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WOOD FLOORINGPublished by: Catalina Research Published: Dec. 4, 2003 - 206 Pages Table of ContentsTABLE OF CONTENTS SECTION 1 U.S. WOOD FLOORING INDUSTRY TRENDS 1 Executive Summary 1 Wood Flooring Sales Trends And Factors Driving Demand 2 Price Trends And Introduction Of Value Added Products 3 Consumers Seeking Wider Choices 4 Wood Flooring’s Growing Position In The U.S. Floor Coverings Market 5 Growing End-Use Markets 6 Changing Retail Distribution Channels 7 Increased Competitive Pressures 8 Industry Profit Margins And The Material Cost Situation 9 Outlook 11 Table 1-1 Value Of U.S. Wood Flooring Market Sales, 1977-2008 (dollars) 12 Figure 1-1 Value Of U.S. Wood Flooring Market Sales, 1993-2008 (dollars) 13 Table 1-2 Quantity U.S. Wood Flooring Market Sales And Average Value Per Square Foot Supplied, 1992-2008 (board feet and dollars) 14 Table 1-3 Wood Flooring's Position In The U.S. Floor Coverings Market, 1992-2008 (dollars, square yards, and percent) 15 Figure 1-2 Wood Flooring’s Share Of The Total U.S. Floor Coverings Market, 1997-2003 (percent) 16 Table 1-4 Wood Floorings' Position In The U.S. Hard Surface Floor Coverings Market, 1992-2008 (dollars, square feet, and percent) 17 Table 1-5 U.S. Wood Flooring Shipments, Exports, And Imports, 1992-2008 (dollars, square feet, and percent): Shipments, Exports, Exports Percent Shipments, Imports, And Imports Percent Market Sales 18 Table 1-6 U.S. Market Sales For Hardwood And Softwood Flooring, 1992-2008 (square feet and dollars) 19 Table 1-7 U.S. Average Value Per Square Foot Of Floor Covering Supplied By Product Sector, 1992-2003 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Floor And Wall Tile, Vinyl Sheet And Floor Tile, Rubber Sheet And Floor Tile, And Laminate Flooring 20 Table 1-8 U.S. Producer Price Trends For Hardwood Flooring And Competing Floor Coverings, 1987-2003 (index): Hardwood Flooring, Carpet And Area Rugs, Resilient Floor Coverings, Ceramic Tile, And Rubber Mats And Stair Treads 21 Table 1-9 Monthly U.S. Producer Price Trends For Hardwood Flooring, 2001-2003 (index) 22 Table 1-10 Gross Plant Profit Margins For Hardwood Flooring Plants And The U.S. Floor Coverings Industry Average, 1982-2003 (percent) 23 SCOPE AND METHODOLOGY 24 SECTION 2 U.S. WOOD FLOORING SHIPMENTS 27 Summary Of Major Findings 27 Manufacturer Shipments 28 Price Trends 29 Solid Versus Engineered Products 30 Prefinished Products 31 Species Shipment Mix 32 Growth Of Exotics 33 Rustic Look 33 Glueless Technology 34 Table 2-1 Value Of Total U.S. Wood Flooring Shipments, 1972-2008 (dollars) 36 Table 2-2 Wood Flooring's Position In The U.S. Floor Coverings Industry, 1972-2008 (dollars and percent): Floor Coverings Product Shipments, Percent GDP, And Wood Percent Total 37 Table 2-3 Quantity Total U.S. Wood Flooring Shipments And Average Value Per Square Foot Shipped, 1972-2008 (board feet and dollars) 38 Table 2-4 Value Of U.S. Hardwood And Softwood Flooring Shipments, 1972-2008 (dollars) 39 Table 2-5 Quantity U.S. Hardwood And Softwood Flooring Shipments And Average Value Per Square Foot Shipped, 1972-2008 (board feet and dollars) 40 Table 2-6 Value Of U.S. Hardwood Flooring Shipments By Product Type, 1972-2008 (dollars): Strip Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck And Railroad Flooring, And Other Hardwoods 42 Table 2-7 Distribution Of U.S. Hardwood Flooring Dollar Shipments By Product Type, 1972-2008 (percent): Strip Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck And Railroad Flooring, And Other Hardwoods 43 Table 2-8 Quantity U.S. Hardwood Flooring Shipments By Product Type, 1972-2008 (board feet): Strip Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck And Railroad Flooring, And Other Hardwoods 44 Table 2-9 Distribution Of U.S. Hardwood Flooring Quantity Shipments By Product Type, 1972-2008 (percent): Strip Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck Trailer And Railroad Oak Flooring, And Other Hardwoods 45 Table 2-10 U.S. Average Value Per Square Foot Shipped By Hardwood Flooring Product Type, 1972-2008 (dollars): Strip Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck And Railroad Flooring, And Other Hardwoods 46 Table 2-11 U.S. Producer Price Trends For Hardwood Flooring Products By Type, 1985-2003 (index): Strip Oak Flooring and Maple Flooring 47 Table 2-12 Product Definitions And Terms 48 Solid Wood Flooring 48 Parquet 48 Engineered Wood Flooring 48 Acrylic Impregnated Wood Flooring 49 Custom Wood Floors 49 Mixed Media And Mixing Species 49 Customized Paint Designs 49 Unfinished Wood Flooring 49 Prefinished Wood Flooring 49 Nail Strip Or Plank Floor 50 Glue-Down Floor 50 Floating Floor 50 Wood Species 50 Wood Flooring Cuts 51 Recycled And Reclaimed Wood Flooring 51 Wood Floor Finishes 51 SECTION 3 U.S. SOLID WOOD FLOORING IMPORTS 53 Summary Of Major Findings 53 Import Shipments 53 Hardwood Versus Softwood Imports 54 Imports By Country 54 Companies Stimulating U.S. Imports 55 Table 3-1 U.S. Solid Wood Flooring Imports, 1992-2008 (square feet and dollars) 57 Table 3-2 U.S. Solid Wood Flooring Imports By Material, 1992-2003 (square feet and dollars): Softwood, Maple, Birch, And Other Hardwood 58 Table 3-3 Imports' Share Of U.S. Wood Flooring Market Sales By Material, 1992-2003 (percent): Softwood And Hardwood 59 Table 3-4 U.S. Solid Wood Flooring Imports For The Top Fourteen Countries Of Origin, 1997-2003 (square feet and dollars) 60 SECTION 4 U.S. WOOD FLOORING END-USE MARKETS AND DISTRIBUTION CHANNELS 62 Summary Of Major Findings 62 New Residential Construction Market 62 Residential Remodeling Market 63 Nonresidential Markets 64 Retail Distribution 65 The Distributor Channel 67 Installation Contractors 67 Solid Wood Flooring Export Shipments 68 Table 4-1 Value Of U.S. Hardwood Flooring Purchases By Major End-Use Market, 1997-2003 (dollars): New Residential Construction, Residential Replacement And Repair, Factory-Built Housing, New Nonresidential Construction, Commercial Contract, And Transportation Equipment 70 Table 4-2 Hardwood Flooring’s Share Of Total Dollar Floor Coverings Purchases By Major U.S. End-Use Market, 1997-2002 (percent): New Residential Construction, Residential Replacement And Repair, Factory-Built Housing, New Nonresidential Construction, Commercial Contract, And Transportation Equipment 71 Table 4-3 Value Of Hardwood Flooring Purchases Per U.S. Contractor-Built Housing Unit Completed And Factory-Built Housing Unit Shipped, 1997-2003 (dollars) 72 Table 4-4 U.S. Wood Flooring Contractor Revenues And Share Of Total U.S. Construction Spending, 1977-2003 (dollars and percent) 73 Table 4-5 Contractor Business By Type Of Job And Products Sold, 1999-2002 (percent): New Home Versus Remodel, Installation Versus Finishing, And Products, Species, Finishes Sold 74 Table 4-6 U.S. Contractor Revenue Per Square Foot Of Wood Flooring Installed, 1992-2003 (dollars) 75 Table 4-7 Number Of U.S. Hardwood Flooring Retailers And Sales By Type Of Outlet, 1997 And 2002 (number, dollars, and percent): Retail Sales, Hardwood Percent Total Floor Covering Sales, Number Of Retailers Carrying Line, And Average Sales Per Retailer 76 Table 4-8 Distributor Business By Type Of Product, Species, And Finish Sold, 1999-2002 (percent) 77 Table 4-9 U.S. Solid Wood Flooring Exports, 1992-2008 (square feet and dollars) 78 Table 4-10 U.S. Solid Wood Flooring Exports By Material, 1992-2003 (square feet and dollars): Softwood And Hardwood 79 Table 4-11 Exports' Share Of U.S. Solid Wood Flooring Shipments By Material, 1992-2003 (percent): Softwood, Hardwood, And Total 80 Table 4-12 U.S. Exports Of Solid Hardwood Flooring For The Top Seven Countries Of Destination, 1997-2003 (square feet and dollars) 81 Table 4-13 U.S. Exports Of Solid Softwood Flooring For The Top Seven Countries Of Destination, 1997-2003 (square feet and dollars) 82 SECTION 5 FACTORS AFFECTING U.S. WOOD FLOORING DEMAND AND DISTRIBUTION 83 Summary Of Major Findings 83 Residential Remodeling Market 83 New Residential Construction Market 84 Retail Distribution 85 Nonresidential Markets 86 Table 5-1 U.S. Spending On Building Construction, 1977-2003 (dollars): Total Buildings, Residential Buildings, And Nonresidential Buildings 87 Table 5-2 U.S. Spending On Construction Put In Place By Market And Building Type, 1999-2003 (dollars) 88 Table 5-3 Total U.S. Housing Demand By Sector By Region, 1998-2003 (number): Northeast, Midwest, South, West, And Total 90 Table 5-4 New U.S. Privately Owned Housing Units Started And By Type Of Structure, 1980-2003 (number): Total Starts; In Structures With 1 Unit, 2 To 4 Units, And 5 Units Or More 92 Table 5-5 Monthly New Private U.S. Housing Units Authorized By 19,000 Building Permit Places By Region, 2002 And 2003 (number) 93 Table 5-6 New Privately Owned Housing Units Authorized By 19,000 Building Permit Places By Region And State, 1997-2003 (number) 94 Table 5-7 Characteristics Of New U.S. Housing Units Affecting Floor Covering Product Demand, 1990-2002 (units): Region, Number Of Bathrooms, Number Of Bedrooms, Garages, Number Of Stories For Single-Family, Multi-Family Structures, And Mobile Homes 96 Table 5-8 Average Size Per New U.S. Housing Unit By Type Of Unit And Region, 1990-2003 (square feet) 99 Table 5-9 New U.S. Single-Family Houses Sold By Sales Price, 1985-2003 (number and dollars): Under $100,000, $100,000 To $149,999, $150,000 To $199,999, $200,000 To $299,999, And $300,000 And Over 100 Table 5-10 Average Value Per New Single-Family House Sold And Average Value Per Square Foot, 1985-2003 (dollars) 101 Table 5-11 U.S. Residential Property Owner Expenditures For Improvements, Additions, Alterations, And Repairs And Spending By Single-Family Homeowners, 1985-2003 (dollars) 102 Table 5-12 U.S. Household Spending On Hard Surface Flooring And Installation For Owner-Occupied And Rental Units And For Material And Installation And Material Only Purchases, 1992-2001 (dollars) 103 Table 5-13 U.S. Household Spending On Hard Surface Flooring And Installation By Demographic Characteristic, 1997 And 2001 (dollars): Household Income, Age Of Household Head, Size Of Household, And Region 104 Table 5-14 Percent Distribution Of U.S. Household Floor Coverings And Installation Spending For Soft And Hard Surface Flooring By Demographic Characteristic, 1997 And 2001 (percent): Household Income, Age Of Household Head, Size Of Household, And Region 106 Table 5-15 U.S. Retail Floor Coverings Sales By Type Of Outlet, 1987-2002 (dollars): Floor Coverings Stores, Building Material Dealers And Home Centers, Furniture Stores, Department Stores And Mass Merchandisers, Paint Stores, Non-Store Retailers, All Other Retailers, And Total Sales 108 Table 5-16 Monthly U.S. Floor Coverings Store Sales, 2000-2003 (dollars) 109 Table 5-17 U.S. Home Mortgage Interest Rates And Personal Income, 1980-2003 (percent and dollars) 110 Table 5-18 Distribution Of U.S. Households By Demographic Characteristic, 1985-2002 (percent): Household Income, Age Of Household Head, Household Size, Region, And Total Households 111 SECTION 6 COST STRUCTURE OF U.S. HARDWOOD FLOORING PLANTS AND THE COMPETITIVE ENVIRONMENT 112 Summary Of Major Findings 112 Number Of Hardwood Flooring Manufacturers And Plants 112 Other Manufacturers And Marketers 113 Market And Brand Shares 115 Industry Profit Margins 117 Material Situation 117 Table 6-1 Number Of U.S. Hardwood Flooring Plants And Facility Revenues, 1972-2003 (dollars) 119 Table 6-2 U.S. Hardwood Flooring Plant Operating Ratios And Gross Profit Margin, 1972-2003 (percent): Payroll, Material Costs, And Gross Profit Margin 120 Table 6-3 U.S. Producer Price Trends For Lumber, 1982-2003 (index): Total, Softwood, And Hardwood 121 Table 6-4 Monthly U.S. Producer Price Trends For Oak And Maple Rough Lumber, 2001-2003 (index) 122 Table 6-5 U.S. Hardwood Lumber Production And Mill Stocks, 1980-2002 (board feet) 123 Table 6-6 U.S. Hardwood Flooring Plant Labor Situation, 1972-2003 (number, percent, and dollars): Number Of Employees, Shipments Per Employee, Production Workers Percent Total Employees, Average Hourly Wages, And Average Weekly Hours 124 Table 6-7 U.S. Hardwood Flooring Plant Capital Expenditures, 1972-2003 (dollars) 125 Table 6-8 Number Of U.S. Hardwood Flooring Manufacturers By Product Type, 1987-1997 (number and dollars): Softwood Flooring, Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck And Railroad Flooring, And Other Hardwoods 126 Table 6-9 Share Of U.S. Wood Flooring Supply For Twelve Leading Manufacturers, 2002 (percent) 127 Table 6-10 Sales And Profit Trends For Armstrong's Wood Flooring Segment, 1999-2003 (dollars and percent) 128 Table 6-11 Top Twelve Hardwood Flooring Brands Used By New U.S. Home Builders And Remodeling Contractors Over The Past Twelve Months, 2002 (percent) 129 Table 6-12 Top Six Hardwood Flooring Brands Used By New U.S. Home Builders By Region, Cost Of Home, Units Built, And Home Type, 2002 (percent) 130 Table 6-13 Top Six Hardwood Flooring Brands Used By Remodeling Contractors By Region, Cost Of Home, Units Remodeled, And Home Type, 2002 (percent) 131 SECTION 7 CANADIAN AND EUROPEAN WOOD FLOORING MARKET 132 Summary Of Major Findings 132 Canadian Market Sales 132 Canadian Shipments And Capacity Expansion 132 Canadian Exports 133 Canadian Imports 134 Leading Canadian Manufacturers 134 European Market Trends 136 Leading European Manufacturers 137 Table 7-1 Value Of Canadian Hardwood Flooring Market Sales, 1992-2002 (Canadian dollars) 139 Table 7-2 Value Of Canadian Hardwood Flooring Shipments, Exports, And Imports, 1992-2002 (Canadian dollars) 140 Table 7-3 Canadian Shipments Of Hardwood Flooring And Average Value By Wood Type, 1990-1999 (Canadian dollars and cubic meters): Maple, Oak, Birch, Other, And Total 141 Table 7-4 Wood Flooring Production For Twelve Leading Canadian Manufacturers, 2002 (square feet): Solid Wood, Engineered Flooring, Mosaic Parquet, And Percent Sales Exported 142 Table 7-5 Canadian Exports And Imports Of Hardwood Flooring And Related Products, 1992-2002 (Canadian dollars) 143 Table 7-6 Value Of Canadian Building Permits And Canadian Housing Starts, 1993-2002 (number and Canadian dollars) 144 Table 7-7 European Wood Flooring Market By Country And Leading Suppliers, 2002 (percent) 145 Table 7-8 Sales And Profit Trends For Five Canadian And European Wood Flooring Suppliers, 2002 (dollars and percent) 146 SECTION 8 COMPANY PROFILES 148 Aged Woods/Yesteryear Floorworks Co. 149 Wood Flooring Products 149 American Biltrite, Inc. 150 Janus Flooring 150 Anderson Hardwood Floors 151 Wood Flooring Products 151 New Products 152 Sales And Market Share 152 Anderson-Tully Lumber Co. 153 Wood Flooring Products 153 Armstrong Holdings, Inc. 155 Wood Flooring Products 155 Marketing And Distribution 155 New Products 156 Sales And Profit Trends 157 Market Shares 158 Award Hardwood Floors 159 Wood Flooring Products 159 New Products And Distribution 159 Sales And Market Share 160 Boa-Franc 161 Wood Flooring Products And Production 161 New Products And Distribution 161 Boen Hardwood Floors Inc. 163 Wood Floor Products 163 Distribution 163 Brand Shares 164 BR-111 Imports & Exports, Inc. 165 Wood Flooring Products 165 Columbia Forest Products 166 Wood Flooring Products 166 New Products 166 Sales And Market Share 167 Acquisition Of Millwood Specialty Flooring 167 D & M Bamboo Flooring Co. 169 Wood Flooring Products 169 Domco Tarkett, Inc. 170 Wood Flooring Products And Manufacturing 170 New Products 170 Sales And Profit Trends 171 Market And Brand Shares 171 Name Change Planned 172 Felix Huard 173 Wood Flooring Products 173 Floorco International North America, Inc. 174 Wood Flooring Products 174 Forbo International SA 176 Wood Flooring Products And Sales 176 Gammapar 177 Wood Flooring Products 177 Acquisition Of PermaGrain Products 177 Johnson Premium Hardwood Flooring 179 Wood Flooring Products 179 F. Junckers Industrier A/S 180 Wood Flooring Products And Sales 180 Junckers Hardwood Subsidiary 180 Kentucky Wood Floors, Inc. 182 Wood Flooring Products 182 New Products 182 Brand Shares 183 Lauzon Industries, Inc. 184 Wood Flooring Products 184 Manufacturing Output And Sales 185 Acquisitions And Partnership 185 Linden Lumber Co. LTD. 186 Wood Flooring Products And Sales 186 Mannington Mills 187 Wood Flooring Products And Market Share 187 Market And Brand Shares 187 Memphis Hardwood Flooring Co. 189 Wood Flooring Products And Sales 189 Mercier Wood Flooring 190 Wood Flooring Products 190 Mohawk Industries, Inc. 191 Wood Flooring Products 191 Mullican Flooring 192 Wood Flooring Products 192 Manufacturing And Sales 192 Acquisitions 193 Nybron Flooring International 194 Wood Flooring Subsidiaries And Sales 194 Bauwerk 194 Kährs 195 Marty 196 Preverco 198 Wood Flooring Products 198 Satin Finish Hardwood Flooring 199 Wood Flooring Products 199 Shaw Industries, Inc. 200 Wood Flooring Products 200 Tarkett Sommer AG 201 Wood Flooring Subsidiaries 201 European Wood Flooring Sales 201 Tembec, Inc. 202 Wood Flooring Products And Sales 202 Upofloor Oy 203 Wood Flooring Products 203 Weyerhaeuser Co. 204 Wood Flooring Products 204 Witex USA 205 Wood Flooring Products 205 Zickgraf Hardwood Flooring Co. 206 Wood Flooring Products 206 AbstractSUMMARY OF MAJOR FINDINGS The $2.2 billion (manufacturers’ dollars) U.S. wood flooring market has made significant inroads in the domestic floor coverings industry. The inroads were stimulated by growing consumer acceptance of high-end hard surface flooring, as well as more diverse offerings by wood flooring manufacturers. Manufacturers now offer a wide range of species, colors, and custom-type designs. The industry has also stimulated demand with easier and less costly to install products such as prefinished, engineered, and glueless wood floors. These new products and technologies have increased competitive pressures. Rising material costs have put additional pressure on the market’s bottom line performance. WOOD FLOORING INDUSTRY TRENDS Catalina Research has uncovered these trends in our in-depth analysis of the North American wood flooring industry. U.S. shipments, exports, and price trends are evaluated for hardwood and softwood flooring products. Hardwood flooring shipments are further segmented for strip oak, oak parquetry, specialty oak, maple, and other hardwood flooring products. Data is provided on a dollar and unit basis. Catalina also reviews market trends for prefinished and engineered products, and increased demand for exotics and other niche products. INTERNATIONAL TRADE ACTIVITY Import data is included in order to evaluate the growing share of foreign-sourced wood flooring products. Import data is provided for softwood flooring; and maple, birch, and other hardwood flooring products. Import data is also provided for major countries of origin. Similar data is available for export shipments. END-USE MARKET ANALYSIS The report’s end-use market analysis provides executives with the growing sales opportunities in residential, nonresidential, and transportation equipment markets. Residential markets are further divided into new construction, residential remodeling, and manufactured housing markets. The demographics of hard surface flooring residential replacement customers are discussed in order to target the most likely purchasers. Nonresidential markets are segmented into new construction and commercial contract purchasers. Installation revenues and costs are also evaluated. Retail distribution channels are analyzed to review the position of floor covering stores and home centers. FACTORS AFFECTING DEMAND AND DISTRIBUTION End-use market trends are correlated with U.S. housing demand, nonresidential construction spending, mortgage interest rates, and other economic indicators to uncover the factors affecting demand, and provide insights into the direction of domestic demand in 2003 and beyond. Catalina Research investigates the growing flooring retail channels as well. PROFIT MARGINS AND THE COMPETITIVE ENVIRONMENT In addition, Catalina Research examined the cost structure and profitability of U.S. hardwood flooring plants. Data trends are compiled for material, labor, and capital inputs. As part of this analysis, Catalina profiled 36 leading North American manufactures and marketers, and compiled company wood flooring sales. Catalina used this information to calculate market shares of leading manufacturers. Company profiles cover product lines, manufacturing and distribution, capital investments, acquisitions, and new products. Executives are urged to review the growth- and profit-oriented strategies of leading North American and foreign-based wood flooring manufacturers and compare their company’s own performance to the industry averages. CANADIAN AND EUROPEAN WOOD FLOORING INDUSTRY
The Canadian wood flooring industry is also analyzed. Market sales are calculated from shipments, exports, and import data. This data was used to evaluate wood flooring’s share of the Canadian floor coverings market. Shipments are segmented for oak, maple, birch, and other hardwood floorings. Market shares and also calculated for the leading Canadian manufacturers. The European market was reviewed as well, including data on country markets and shares of the leading manufacturers.
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