. gypsum imports decreased by an estimated 4% compared with those of 2019. Exports, although very low compared with imports and often subject to wide fluctuations, decreased by 14%.
Demand for gypsum depends principally on construction industry activity, particularly in the United States, where the majority of gypsum consumed is used for agriculture, building plasters, the manufacture of portland cement, and wallboard products. The construction of wallboard manufacturing plants designed to use synthetic gypsum from coal flue gas desulfurization (FGD) units as feedstock has resulted in less mining of natural gypsum. The availability of inexpensive natural gas, however, has limited the additional construction of FGD units and, therefore, the use of synthetic gypsum in wallboard.