Serious Materials, an indoor building material manufacturer, successfully raised an impressive $50 million in late 2007 to support its efforts in bringing it’s new green dry wall product to the marketplace. The venture capital funding is in response to Serious Material’s 2006 research and development success that discovered a way to replace the energy-intensive calcine process used to make drywall. What the company came up with was a gypsum-free drywall they named EcoRock.

You may not think much about drywall, but it is the most common indoor building material in the United States. It does have a dirty secret, though. Typical drywall consist of gypsum, a calcined product which, like cement, needs to be cooked. Basically, it’s calcined (a thermal treatment process) and then dried. That energy-intensive process generates some 20 to 25 billion pounds of CO2 a year. The energy used to make a standard sheet of drywall is 100,000 BTUs or more per sheet, 4×8. When factoring in how much the drywall industry produces a year as a whole: upwards of 30 to 40 billion square feet in the U.S. alone, the CO2 emissions become staggering. In fact, the drywall manufacturing process produces 51 million tons of greenhouse gases and consumes almost 1 percent of all U.S. Energy annually.

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