Solid Surface & Other Cast Polymers

INDUSTRY MARKET RESEARCH FOR BUSINESS LEADERS, STRATEGISTS, DECISION MAKERS CLICK TO VIEW

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Solid Surface & Other Cast Polymers

US Industry Study with Forecasts for 2016 & 2021

Study #2873 | April 2012 | $5100 | 318 pages

The Freedonia Group 767 Beta Drive www.freedoniagroup.com Cleveland, OH • 44143-2326 • USA Toll Free US Tel: 800.927.5900 or +1 440.684.9600 Fax: +1 440.646.0484 E-mail: [email protected] Study #2873 April 2012 Solid Surface & Other Cast Polymers $5100 318 Pages US Industry Study with Forecasts for 2016 & 2021

Table of Contents Solid Surface Materials...... 83 Regional Construction Expenditures...... 195 Supply & Demand...... 84 Regional Housing Trends...... 197 Executive Summary Value Outlook...... 86 Regional Cast Polymer Demand...... 200 Characteristics...... 88 Northeast...... 205 Types...... 91 New England...... 208 Market EnvironmenT Acrylic...... 92 Middle Atlantic...... 209 Polyester & Polyester/Acrylic Blends...... 95 Midwest...... 210 General ...... 4 Market Share...... 98 East North Central...... 214 Macroeconomic Environment...... 4 Gel-Coated Composites...... 103 West North Central...... 215 Demographic Trends...... 8 Supply & Demand...... 104 South...... 217 Consumer Trends...... 11 Value Outlook...... 106 South Atlantic...... 219 Personal Income & Expenditures...... 12 Characteristics...... 107 East South Central...... 221 Consumer Financing...... 14 Types...... 108 West South Central...... 223 Building Construction Expenditures...... 18 Cultured Marble...... 109 West...... 224 Residential Building Construction...... 20 Other Gel-Coated Composites...... 112 Mountain...... 227 Housing Completions...... 22 Suppliers...... 114 Pacific...... 229 Housing Stock...... 26 Engineered Stone...... 114 Improvements & Repairs...... 30 Supply & Demand...... 115 Nonresidential Building Construction...... 31 INDUSTRY STRUCTURE Value Outlook...... 117 Nonresidential Building Stock...... 34 Characteristics...... 119 General ...... 231 Improvements & Repairs...... 36 Types...... 122 Industry Composition...... 231 Countertop Overview...... 37 Quartz...... 122 Market Share...... 236 Sink Overview...... 39 Other Engineered Stone...... 126 Competitive Strategies...... 240 Environmental Considerations...... 40 Market Share...... 128 Research & Development...... 243 Training & Standards...... 42 Marketing...... 244 Historical Market Trends...... 44 Distribution...... 248 Competitive Materials Overview...... 46 APPLICATIONS Cooperative Agreements...... 250 Laminates...... 46 General ...... 133 Natural Stone...... 47 Countertops...... 135 Other...... 49 Company Profiles Residential...... 138 Pricing Trends...... 50 New Construction...... 143 AGCO Marble...... 255 Solid Surface...... 51 Remodeling...... 146 Aristech Acrylics...... 256 Gel-Coated Composites...... 53 Demand by Housing Type...... 150 Baker (Craig) Marble...... 259 Engineered Stone...... 53 Single-Family...... 151 BLANCO GmbH...... 261 World Market...... 55 Multifamily...... 154 Breton SpA...... 262 Foreign Trade...... 56 Manufactured Housing...... 157 Caesarstone Sdot-Yam...... 264 Solid Surface...... 58 Nonresidential...... 159 California Crafted Marble...... 266 Gel-Coated Composites...... 60 Institutional...... 164 Cambria...... 267 Engineered Stone...... 60 Office & Commercial...... 167 Central Marble Products...... 268 Other Nonresidential Buildings...... 169 Cheil Industries...... 269 MATERIALS Nonbuilding...... 170 Chemcore Industries...... 272 Other Building Surfaces...... 172 Cosentino SA...... 273 General ...... 62 Sink Fixtures...... 174 Custom Marble...... 276 Marble & Related Materials...... 63 Demand by Material...... 177 DuPont (EI) de Nemours...... 277 Resins...... 66 Demand by Product...... 179 EOS Surfaces...... 279 Polyester...... 67 Other Bathroom Applications...... 181 Fama Industries...... 280 Acrylic...... 69 All Other Building Surfaces...... 184 Fletcher Building...... 281 Alumina Trihydrate...... 70 Other Applications...... 187 Hanwha Group...... 283 Quartz & Other Stone...... 72 Huber (JM) Corporation...... 285 Other...... 73 REGIONAL MARKETS Illinois Tool Works...... 287 InPro Corporation...... 289 PRODUCTS General ...... 190 International Marble Industries...... 291 Regional Demographic & Economic Trends...... 191 K&K Langham...... 292 General ...... 76 Regional Population Patterns...... 191 Supply & Demand...... 77 Regional Economic Trends...... 193 (continued on following page) Value Outlook...... 81

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Table of Contents 14 Sink Fixture Shipments...... 40 4 New Residential Construction Cast 15 Cast Polymers Historical Polymer Countertop Demand...... 146 Company Profiles Market, 2001-2011...... 45 5 Remodeling Residential Cast 16 Foreign Trade in Cast Polymers...... 58 Polymer Countertop Demand...... 150 (continued from previous page) 6 Residential Cast Polymer Countertop Demand by Housing Type...... 151 Lehigh Surfaces...... 293 MATERIALS 7 Single-Family Housing Cast Polymer LG Hausys...... 295 1 Materials Demand in Cast Polymers...... 63 Countertop Demand...... 154 Majestic Marble & Glass...... 297 2 Marble & Related Materials 8 Multifamily Housing Cast Polymer Marbled Elegance...... 298 Demand in Cast Polymers...... 66 Countertop Demand...... 157 Marmol Compac...... 299 3 Resin Demand in Cast Polymers...... 67 9 Manufactured Housing Cast Polymer Meganite Incorporated...... 301 4 Alumina Trihydrate Demand Countertop Demand...... 159 Princess Marble...... 302 in Cast Polymers...... 71 10 Nonresidential Building Construction Royal Baths Manufacturing...... 303 5 Quartz & Other Stone Demand Cast Polymer Countertop Demand...... 164 Royal Stone Industries...... 304 in Cast Polymers...... 73 11 Institutional Building Cast Polymer Santa Margherita...... 305 6 Other Materials in Cast Polymers...... 75 Countertop Demand...... 167 Swan Corporation...... 307 12 Office & Commercial Building Cast Syn-Mar Products...... 308 Polymer Countertop Demand...... 169 Technistone AS...... 309 PRODUCTS 13 Other Nonresidential Building Tiffany Marble...... 310 Construction Cast Polymer Tower Industries...... 311 1 Cast Polymer Supply & Demand...... 80 Countertop Demand...... 170 United States Marble...... 313 Cht Cast Polymer Demand by Product, 2011....81 14 Nonbuilding Cast Polymer Venetian Marble...... 314 2 Cast Polymer Demand by Value...... 82 Countertop Demand...... 172 Additional Companies Mentioned Cht Cast Polymer Demand by Value, 2011...... 83 15 Other Building Surfaces Demand in the Study...... 316 3 Solid Surface Supply & Demand...... 86 4 Solid Surface Demand by Value...... 88 for Cast Polymers...... 174 5 Solid Surface Demand by Type...... 92 16 Sink Fixture Demand for Cast Polymers.... 177 6 Acrylic-Based Solid Surface Demand...... 95 17 Cast Polymer Sink Demand by Product.... 179 List of Tables/Charts 7 Polyester & Polyester/Acrylic Blend 18 Other Bathroom Applications Demand Solid Surface Demand...... 98 for Cast Polymers...... 184 Cht Solid Surface Market Share 19 All Other Building Surfaces Demand Executive Summary by Company, 2011...... 99 for Cast Polymers...... 187 8 Gel-Coated Composites 20 Other Applications Demand 1 Summary Table...... 3 Supply & Demand...... 106 for Cast Polymers...... 189 9 Gel-Coated Composites Market EnvironmenT Demand by Value...... 107 REGIONAL MARKETS 10 Gel-Coated Composites Demand by Type. 109 1 Macroeconomic Indicators...... 7 11 Cultured Marble Demand...... 111 1 Population by Region...... 193 2 Population & Households...... 11 12 Other Gel-Coated Composites Demand.... 113 2 Gross Domestic Product by Region...... 195 3 Personal Consumption Expenditures...... 14 13 Engineered Stone Supply & Demand...... 117 3 Construction Expenditures by Region...... 197 4 Consumer Financing Environment, 14 Engineered Stone Demand by Value...... 119 4 Regional Housing Indicators...... 200 2001-2011...... 17 15 Engineered Stone Demand by Type...... 122 5 Cast Polymer Demand by Region...... 204 5 Building Construction Expenditures...... 20 16 Engineered Quartz Demand...... 126 Cht Cast Polymer Demand by Region, 2011... 205 6 Residential Building Construction 17 Other Engineered Stone Demand...... 128 6 Northeast Cast Polymer Demand...... 208 Expenditures...... 22 Cht Engineered Stone Market Share 7 Midwest Cast Polymer Demand...... 214 7 Housing Completions...... 26 by Company, 2011...... 129 8 South Cast Polymer Demand...... 219 8 Housing Stock by Type...... 29 9 West Cast Polymer Demand...... 227 Cht Year of Construction of Housing Stock, 2011...... 29 APPLICATIONS 9 Residential Improvement INDUSTRY STRUCTURE 1 Cast Polymer Demand by Application...... 134 & Repair Expenditures...... 31 Cht Cast Polymer Demand 1 US Cast Polymer Sales 10 Nonresidential Building Construction by Application, 2011...... 134 by Company, 2011...... 235 Expenditures...... 33 2 Cast Polymer Countertop Demand Cht US Cast Polymer Sales 11 Nonresidential Building Stock...... 36 by Market, Room & Material...... 138 by Company, 2011...... 237 12 Nonresidential Building Improvement 3 Residential Cast Polymer Countertop 2 Selected Cooperative Agreements...... 252 & Repair Expenditures...... 37 Demand by Market...... 143 13 Countertop Demand...... 38

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Gains will be driven by performance advantages such as minimal maintenance requirements and resistance to stains, impact, moisture, and other damage caused by wear and tear.

US demand to rise 6.3% annually through 2016 US Solid Surface & Other Cast Solid Surface 40% Demand for cast polymers in the US is Polymers Demand, 2016 forecast to increase 6.3 percent per year (251 million square feet) to 251 million square feet in 2016. In most applications, cast polymers offer performance advantages such as minimal maintenance requirements and resistance to stains, impact, moisture, Gel-Coated and other damage caused by wear and Composites 31% tear. Further advances will be restrained by competition from other surfacing options, including granite and laminates. Engineered Stone Engineered stone to remain 29%

fastest growing products photo: Kromark The market for cast polymers underwent a significant transformation over the past decade with engineered stone rising from a niche product to controlling over a register healthy gains based on its well Residential improvements quarter of sales. Demand for engineered established market presence and high stone grew rapidly from a small base degree of durability. Solid surfaces are and repairs to remain during the 2001-2006 period due to its positioned as a mid level material in largest application significant performance advantages over terms of pricing and performance. Following the declines of the 2006-2011 competitive products. Engineered stone period, gains will be driven by a sharp continued to gain market share during Demand for gel-coated composites will rebound in housing completions from the downturn, buoyed by sales to higher- rebound strongly through 2016 from the depressed 2011. The residential im- end customers who were less impacted significant losses during the previous five provement and repair segment will by the weak economy. While growth will years. Gel-coated composites registered continue to account for the majority of continue to be above average, increases the biggest declines during this time due cast polymer demand, so an upswing in in demand will decelerate, tempered by to their heavy use in new construction. residential remodeling activity and the material’s high price, limiting further Going forward, gel-coated composites greater credit availability will also support market penetration. will benefit from the recovery in new gains. Sales of cast polymers will be housing construction, as well as design further aided by a recovery in office and After declining significantly during the trends featuring a greater number of and commercial, and institutional construc- 2006-2011 period due to a weak econo- more elaborate bathrooms in homes tion through 2016 -- the two nonresiden- my and fierce competition from engi- since gel-coated composites are pri- tial segments where cast polymers are neered stone products, solid surface will marily installed in bathrooms. most likely to be installed.

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Sample Text, TABLE V-3

Table & Chart RESIDENTIAL CAST POLYMER COUNTERTOP DEMAND BY MARKET (million square feet)

Item 2001 2006 2011 2016 2021

Residential Countertop Demand 437 565 472 596 682 products % cast polymer 26.2 28.8 29.9 32.1 33.4

Residential Cast Polymer Countertop 114.7 162.8 141.0 191.5 228.0 Supply & Demand By Segment: Demand for engineered stone materials is projected to increase 8.2 New Construction 38.2 54.8 16.5 43.2 58.3 percent per year to 73 million square feet in 2016. Unlike other cast sample Remodeling 76.5 108.0 124.5 148.3 169.7 polymers, engineered stone achieved favorable growth through the 2007- By Room: 2009 recession, due to the ability of affluent individuals to continue to table sample Kitchen 50.9 69.5 63.2 92.0 112.4 invest in their homes and in higher-end materials such as these products. Bathroom 56.3 80.4 66.8 85.4 99.4 Going forward, engineered stone is projected to achieve the most rapid text Other 7.5 12.9 11.0 14.1 16.2 gains in demand of all cast polymer materials. Gains in area demand

will reflect the growing consumer interest in engineered quartz, the most % residential 87.6 88.4 87.6 87.6 87.7 common type of engineered stone, due to its performance and decora- Cast Polymer Countertop Demand 131.0 184.1 161.0 218.5 260.0 tive qualities. Engineered stone surfaces are durable, nonporous, easy to clean, and do not require regular maintenance such as sealing that can be burdensome. Engineered quartz is a biologically inert material, making it ideal for both residential and nonresidential applications. Its aesthetic qualities will also promote demand growth. Engineered stone resembles natural stone in appearance, but has a smoother surface and a consistent color and pattern. Like solid surface materials, engineered stone can be used to make the seamless countertop surfaces and integrated sinks popu- lar with homeowners due to the ease of wiping down and cleaning them.

Demand gains will be promoted by a rebounding residential construction market. The expected increase in housing completions from the low levels of 2011 will boost demand for engineered stone. In the remodeling market, rising improvement and repair expenditures will spur growth. Kitchen and bathroom renovation projects are among the most common remodeling projects, and consumers frequently replace worn or less fashionable countertops with more attractive materials. Addition- CHART VII-1 ally, as consumers renovate their kitchens, they often increase their size, which will create more space for countertops. US CAST POLYMER SALES BY COMPANY, 2011 ($1.6 billion) Demand for engineered stone in the nonresidential building construction market will also increase. Engineered stone can be used for a

M a rke t O th e rs sample L e a d e rs 5 6 .9 % 8.8% C o sen tin o 4 3 .1c% hart 6.3% C am b ria

2.8% Aristech 2.8% W ilso n art 2.5% H an wh a 2.2% L G H au sys

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Sample Profile, TABLE VI-8 Table & Forecast SOUTH CAST POLYMER DEMAND (million square feet)

Item 1996 2001 2006 2011 2016

South Construction Expend (bil 2005$)384.6 431.4 262.5 393.0 476.0 sq ft cast polymer/mil $ construction 142 185 282 255 248

South Cast Polymer Demand 54.7 79.6 74.0 100.3 118.1 By Subregion: South Atlantic 28.7 40.5 34.0 49.0 59.0 East South Central 9.2 13.5sam 12.5ple 17.0 19.5 West South Central 16.8 25.6 27.5 34.3 39.6 By Product: table Countertops 48.0 71.4 66.8 90.4 106.6 COMPANY PROFILES Other Building Surfaces 6.0 7.4 6.6 9.2 10.7 Other 0.7 0.8 0.6 0.7 0.8

Breton SpA % South 34.8 37.0 40.1 40.0 39.5 Via Garibaldi 27 Cast Polymer Demand 157.2 215.3 184.5 251.0 299.0 31030 Castello di Godego, Treviso Italy 39-0423-7691 http://www.breton.it Annual Sales: $225 millions (estimated)ample Employment: over 500 (estimated) profile Key Technologies: engineered stone and cement-based compound stone production processes “The South is the largest regional market for cast polymers, representing Breton develops manufactures and markets equipment to process 40 percent of total demand in 2011. and produce engineered stone, ceramics, porcelain, and natural stone. The privately held company also licenses its manufacturing technolo- Demand for cast polymers in the region gies worldwide. Breton operates via two divisions: Natural and is expected to increase 6.3 percent Compound Stone, and Machine Tool. The Company has a production per year to 100.3 million square feet and development center in Castello di Godego, Treviso, Italy. in 2016. Gains will be spurred by The Company is active in the US cast polymer industry via the growth in housing completions in the Natural and Compound Stone division, which licenses Breton’s propri- region from the depressed 2011 levels. etary BRETONSTONE and BRETONTERASTONE engineered stone Moreover, the South is forecast to see production processes and BRETONSTONE CEMENT cement-based the fastest growth in sales of existing compound stone production process. These processes are licensed to third-party manufacturers in the US, Europe, the Africa/Mideast region homes through 2016, as transplants and the Asia/Pacific region. from the Northeast and Midwest arrive in the region.” Breton’s BRETONSTONE process combines quartz, marble, --Section VI, pg. 217-8 granite and other natural stones with polymer- or cement-based resins and pigments to form engineered stone. These materials are mixed and compacted using a vibrocompression vacuum process that removes

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Page 8 The Freedonia Group, Inc. 767 Beta Drive • Cleveland, OH • 44143-2326 • USA • Web site: www.freedoniagroup.com Tel US: 800.927.5900 or +1 440.684.9600 • Fax: +1 440.646.0484 • e-mail: [email protected]