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Floor Coverings Industry Trends

Floor Coverings Industry Trends


SUMMARY OF MAJOR FINDINGS
The $25.5 billion U.S. floor coverings market has entered a more mature growth stage of the current recovery period. During 2017, dollar sales are estimated to climb by 4.3% and square foot sales could rise by 3.6%. The builder market remains the growth leader as construction of larger, single-family homes is offsetting the decline in multi-family starts. The key growth factor during 2017 has been stronger gains in the important residential replacement market. Home improvement spending is increasing sharply during 2017, and floor covering sales are benefiting from the pent-up demand of non-moving households. Stronger residential spending is offsetting the weakening gains in commercial markets as nonresidential building construction spending slows. Hard surface flooring purchases also continue to outpace overall industry trends as residential and commercial users move away from the use of wall-to-wall carpet. Ceramic tile, engineered wood flooring, and luxury vinyl tile are leading the way. Commercial users are also increasing their use of carpet tile. The U.S. floor coverings industry, however, remains highly competitive as U.S- and foreign-based manufacturers invest in new domestic production capacity, while import penetration levels continue to grow. The intense competitive environment has led to acquisition activity in the U.S. flooring industry.

FLOORING SECTOR TRENDS
Catalina Research uncovered these findings in our in-depth 199-page report on U.S. floor coverings industry trends and an analysis of end-use markets. U.S. shipments, exports, imports, and price trends are evaluated for carpet and area rugs, wood flooring, ceramic tile, vinyl sheet and floor tile, other resilient flooring, laminate flooring, and stone flooring. Soft surface floor covering sales are further segmented into wall-to-wall carpet, carpet tile, and area rugs. Data is in dollars and square feet. Import sales are tracked by major country of origin, which uncover the inroads made by Chinese and other foreign-based manufacturers. U.S. export shipments are analyzed by major country of destination.

PROFIT MARGINS AND THE COMPETITIVE ENVIRONMENT
In addition, Catalina Research investigated the cost structure and profit margins of U.S. floor coverings plants. Data trends are compiled for material, labor, and capital inputs. As part of this analysis, Catalina Research profiled 10 leading U.S. manufacturers, compiled company sales and profit margins, and calculated company market shares. Market shares were also calculated for the soft and hard surface flooring sectors. Company profiles cover product lines, manufacturing and distribution, capital investments, acquisitions, and new products.

END-USE MARKET ANALYSIS
Catalina investigates the industry’s end-use markets in three separate sections: Residential Replacement Sales, Builder and Manufactured Home Producer Purchases, and Commercial and Transportation Equipment Markets. Each section evaluates end-use market sales trends, purchases by flooring type, share of total flooring sales, and floor coverings share of inputs for each end-use market. For example, Catalina examines flooring material’s share of total builder spending and the average value per square foot of flooring purchased. For the residential replacement market, Catalina Research tracks the markets for wall-to-wall carpet versus area rugs. Existing home sales, housing characteristics, and household income and demographics are analyzed to evaluate the drivers of residential replacement demand. A similar analysis was conducted for the builder and manufactured home markets. In this section, Catalina analyzed new home completions, total square footage built, housing starts and permits to uncover opportunities in this market. For commercial markets, Catalina tracked flooring purchases for new construction and remodeling projects. Construction spending by type of building and region was analyzed as part of this process. Catalina also segmented the commercial soft surface market into wall-to-wall carpet and carpet tile sales.


SECTION 1
U.S. FLOOR COVERINGS INDUSTRY TRENDS AND END-USE MARKET ANALYSIS
Executive Summary
Market Size And Factors Driving Demand
Market Product Mix
Competitive Environment
Industry Profit Margins
Capital Expenditures
Outlook
Table 1-1
Value Of U.S. Floor Coverings Sales, 1987-2022 (dollars)
Figure 1-1
Value Of U.S. Floor Coverings Sales, 2007-2022 (dollars)
Table 1-2
Quantity U.S. Floor Coverings Sales And Average Value Per Square Foot, 1987-2022 (square feet)
Figure 1-2
Quantity U.S. Floor Coverings Sales, 2007-2022 (square feet)
Figure 1-3
Quantity U.S. Floor Coverings Sales By Product Sector, 2016 (square feet) : Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, Laminate Flooring, And Stone Flooring
Table 1-3
Value Of U.S. Floor Coverings Sales By Product Sector, 1987-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, Laminate Flooring, And Stone Flooring
Table 1-4
U.S. Square Feet Floor Coverings Sales By Product Sector, 1987-2016 (square feet): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, Laminate Flooring, And Stone Flooring
Table 1-5
Share Of U.S. Floor Coverings Dollar Sales By Product Sector, 1987-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, Laminate Flooring, And Stone Flooring
Table 1-6
Share Of U.S. Floor Coverings Square Foot Sales By Product Sector, 1987-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, Laminate Flooring, And Stone Flooring
Table 1-7
U.S. Average Value Per Square Foot Of Flooring Supplied By Product Sector, 1987-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, Laminate Flooring, And Stone Flooring
Table 1-8
U.S. Sales Comparative Growth Analysis By Product Sector, 1987-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, Laminate Flooring, And Stone Flooring
Table 1-9
Average Value Per Square Foot For U.S. Shipments, Imports, And Exports By Product Sector, 2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Floor And Wall Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Figure 1-4
U.S. Floor Coverings Source Of Supply By Country, 2016 (dollars and percent): United States, China, India, Italy, Turkey, Mexico, Canada, And Others
Table 1-10
U.S. Floor Coverings Industry Estimated And Forecasted Sales By Product Sector, 2017 And 2022 (dollars and square feet): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Resilient Flooring, Laminate Flooring, And Stone Flooring
Table 1-11
Value Of U.S. Floor Coverings Purchases By End-Use Market, 2007-2017 (dollars and percent): New Residential Construction, Residential Replacement, Factory-Built Housing, New Nonresidential Construction, Commercial Contract, And Transportation Equipment
Table 1-12
Value Of U.S. Floor Coverings Sales By End-Use Market By Type Of Flooring Material, 2007-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Floor And Wall Tile, Resilient Flooring, Stone Flooring, And Laminate Flooring; New Residential Construction, Residential Replacement, Commercial New And Replacement, And Transportation Equipment
Table 1-13
Percent Distribution Of U.S. Floor Coverings End-Use Market Sales By Type Of Flooring Material, 2007-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Floor And Wall Tile, Resilient Flooring, Laminate Flooring, And Stone Flooring; New Residential Construction, Residential Replacement, Commercial New And Replacement, And Transportation Equipment
Table 1-14
U.S. Spending On Building Construction, 1997-2017 (dollars)
Table 1-15
Percent Of U.S. Households Purchasing A New Or Existing Housing Unit, 1997-2017 (number, percent, and dollars)
SCOPE AND METHODOLOGY
SECTION 2
U.S. FLOOR COVERINGS INDUSTRY TRENDS
Summary Of Major Findings
U.S. Floor Covering Shipments And Product Mix
Carpet
Area Rugs
Carpet Tile
Wood Flooring
Ceramic Tile
Resilient Flooring
Laminate Flooring
Table 2-1
U.S. Floor Coverings Factory Shipments, 1987-2017 (square feet and dollars) Table 2-2 Value Of U.S. Floor Coverings Factory Shipments By Product Sector, 1987-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Table 2-3
Square Foot U.S. Floor Coverings Factory Shipments By Product Sector, 1987-2016 (square feet): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Table 2-4
Distribution Of U.S. Floor Coverings Shipments By Product Sector, 1997-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Table 2-5
U.S. Average Value Per Square Foot Shipped By Product Sector, 1987- 2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Table 2-6
Comparative Growth Analysis Of U.S. Floor Coverings Factory Shipments And Average Price Shipped By Product Sector, 1987-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Table 2-7
Value Of U.S. Carpet, Carpet Tile, And Area Rug Sales, 2007-2016 (dollars)
Table 2-8
Quantity U.S. Carpet, Carpet Tile, And Area Rug Sales, 2007-2016 (square feet)
Table 2-9
U.S. Carpet And Area Rug Sales Trends By Product Type, 1997-2016 (dollars and square feet): Sales, Factory Shipments, Exports, And Imports; Tufted, Woven, And
Other
Table 2-10
Monthly U.S. Carpet And Area Rug Production Index, 2015-2017 (index)
Table 2-11
U.S. Shipments Of Tufted Carpet And Rugs By Type, 1997-2016 (dollars and square feet): Roll Goods, Modular Carpet Tile, Bathmats, Area Rugs, Automobile And Aircraft Carpeting, And Tufted Artificial Grass For Non-Athletic Surfaces
Table 2-12
U.S. Area Rug Sales, 2007-2016 (dollars and square feet) Table 2-13 U.S. Carpet Tile Sales, 2007-2016 (dollars and square feet)
SECTION 3
U.S. FLOOR COVERINGS IMPORTS
U.S. Floor Coverings Imports
Import Penetration By Industry Sector
Import Pricing
Major Countries Of Origin
Table 3-1
U.S. Floor Coverings Imports And Share Of Manufacturer Sales, 1987-2017 (square feet, dollars, and percent)
Table 3-2
Value Of U.S. Floor Coverings Imports By Product Sector, 1987-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Table 3-3
Square Foot U.S. Floor Coverings Imports By Product Sector, 1987-2016 (square feet): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Table 3-4
U.S. Floor Coverings Imports As A Share Of Manufacturer Sales By Product Sector, 1987-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Table 3-5
U.S. Average Value Per Square Foot Of Flooring Imported By Product Sector, 1987-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Table 3-6
Comparative Growth Analysis Of U.S. Floor Coverings Imports By Product Sector, 1987-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, Other Resilient Flooring, And Laminate Flooring
Table 3-7
Value Of U.S. Floor Coverings Imports For The Top Fifteen Countries Of Origin, 2007-2016 (dollars)
Table 3-8 Value Of U.S. Floor Coverings Imports For The Top Five Countries Of Origin By Product Sector, 2007-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Resilient Flooring, And Laminate Flooring
Table 3-9
Share Of U.S. Import Value By Product Cost, Insurance And Freight Cost, And Tariff Charges, And By Product Sector, 2007-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Resilient Flooring, And Laminate Flooring
SECTION 4
U.S. FLOOR COVERINGS EXPORT SHIPMENTS
U.S. Floor Coverings Exports And By Product
Major Countries Of Destination
Table 4-1
U.S. Floor Coverings Exports And Share Of Factory Shipments, 1987-2017 (square feet, dollars, and percent)
Table 4-2
Value Of U.S. Floor Coverings Exports By Product Sector, 1987-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, And Other Resilient Flooring
Table 4-3
Square Foot U.S. Floor Coverings Exports By Product Sector, 1987-2016 (square feet): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, And Other
Resilient Flooring
Table 4-4
Exports’ Share Of U.S. Floor Coverings Shipments By Product Sector, 1987-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, And Other Resilient Flooring
Table 4-5
U.S. Average Value Per Square Foot Of Flooring Exported By Product Sector, 1987-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, And Other Resilient Flooring
Table 4-6
Comparative Growth Analysis Of U.S. Floor Coverings Exports By Product Sector, 1987-2016 (percent): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile, And Other Resilient Flooring
Table 4-7
Value Of U.S. Floor Coverings Exports For The Top Fifteen Countries Of Destination, 2007-2016 (dollars)
Table 4-8
Value Of U.S. Floor Coverings Exports For The Top Five Countries Of Destination By Product Sector, 2007-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, And Resilient Flooring
SECTION 5
U.S. RESIDENTIAL REPLACEMENT MARKET
U.S. Residential Replacement Market
Soft Versus Hard Surface Flooring Purchases
Table 5-1
Value Of U.S. Residential Floor Coverings Replacement Purchases And Share Of Residential Improvement Construction Spending, 1997-2017 (dollars and percent)
Table 5-2 Value Of U.S. Floor Coverings Purchases For Residential Replacement By Type Of Product, 1997-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Resilient Flooring, Stone Flooring, And Laminate Flooring
Table 5-3
Residential Purchases Of Wall-To-Wall Carpet And Area Rugs, 2007-2016 (dollars)
Table 5-4
Percent Distribution Of Residential Floor Coverings Spending For Do-It- Yourself/Buy-It-Yourself Purchases Versus Contractor Purchases By Flooring Type, 1997-2015 (percent): Wood Flooring, Ceramic Tile, Resilient Flooring, Laminate Flooring, And Stone Flooring
Table 5-5
Number Of Owner-Occupied Housing Units By Value By Region, 2011-2015 (in thousands of units)
Table 5-6
U.S. Existing Home Sales By Region, 2007-2017 (number)
Table 5-7
U.S. Home Mortgage Interest Rates And Personal Income, 1997-2017 (percent and dollars)
Table 5-8
Distribution Of U.S. Households By Demographic Characteristic, 2010-2015 (percent)
SECTION 6
U.S. BUILDER MARKET
U.S. Builder Market
Builder And Manufactured Home Producer Purchases By Material
New Home Construction Trends And Characteristics
Table 6-1
Value Of Floor Coverings Purchases By U.S. Builders And Manufactured Home Producers And Share Of New Residential Construction Spending, 1997-2017 (dollars and percent)
Table 6-2
Value Of U.S. Floor Coverings Purchases By New Residential Contractors And Factory-Built Housing Manufacturers By Type Of Product, 1997-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Resilient Flooring, Stone Flooring, And Laminate Flooring
Table 6-3
Value Of Floor Coverings Purchases Per U.S. Contractor Completed Housing Unit And Factory-Built Housing Unit, 1997-2017 (number and dollars): Housing Units, Purchases Per Unit, And Average Value Per Square Foot
Table 6-4
New U.S Privately Owned Housing Units Started And By Type of Structure 1997-2017 (units)
Table 6-5
Monthly New Private U.S. Housing Units Authorized By 20,000 Building Permit Places By Region, 2016 And 2017 (units)
Table 6-6
New U.S. Single-Family Houses Sold By Sales Price, 1995-2017 (unit and percent)
Table 6-7
Average Value Per New Single-Family House Sold And Average Value Per Square Foot, 1997-2017 (dollars)
Table 6-8
Number Of U.S. New Housing Units Completed And Square Feet Built, 1997-2017 (number and square feet)
Table 6-9
Average Size Per New U.S. Housing Unit Completed By Type Of Unit And Region, 2000-2017 (square feet)
Table 6-10
U.S. Homes Closed By Eleven Leading Domestic Homebuilders, 2013-2017 (number)
SECTION 7
U.S. COMMERCIAL FLOOR COVERINGS MARKET
U.S. Commercial Floor Coverings Market
Commercial Market Sales By Flooring Material
New Nonresidential Building Construction Market
Commercial Contract Market
Transportation Equipment Market
Table 7-1
Value Of Floor Coverings Purchases By U.S. Nonresidential Construction Contractors And Share Of Nonresidential Building Construction Spending, 1997-2017 (dollars and percent)
Table 7-2
Value Of Floor Coverings Purchases By U.S. Nonresidential Construction Contractors For New Buildings And Remodeling And Replacement Work, 1997-2017 (dollars)
Table 7-3
Percent Distribution Of Commercial Contract Market By Type Of Buyer, 1997-2015 (percent): Contractors And Property Managers, Main Street Commercial, And Government
Table 7-4
Value Of Floor Coverings Purchases By U.S. Nonresidential Construction Contractors By Type Of Product, 1997-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Resilient Flooring, Laminate Flooring, And Stone Flooring
Table 7-5
Value Of U.S. Floor Coverings Purchases By New Nonresidential Building Contractors And Commercial Contract Market By Type Of Product, 1997-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, Resilient Flooring, Stone Flooring, And Laminate Flooring
Table 7-6
Value Of U.S. Commercial Carpet And Carpet Tile Market, 2007-2016 (dollars)
Table 7-7
U.S. Spending On Nonresidential Building Construction Put In Place By Building Type, 2012-2017 (dollars)
Table 7-8
Value Of Private Nonresidential Building Construction Spending By Region, By Building Type, 2007-2016 (dollars): Lodging, Office, Commercial, Healthcare, Education, Religion, Amusement And Recreation, Manufacturing, And Total; Northeast, Midwest, South, And West
Table 7-9
Value Of U.S. Floor Coverings Purchases By Transportation Equipment Markets, 1997-2016 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Tile, And Resilient Flooring
Table 7-10
Monthly U.S. Transportation Equipment Production Trends, 2015-2017 (index)
SECTION 8
U.S. PLANT COST STRUCTURE, COMPETITIVE ENVIRONMENT, AND COMPANY MARKET SHARES
Summary of Major Findings
Industry Profit Margins And By Sector
Capital Expenditures
Competitive Environment
Soft Versus Hard Surface Flooring Market Concentration
Table 8-1
Number Of U.S. Floor Coverings Plants, Plant Shipments, Facility Operating Ratios, And Gross Profit Margins, 1997-2016 (number, dollars, and percent)
Table 8-2
Number Of U.S. Floor Coverings Plants, Plant Shipments, Facility Operating Ratios, And Gross Profit Margins By Facility Product Specialization, 1997-2016 (numbers, dollars, and percent): Carpet And Area Rugs, Hardwood Flooring, Ceramic Tile, And Resilient Floor Coverings
Table 8-3
U.S. Producer Price Trends For Major Material Inputs, 1997-2017 (index): Processed Yarns, Plastics Resins, Lumber, Clay Refractories, Rubber, And Rough Quarried Stone
Table 8-4
U.S. Floor Coverings Plants Capital Expenditures By Facility Product Specialization, 1997-2016 (dollars and percent): Capital Expenditures And Percent Value Added; Carpet And Area Rugs, Hardwood Flooring, Ceramic Tile, And Resilient Flooring
Table 8-5
Share Of U.S. Floor Coverings Market For Ten Top Manufacturers And Marketers, 2012-2016 (percent)
Table 8-6
Share Of U.S. Soft And Hard Surface Flooring Markets For The Top Manufacturers And Marketers, 2012-2016 (percent)
Table 8-7
Annual Sales And Profit Trends For Six Major U.S. Floor Coverings Manufacturers, 2011-2016 (dollars and percent)
Table 8-8
First Half Sales And Profit Trends For Six Major U.S. Floor Coverings Manufacturers, 2016 And 2017 (dollars)
SECTION 9
COMPANY PROFILES
Armstrong Flooring, Inc.
Resilient Flooring Product Segment
Wood Flooring Products Segment
Resilient Flooring Manufacturing And Markets
Wood Flooring Manufacturing And Markets
Sales And Profit Margins
Market Share
Crossville Inc.
Ceramic Tile Products
Sales And Market Share
The Dixie Group, Inc.
Floor Coverings Products And Markets
Manufacturing And Distribution
Sales And Market Share
Engineered Floors LLC
Carpet Products
Manufacturing And Distribution
Beaulieu Acquisition
Sales And Market Share
Interface, Inc.
Modular Carpet
Modular Resilient Flooring
Manufacturing And Marketing
Sales And Market Share
Lumber Liquidators, Inc.
Flooring Products And Sources Of Supply
Distribution And Store Network
Governmental Actions
Sales And Market Share
Mannington Mills, Inc.
Sales And Market Shares
Resilient Flooring
Rubber Flooring
Carpet
Wood Flooring Products
Laminate Flooring Products
Mohawk Industries, Inc.
Sales And Market Share
Carpet Manufacturing And Distribution
Ceramic And Stone Products, Manufacturing, And Distribution
Resilient Flooring Products, Manufacturing, And Distribution
Laminate And Wood Products, Manufacturing, And Distribution
Quarterly Trends
Mullican Flooring
Wood Flooring Products
Sales And Market Share
Shaw Industries, Inc.
Soft Surface Products
Hard Surface Products
Distribution
Sales And Market Share
Tarkett SA
Flooring Products And Sales
Tarkett North America Hard Surface Flooring
Tandus North American Soft Surface Flooring
U.S. Sales And Market Share

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