Clay Product & Refractory Manufacturing
Description
Companies in this industry manufacture clay pottery, ceramics, plumbing fixtures, building materials, and refractory products. Major companies include Dal-Tile, Gerber Plumbing Fixtures, and Kohler (all of the US) as well as Kyocera, Shinagawa Refractories, and TOTO (all of Japan), Interceramic (Mexico), RHI Magnesita (the Netherlands), and Vesuvius (UK).
The global refractory market is forecast to have a compound annual growth rate (CAGR) of about 5% by 2034 to occupy a market size of about $40 billion, according to Fact.MR. Worldwide demand for plumbing accessories is expected to develop at a CAGR of about 5%, reaching about $40 billion by 2033, according to the Business Research Company. Urbanization and rising incomes in the developing world, along with recovering construction markets in North America and Western Europe, are the chief demand drivers for plumbing fixtures.
The US clay product and refractory industry includes about 1,100 establishments (single-location companies and units of multi-location companies) with combined revenue of about $8 billion.
COMPETITIVE LANDSCAPE
Demand is driven by industrial production of metals, glass, and other mineral-based products, as well as construction spending. The profitability of individual companies depends on efficient operations, as many products are considered commodities. Large companies enjoy economies of scale in purchasing and marketing. Small companies can compete effectively by developing new products with innovative features. The US industry is concentrated: the top 50 companies account for about 70% of industry revenue.
Imports, which primarily come from China, Mexico, Italy, and Japan, account for about 55% of the US market. Exports account for about 30% of US production. Top export markets for US manufacturers of clay and refractory products include China, Mexico, Italy, and Japan.
PRODUCTS, OPERATIONS & TECHNOLOGY
Major product groups include clay floor (more than 15% of industry revenue), all wet and dry process porcelain products (some 10%), and vitreous plumbing fixtures (nearly 10%). The remaining revenue is made up from other products that includes stoneware tables, industrial pottery ware, other structural clay products, and brick, block, and tile.
Refractories are heat resistant materials that provide the linings for high-temperature furnaces, reactors, incinerators, kilns, and crucibles. Refractory products are made of nonmetallic materials, are generally designed to withstand processes that involve temperatures above 1,000 degrees Fahrenheit. The two basic types of refractories are monolithic and fired brick shapes. Monolithic refractories are typically applied on-site using gunning techniques that spray the refractory material onto the desired surface through a nozzle. Refractory bricks are typically cast in a metal, plastic, or wooden form depending on required size, complexity, and tolerance. Primary inputs include clays and oxides of aluminum, silicon, and magnesium. For extremely high temperatures, materials such as zirconia, silicon carbide, and carbon may be used. Refractory brick production is highly automated. A typical production line includes mixers, conveying systems, vibration tables, digitally-controlled water addition, and mold filling. Refractory shapes are then fired in furnaces at temperatures of at least 1,300 degrees Fahrenheit. Both refractory shapes and the molds used to make them are designed using computer-aided drafting (CAD) software.
Clay building materials -- bricks, blocks, and roofing tiles -- are made by first mixing clay minerals (kaolin and shale) with additives such as manganese and barium, which impart various performance characteristics, including resistance to the elements. Raw materials are pulverized in a crusher, then mixed with water. Individual bricks and blocks are usually produced with an extruding machine. Extruded bricks are dried to prevent cracking, then fired in a kiln. Automated equipment is used to stack bricks and wrap them with metal banding for shipping.
The method for making ceramic tile is similar to that of making bricks. Raw materials (clay, chemical additives, and water) are mixed then tiles are formed, dried, kiln-fired, and packaging for shipping. Ceramic tile usually includes a glazing step which adds color, decoration, and texture. Like brick production, ceramic tile manufacture is highly automated.
Plumbing fixtures (toilets, sinks, and bidets) are made with a liquid form of vitreous china, called slurry slip. The slip is thinned with water, filtered to remove impurities, and re-thickened. The slip is then poured into plaster of Paris molds for toilets, sinks, bidets, or other fixtures. The molds are designed to be about 15% larger than the desired finished product to allow for shrinkage. Products are then removed from the molds and smoothed before being dried, glazed and fired. China, pottery, and earthenware products are made using methods similar to those used to make plumbing fixtures and clay building materials. Raw materials are mixed, formed or cast, dried, glazed, and fired in a kiln.
The global refractory market is forecast to have a compound annual growth rate (CAGR) of about 5% by 2034 to occupy a market size of about $40 billion, according to Fact.MR. Worldwide demand for plumbing accessories is expected to develop at a CAGR of about 5%, reaching about $40 billion by 2033, according to the Business Research Company. Urbanization and rising incomes in the developing world, along with recovering construction markets in North America and Western Europe, are the chief demand drivers for plumbing fixtures.
The US clay product and refractory industry includes about 1,100 establishments (single-location companies and units of multi-location companies) with combined revenue of about $8 billion.
COMPETITIVE LANDSCAPE
Demand is driven by industrial production of metals, glass, and other mineral-based products, as well as construction spending. The profitability of individual companies depends on efficient operations, as many products are considered commodities. Large companies enjoy economies of scale in purchasing and marketing. Small companies can compete effectively by developing new products with innovative features. The US industry is concentrated: the top 50 companies account for about 70% of industry revenue.
Imports, which primarily come from China, Mexico, Italy, and Japan, account for about 55% of the US market. Exports account for about 30% of US production. Top export markets for US manufacturers of clay and refractory products include China, Mexico, Italy, and Japan.
PRODUCTS, OPERATIONS & TECHNOLOGY
Major product groups include clay floor (more than 15% of industry revenue), all wet and dry process porcelain products (some 10%), and vitreous plumbing fixtures (nearly 10%). The remaining revenue is made up from other products that includes stoneware tables, industrial pottery ware, other structural clay products, and brick, block, and tile.
Refractories are heat resistant materials that provide the linings for high-temperature furnaces, reactors, incinerators, kilns, and crucibles. Refractory products are made of nonmetallic materials, are generally designed to withstand processes that involve temperatures above 1,000 degrees Fahrenheit. The two basic types of refractories are monolithic and fired brick shapes. Monolithic refractories are typically applied on-site using gunning techniques that spray the refractory material onto the desired surface through a nozzle. Refractory bricks are typically cast in a metal, plastic, or wooden form depending on required size, complexity, and tolerance. Primary inputs include clays and oxides of aluminum, silicon, and magnesium. For extremely high temperatures, materials such as zirconia, silicon carbide, and carbon may be used. Refractory brick production is highly automated. A typical production line includes mixers, conveying systems, vibration tables, digitally-controlled water addition, and mold filling. Refractory shapes are then fired in furnaces at temperatures of at least 1,300 degrees Fahrenheit. Both refractory shapes and the molds used to make them are designed using computer-aided drafting (CAD) software.
Clay building materials -- bricks, blocks, and roofing tiles -- are made by first mixing clay minerals (kaolin and shale) with additives such as manganese and barium, which impart various performance characteristics, including resistance to the elements. Raw materials are pulverized in a crusher, then mixed with water. Individual bricks and blocks are usually produced with an extruding machine. Extruded bricks are dried to prevent cracking, then fired in a kiln. Automated equipment is used to stack bricks and wrap them with metal banding for shipping.
The method for making ceramic tile is similar to that of making bricks. Raw materials (clay, chemical additives, and water) are mixed then tiles are formed, dried, kiln-fired, and packaging for shipping. Ceramic tile usually includes a glazing step which adds color, decoration, and texture. Like brick production, ceramic tile manufacture is highly automated.
Plumbing fixtures (toilets, sinks, and bidets) are made with a liquid form of vitreous china, called slurry slip. The slip is thinned with water, filtered to remove impurities, and re-thickened. The slip is then poured into plaster of Paris molds for toilets, sinks, bidets, or other fixtures. The molds are designed to be about 15% larger than the desired finished product to allow for shrinkage. Products are then removed from the molds and smoothed before being dried, glazed and fired. China, pottery, and earthenware products are made using methods similar to those used to make plumbing fixtures and clay building materials. Raw materials are mixed, formed or cast, dried, glazed, and fired in a kiln.
Table of Contents
- Industry Overview
- Quarterly Industry Update
- Business Challenges
- Business Trends
- Industry Opportunities
- Call Preparation Questions
- Financial Information
- Industry Forecast
- Web Links and Acronyms
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