Laminate Flooring

Report Description

SUMMARY OF MAJOR FINDINGS
The U.S. laminate flooring market is expected to begin to recover during 2010 as the rise in existing home sales since the third quarter 2009 gives a boost to the important residential replacement market. However, laminate flooring could continue to lose share in the U.S. floor coverings industry as competition increases from resilient flooring, engineered wood floors, and click installed bamboo and cork. Prices could also remain weak due to rising competition from Chinese manufacturers and U.S and European manufacturer overcapacity. Manufacturers and marketers must increase their emphasis on unique designs and products in order to hold onto their share of U.S. floor coverings sales. Producers are introducing exotic and extinct wood looks, ceramic and stone looks, and long planks as part of this strategy.

LAMINATE FLOORING INDUSTRY TRENDS

Catalina Research has uncovered these trends in our 156-page in-depth report on the U.S. and world laminate flooring market. Report sections cover the U.S. market on a dollar and square foot basis. Catalina has calculated laminate’s position in the total U.S. floor coverings industry and the hard surface flooring market. Catalina also conducted a comparative analysis of laminate flooring prices and other floor material prices.

U.S. SHIPMENTS AND IMPORTS

Data trends on U.S. laminate flooring shipments and imports are compiled from various industry sources in order to calculate the total market. The report includes an analysis of U.S. imports including shipments by major country of origin. In addition, information on over 30-leading manufacturers and marketers is compiled to quickly review the products, source of supply, and pricing of the leading competitors. Catalina reviewed industry and company literature to uncover trends on new technologies and new products. Catalina also compiled information on U. S. plant production capacity

WORLD LAMINATE FLOORING MARKETS

Laminate flooring markets are also evaluated by world area. European production and sales trends are included in order to indicate laminate’s position in the European floor coverings market, and European company’s position in world markets. Pergo and Unilin’s financial trends are analyzed as well. Chinese production and Chinese company laminate flooring manufacturing capacity is also investigated.

END-USE MARKETS AND RETAIL DISTRIBUTION CHANNELS

Laminate flooring sales are provided for residential replacement, new residential construction, and commercial markets. Laminate’s level of penetration is calculated for each market. Sales data is also analyzed by retail sales channel- specialty floor coverings stores, home centers and other building material dealers, and other retailers. Catalina investigates the sales and market shares of leading U.S. laminate flooring retailers

FACTORS AFFECTING DEMAND

A separate section analyzes the factors driving laminate flooring demand. Data trends include household hard surface flooring spending and purchaser demographics, residential construction activity and existing home sales, regional housing markets, and commercial construction spending. This provides insights into the direction of domestic demand in 2010 and beyond.

COMPANY PROFILES AND THE COMPETITIVE ENVIRONMENT

Catalina Research profiled 31-leading U.S.-, European-, and Asian-based laminate flooring manufacturers and marketers. Company profiles cover product lines, manufacturing and distribution, capital investments and acquisitions, and new products and technology enhancements. Catalina utilized this valuable information to uncover competitor strategies. Sales data was compiled in order to calculate company market shares.

Laminate Flooring

TABLE OF CONTENTS
SECTION 1 U.S.LAMINATE FLOORING INDUSTRY TRENDS .......................................... 1
Executive Summary.............................................................................................. 1
Market Trends And Share Of U.S. Floor Coverings Industry................................ 2
Price Trends And Source Of Supply..................................................................... 4
Competitive Environment And New Products....................................................... 5
End-Use Markets And Distribution Channels........................................................ 6
Market Outlook And The Need For Unique Designs............................................. 7

Figure 1-1 U.S. Laminate Flooring Market Sales, 2000-2015 (square feet
and dollars)........................................................................................... 9
Figure 1-2 Laminate Flooring’s Share Of Total U.S. Floor Coverings Sales,
2000-2015 (percent) ........................................................................... 10
Figure 1-3 U.S. Average Value Per Square Foot Of Laminate Flooring
Supplied, 2000-2015 (dollars) ........................................................... 11
Figure 1-4 U.S. Laminate Flooring Source Of Supply By Country, 2009
(dollars and percent)........................................................................... 12
SCOPE AND METHODOLOGY ....................................................................................... 13

SECTION 2 U.S.LAMINATE FLOORING MARKET TRENDS .......................................... 15
Summary Of Major Findings............................................................................... 15
Market Size And Growth..................................................................................... 16
Price Trends ....................................................................................................... 17
Share Of Floor Coverings Market ....................................................................... 18
Share Of Hard Surface Flooring Market ............................................................. 18
Market Outlook ................................................................................................... 19

Table 2-1 U.S. Laminate Flooring Sales, 1995-2015 (square feet and
dollars)................................................................................................ 21
Table 2-2 Laminate Flooring's Position In The U.S. Floor Coverings
Industry, 1995-2015 (square feet, dollars, and percent): Total
Floor Coverings Sales And Laminate Flooring Percent Total ............. 22
Table 2-3 Laminate Flooring's Position In The U.S. Hard Surface Floor
Covering Market, 1997-2015 (square feet, dollars, and percent):
Hard Surface Flooring Sales, Hard Surface Flooring Percent
Total Floor Coverings, And Laminate Flooring Percent Hard
Surface Flooring ................................................................................. 23
Table 2-4 U.S. Average Value Per Square Foot Supplied For Laminate
Flooring And Total Floor Coverings, 1995-2015 (dollars) ................... 24
Table 2-5 U.S. Average Value Per Square Foot Supplied By Floor
Covering Product, 2002-2009 (dollars): Carpet And Area Rugs,
Wood Flooring, Ceramic Tile, Vinyl Sheet And Floor Tile,
Rubber Sheet And Floor Tile, Other Resilient Flooring, Laminate
Flooring, Stone Flooring, And Total Floor Coverings.......................... 25

SECTION 3 U.S.SHIPMENTS, IMPORTS, PRODUCT INNOVATION, AND COMPANY
SHARES ............................................................................................... 26
Summary Of Major Findings............................................................................... 26
U.S. Shipments And Capacity ............................................................................ 27
U.S. Import Trends ............................................................................................. 27
New Looks And Technological Innovations ........................................................ 28
Intellectual Property And Patent Issues.............................................................. 30
Competitive Environment And Leading Manufacturers....................................... 32
Table 3-1 U.S. Laminate Flooring Shipments, 2002-2010 (square feet and
dollars)................................................................................................ 34
Table 3-2 Select U.S. Laminate Flooring Plant Capacity By Company,
2009 (square feet): Company, Location, And Capacity ...................... 35
Table 3-3 U.S. Laminate Flooring Imports, 2002-2010 (square feet and
dollars)................................................................................................ 36
Table 3-4 Share Of U.S. Laminate Flooring Sales By Source Of Supply,
2002-2010 (percent) ........................................................................... 37
Table 3-5 U.S. Laminate Flooring Import Product Costs, Insurance And
Freight Costs, And Tariff Charges, 1997-2009 (dollars) ..................... 38
Table 3-6 Value Of U.S. Laminate Flooring Imports For The Top Twelve
Countries Of Origin, 2004-2009 (dollars)............................................ 39
Table 3-7 U.S. Laminate Flooring Import Product Costs, Insurance And
Freight Costs, And Tariff Charges By The Top Twelve Countries
Of Origin, 2009 (dollars) ..................................................................... 40
Table 3-8 Quantity U.S. Laminate Flooring Imports For The Top Twelve
Countries Of Origin, 2009 (square feet and dollars) ........................... 41
Table 3-9 Exchange Rates For Currencies Of Leading Laminate Flooring
Importers, 2006-2010 (rate): Euro, Yuan, And Canadian Dollar......... 42
Table 3-10 Share Of U.S. Laminate Flooring Sales For Nine Leading
Marketers, 2003-2009 (percent) ......................................................... 43
Table 3-11 Pfleiderer North American Sales And Profit Trends, 2007-2009
(dollars and percent)........................................................................... 44

SECTION 4 WORLD LAMINATE FLOORING MARKET .................................................. 45
Summary Of Major Findings............................................................................... 45
World Shipments And Leading Manufacturers ................................................... 45
European Shipments And Markets ..................................................................... 47
European Competitive Environment ................................................................... 47
Chinese Production And Market Trends............................................................. 48
Chinese Competitive Environment ..................................................................... 49
Table 4-1 World Laminate Flooring Shipments, 2000-2010 (square feet) .......... 51
Table 4-2 Laminate Flooring Shipments By World Area, 2005-2010
(square feet) ....................................................................................... 52
Table 4-3 European Laminate Flooring Shipments, 1995-2010 (square
feet) .................................................................................................... 53
Table 4-4 European Laminate Flooring Factory Shipments By Market,
2005-2009 (square feet): Western Europe, Eastern Europe,
North America, South America, Asia, And Other Areas...................... 54
Table 4-5 Percent Of European Laminate Flooring Factory Shipments By
Market, 2005-2009 (percent): Western Europe, Eastern Europe,
North America, South America, Asia, And Other Areas...................... 55
Table 4-6 Mohawk's Unilin Segment Sales And Profit Trends, 2006-2009
(dollars and percent)........................................................................... 56
Table 4-7 Chinese Laminate Flooring Production, 2004-2010 (square feet) ...... 57
Table 4-8 Annual Production Capacity Of Select Chinese Laminate
Flooring Manufacturers, 2009 (square feet) ....................................... 58
Table 4-9 Value Of Canadian Building Permits And Canadian Housing
Starts, 1993-2009 (number and Canadian dollars)............................. 59

SECTION 5 U.S.END-USE MARKETS AND DISTRIBUTION CHANNELS ........................ 60

Summary Of Major Findings............................................................................... 60
Residential Replacement Market........................................................................ 61
Retail Sales Trends ............................................................................................ 62
Home Center And Hard Surface Flooring Channel............................................. 63
Home Depot, Lowe’s, And Lumber Liquidator Sales .......................................... 63
Specialty Floor Coverings Retailers.................................................................... 64
New Residential Construction Market................................................................. 65
Commercial Markets........................................................................................... 66

Table 5-1 U.S. Laminate Flooring Retail Sales By Outlet, 2002-2010
(dollars): Floor Covers Stores, Home Centers And Building
Material Dealers, And Other Retailers ................................................ 67
Table 5-2 U.S. Retail Floor Coverings Sales By Type Of Channel, 2002-
2009 (dollars): Floor Coverings Stores, Home Centers, Hard
Surface Flooring Stores, Furniture Stores, Department Stores,
Other Home Furnishings Stores, Warehouse Clubs And Super
Centers, Direct Sellers, Electronic And Internet, And Others ............. 68
Table 5-3 Percent Distribution Of U.S. Retail Floor Coverings Sales By
Type Of Channel, 2002-2009 (percent): Floor Coverings Stores,
Home Centers, Hard Surface Flooring Stores, Furniture Stores,
Department Stores, Other Home Furnishings Stores,
Warehouse Clubs And Super Centers, Direct Sellers, Electronic
And Internet, And Others.................................................................... 69
Table 5-4 Number Of U.S. Retailers Carrying Floor Coverings By Type Of
Channel And Average Sales, 1997-2009 (number and dollars):
Floor Coverings Stores, Home Centers, Other Building Material
Dealers, Furniture Stores, Department Stores And Mass
Merchandisers, Other Home Furnishings Stores, Paint And
Wallpaper Stores, Non-Store Retailers, All Other Retailers, And
Total Stores ........................................................................................ 70
Table 5-5 Monthly U.S. Floor Coverings Store Sales, 2006-2009 (dollars) ........ 71
Table 5-6 Lumber Liquidators Laminate Flooring Sales, 2006-2009
(dollars) .............................................................................................. 72
Table 5-7 U.S. Laminate Flooring Purchases By End-Use Market, 1997-
2010 (dollars): New Residential Construction, Residential
Replacement, And Nonresidential ...................................................... 73

SECTION 6 FACTORS AFFECTING U.S. LAMINATE FLOORING DEMAND ...................... 74
Summary Of Major Findings............................................................................... 74
Residential Hard Surface Flooring Market.......................................................... 75
Residential Remodeling And Replacement Market ............................................ 75
New Residential Market...................................................................................... 76
Nonresidential Markets....................................................................................... 77

Table 6-1 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, 1997-
2008 (dollars) ..................................................................................... 78
Table 6-2 U.S. Household Spending On Hard Surface Flooring And
Installation By Demographic Characteristic, 2002-2008 (dollars):
Household Income, Age Of Household Head, Size Of
Household, And Region...................................................................... 79
Table 6-3 Number Of Household Hard Surface Flooring Replacement,
Maintenance, And Repair Jobs And By Recent Movers And
Region, 2007 (number): Do-It-Yourself And Contractor Jobs ............. 80
Table 6-4 Average U.S. Household Spending On Hard Surface Flooring
And Installation By Demographic Characteristic For
Homeowners And Renters, 2008 (dollars): Household Income,
Age Of Household Head, Size Of Household, And Region ................ 81
Table 6-5 Average U.S. Household Spending On Hard Surface Flooring
And Installation Through Contractors And D-I-Y And B-I-Y
Purchases By Demographic Characteristic, 2008 (dollars):
Household Income, Age Of Household Head, Size Of
Household, And Region...................................................................... 83
Table 6-6 U.S. Spending On Building Construction, 1987-2010 (dollars):
Total Buildings, Residential Buildings, And Nonresidential
Buildings............................................................................................. 85
Table 6-7 U.S. Spending On Construction Put In Place By Market And
Building Type, 2005-2009 (dollars): Residential, Lodging, Office,
Commercial, Healthcare, Educational, Religious, Public Safety,
Amusement And Recreation, Manufacturing, And Public
Buildings............................................................................................. 86
Table 6-8 Percent Of U.S. Households Purchasing A New Or Existing
Housing Unit, 1992-2010 (number, percent, and dollars): Total
Households, Total Housing Demand, Percent Households
Purchasing, Interest Rates, And Average Value Per Existing
Home Sold.......................................................................................... 88
Table 6-9 Total U.S. Housing Demand By Sector By Region, 2005-2010
(number): Existing Home Sales, New Housing Completions, And
Mobile Home Placements................................................................... 89
Table 6-10 New U.S. Privately Owned Housing Units Started And By Type
Of Structure, 1980-2010 (number): Total Starts; In Structures
With 1 Unit, 2 To 4 Units, And 5 Units Or More .................................. 90
Table 6-11 Monthly New Private U.S. Housing Units Authorized By 20,000
Building Permit Places By Region, 2009 And 2010 (number) ............ 91
Table 6-12 New Privately Owned Housing Units Authorized By 20,000
Building Permit Places By Region And State, 2007-2009
(number)............................................................................................. 92
Table 6-13 Number Of Existing Single-Family Homes, Condos, And Co-Ops
Sold By Region And State, 2002-2009 (number) ............................... 94
Table 6-14 Characteristics Of New U.S. Housing Units Affecting Floor
Covering Product Demand, 1990-2008 (units): Region, Number
Of Bathrooms, Number Of Bedrooms, Garages, And Number Of
Stories; For Single-Family, Multi-Family Structures, And Mobile
Homes................................................................................................ 96
Table 6-15 Average Size Per New U.S. Housing Unit Completed By Type
Of Unit And Region, 1990-2009 (square feet): Single-Family
Homes, Multi-Family Units, And Mobile Homes ................................. 99
Table 6-16 New U.S. Single-Family Houses Sold By Sales Price, 1985-
2009 (number): Under $150,000, $150,000 To $199,999,
$200,000 To $299,999, $300,000 To $499,999, And $500,000
And Over .......................................................................................... 100
Table 6-17 Average Value Per New Single-Family House Sold And Average
Value Per Square Foot, 1992-2009 (dollars) .................................... 101
Table 6-18 U.S. Homes Closed By Ten Leading Domestic Home Builders,
2002-2009 (number)......................................................................... 102
Table 6-19 U.S. Residential Property Owner Expenditures For
Improvements, Additions, Alterations, And Repairs And
Spending By Single-Family Homeowners, 1985-2009 (dollars)........ 103
Table 6-20 U.S. Home Mortgage Interest Rates And Personal Income,
1982-2010 (percent and dollars) ...................................................... 104
Table 6-21 Distribution Of U.S. Households By Demographic Characteristic,
1995-2008 (percent): Household Income, Age Of Household
Head, Household Size, Region, And Total Households ................... 105

SECTION 7 COMPANY PROFILES........................................................................... 106
Abet, Inc. ............................................................................................................. 107
Laminate Flooring Products.............................................................................. 107
Manufacturing And Distribution......................................................................... 107
Armstrong World Industries ................................................................................... 109
Laminate Flooring Products.............................................................................. 109
Sales Trends And Market Share....................................................................... 110
Asia Timber Products Group.................................................................................. 111
Laminate Flooring Products And Manufacturing............................................... 111
Balterio Laminate Flooring ..................................................................................... 112
Manufacturing And Sales ................................................................................. 112
Laminate Flooring Products.............................................................................. 112
Beaulieu International Group ................................................................................. 114
Alloc Laminate Flooring Products ..................................................................... 114
Berry Floor........................................................................................................ 116
Manufacturing And Distribution......................................................................... 116
BHK Of America..................................................................................................... 118
Laminate Flooring Products.............................................................................. 118
BKR Building Products LLC ................................................................................... 119
Laminate Flooring Products.............................................................................. 119
Manufacturing And Distribution......................................................................... 119
BuildDirect ............................................................................................................ 120
Laminate Flooring Products And Distribution.................................................... 120
Changzhou Jiaan Decorative Material Co. Ltd....................................................... 121
Laminate Flooring Products And Manufacturing............................................... 121
Chinafloors ........................................................................................................... 122
Laminate Flooring Products.............................................................................. 122
Manufacturing And Distribution......................................................................... 122
Clarion Laminates, LLC ......................................................................................... 124
Laminate Flooring Manufacturing And Distribution ........................................... 124
Classen Gruppe..................................................................................................... 125
Laminate Flooring Manufacturing And Products............................................... 125
New Products ................................................................................................... 125
Fold-Down Patent Agreements......................................................................... 126
DuPont E.I. De Nemours & Co. ............................................................................. 127
Laminate Flooring Products.............................................................................. 127
Elegant Living Corp................................................................................................ 128
Laminate Flooring Products And Manufacturing............................................... 128
Fritz Egger GmbH & Co. ........................................................................................ 129
Laminate Flooring Products.............................................................................. 129
Faus Group ........................................................................................................... 130
Laminate Flooring Products.............................................................................. 130
Manufacturing And Distribution......................................................................... 130
Chinese Patent Situation .................................................................................. 131
Jiangsu Kentier Wood Co. Ltd. .............................................................................. 132
Laminate Flooring Products And Manufacturing............................................... 132
Kaindl Flooring GmbH............................................................................................ 133
Laminate Flooring Products And Manufacturing............................................... 133
Kronoflooring GmbH .............................................................................................. 134
Laminate Flooring Products And Sales ............................................................ 134
Kronotex GmbH & Co. KG ..................................................................................... 135
KronoGroup Parent .......................................................................................... 135
Kronotex USA................................................................................................... 135
Lumber Liquidators, Inc. ........................................................................................ 137
Laminate Flooring Products And Sales ............................................................ 137
Mannington Mills, Inc. ............................................................................................ 138
Laminate Flooring Products.............................................................................. 138
New Products ................................................................................................... 139
Sales And Market Share................................................................................... 139
Mohawk Industries, Inc. ......................................................................................... 140
Laminate Flooring Products.............................................................................. 140
Unilin Segment Manufacturing And Distribution ............................................... 141
Patent Issues And Licensing Agreements ........................................................ 142
Sales Trends And Market Share....................................................................... 143
Pfleiderer AG ......................................................................................................... 144
Laminate Flooring Products.............................................................................. 144
Manufacturing And Distribution......................................................................... 145
Sales And Market Share................................................................................... 146
Power Dekor Group Co. Ltd................................................................................... 147
Laminate Flooring Products And Manufacturing............................................... 147
Robina Flooring...................................................................................................... 148
Laminate Flooring Products And Manufacturing............................................... 148
Robina Floors ................................................................................................... 149
Shanghai Allsun Wood Industry Co. Ltd. ............................................................... 150
Laminate Flooring Products And Manufacturing............................................... 150
Shaw Industries, Inc............................................................................................... 151
Laminate Flooring Products.............................................................................. 151
Manufacturing................................................................................................... 152
Sales Trends And Market Share....................................................................... 152
Tarkett SA ............................................................................................................ 153
Laminate Flooring Products And Sales ............................................................ 153
Tarkett North America ...................................................................................... 154
Wilsonart International, Inc. ................................................................................... 155
Laminate Flooring Products.............................................................................. 155
Sales And Market Share................................................................................... 155
Witex USA Flooring, Inc......................................................................................... 156
Laminate Flooring Products.............................................................................. 156