US demand to rise 7.9% annually through 2015 US demand for carpet and rug products is projected to increase 7.9 percent annually from a weak 2010 base to 16.5 billion square feet in 2015. The primary driver of growth will be the expected recovery of the US economy, which will spark renewed demand for carpets and rugs across all market segments. Specifically, a rebound in the battered new residential construction sector will lead to a surge in demand for tufted carpet and area rugs. Prospects will improve in both the residential and nonresidential replacement markets as well, reflecting improvements in consumer confidence and discretionary spending and a more robust housing market on the residential side; and lower vacancy rates and an expansion in new office and commercial space on the nonresidential side. Carpet tile to gain market share, expand applications Demand for carpet tile, while still accounting for a relatively small portion of overall carpet and rug demand, is expected to increase its presence in nonresidential markets. This product, long viewed as inferior in quality, has improved dramatically in recent years. Enhanced durability and improved appearance, along with a much broader selection of styles, patterns and colors, have vaulted modular carpet products into the mainstream. Demand is also expanding out of the traditional office and commercial sectors to institutional and government markets, and even residential markets. Polyester to become second leading carpet/rug face fiber Nylon will continue to be the primary fiber used in carpet and rug products for the foreseeable future, but improved fiber quality and high petroleum prices have propelled polyester fibers into the runnerup position, ahead of polypropylene fibers. With much of the polyester fiber used in carpets and rugs coming from recycled beverage bottles, these fibers have a significant economic advantage compared to nylon and polypropylene, both of which are derived from petroleum. Improvements to the feel and durability of polyester fibers, coupled with their inherent colorfastness and stain resistance, have made these fibers much more competitive in an environment where customers are seeking lower cost alternatives without having to sacrifice quality. Study coverage Details on these and other findings are available in the upcoming industry study, Carpets & Rugs. The study examines the 11.3 billion square foot US market for carpet and rug products. The study presents historical demand data (2000, 2005, 2010) plus forecasts for 2015 and 2020 by carpet and rug raw material, product and market. The study also considers market environment factors, evaluates company market share and profiles industry competitors, including Beaulieu of America, Interface, Mannington Mills, Milliken, Mohawk Industries and Shaw Industries (Berkshire Hathaway).
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US Carpets & Rugs Market
Published on February 2012
Report Summary
US demand to rise 7.9% annually through 2015
US demand for carpet and rug products is projected to increase 7.9 percent annually from a weak 2010 base to 16.5 billion square
feet in 2015. The primary driver of growth will be the expected recovery of the US economy, which will spark renewed demand for
carpets and rugs across all market segments. Specifically, a rebound in the battered new residential construction sector will lead to a
surge in demand for tufted carpet and area rugs. Prospects will improve in both the residential and nonresidential replacement
markets as well, reflecting improvements in consumer confidence and discretionary spending and a more robust housing market on
the residential side; and lower vacancy rates and an expansion in new office and commercial space on the nonresidential side.
Carpet tile to gain market share, expand applications
Demand for carpet tile, while still accounting for a relatively small portion of overall carpet and rug demand, is expected to increase its
presence in nonresidential markets. This product, long viewed as inferior in quality, has improved dramatically in recent years.
Enhanced durability and improved appearance, along with a much broader selection of styles, patterns and colors, have vaulted
modular carpet products into the mainstream. Demand is also expanding out of the traditional office and commercial sectors to
institutional and government markets, and even residential markets.
Polyester to become second leading carpet/rug face fiber
Nylon will continue to be the primary fiber used in carpet and rug products for the foreseeable future, but improved fiber quality and
high petroleum prices have propelled polyester fibers into the runnerup position, ahead of polypropylene fibers. With much of the
polyester fiber used in carpets and rugs coming from recycled beverage bottles, these fibers have a significant economic advantage
compared to nylon and polypropylene, both of which are derived from petroleum. Improvements to the feel and durability of polyester
fibers, coupled with their inherent colorfastness and stain resistance, have made these fibers much more competitive in an
environment where customers are seeking lower cost alternatives without having to sacrifice quality.
Study coverage
Details on these and other findings are available in the upcoming industry study, Carpets & Rugs. The study examines the 11.3 billion
square foot US market for carpet and rug products. The study presents historical demand data (2000, 2005, 2010) plus forecasts for
2015 and 2020 by carpet and rug raw material, product and market. The study also considers market environment factors, evaluates
company market share and profiles industry competitors, including Beaulieu of America, Interface, Mannington Mills, Milliken,
Mohawk Industries and Shaw Industries (Berkshire Hathaway).
Table of Content
TABLE OF CONTENTS
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INTRODUCTION viii
I. EXECUTIVE SUMMARY 1
II. MARKET ENVIRONMENT 4
General 4
Macroeconomic Overview 5
Consumer Income & Spending 9
Personal Income & Expenditures 9
Consumer Financing 11
Demographic Trends 15
Building Construction Trends 20
Residential Construction 23
Housing Outlook 25
Single-Family Home Sales 29
Residential Floor Space 30
Improvements & Repairs 32
Nonresidential Construction 34
Nonresidential Floor Space 37
Improvements & Repairs 39
Transportation Equipment Trends 40
Motor Vehicle Outlook 41
Other Transportation Equipment 44
Pricing Patterns 47
Historical Market Trends 49
Environmental & Regulatory Issues 52
Waste Disposal & Recycling 53
Indoor Air Quality 57
Green Building Trends 59
Other Issues 61
World Carpet & Rug Overview 62
Foreign Trade 64
Imports 66
Exports 67
Competitive Floor Coverings Overview 69
III. MATERIALS 71
General 71
Face Fibers 74
Nylon 77
Polyester 80
Polypropylene 83
Wool & Other Fibers 85
Primary Backing 88
Secondary Backing 90
Adhesives 92
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Styrene-Butadiene Latex 94
Other Adhesives 95
IV. PRODUCTS 97
General 97
Tufted Carpets & Rugs 100
Broadloom 103
Vehicular Carpets & Rugs 107
Carpet Tile 109
Scatter Rugs & Bath Mats 111
Artificial Grass 113
Woven Carpets & Rugs 115
Product Characteristics 117
Product Innovation 118
Other Carpets & Rugs 119
Needle-Punched 121
All Other 122
V. MARKETS 124
General 124
Residential Building 127
New 130
Replacement 132
Residence Type 134
Single-Family Housing 135
Multifamily Housing 137
Manufactured Housing 139
Nonresidential Building 140
New 142
Replacement 144
Building Type 146
Office & Commercial 147
Institutional 151
Industrial 153
Other Nonresidential Buildings 154
Transportation Equipment 156
Motor Vehicles 157
Other Transportation Equipment 159
VI. INDUSTRY STRUCTURE 161
General 161
Industry Composition 162
Market Share 166
Competitive Strategies 169
Product Development 170
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Manufacturing 172
Marketing 173
Distribution 175
Mergers & Acquisitions 177
Cooperative Agreements 179
Company Profiles 183
Abbey Carpet Company Incorporated 184
Ascend Performance Materials LLC 185
Astroturf LLC 186
Atlas Carpet Mills Incorporated 189
Autoneum Holding AG 191
Bacova Guild Limited 193
Barrett Carpet Mills Incorporated, see Kraus Carpet Mills
BASF SE 194
Beaulieu Group LLC 196
Bentley Prince Street Incorporated, see Interface
Berkshire Hathaway Incorporated 199
Cambridge Weavers Group, see Oriental Weavers
Camelot Carpet Mills, see Royalty Carpet Mills
Candlewick Yarns LLC, see Dixie Group
Capel Incorporated 204
Cargill Incorporated 209
Dixie Group Incorporated 211
Dow Chemical Company 213
DuPont (EI) de Nemours 215
Fabrica International Incorporated, see Dixie Group
Feizy Import and Export Company Limited 218
FieldTurf USA Incorporated, see Tarkett
FLOR Incorporated, see Interface
Gulistan Carpet Incorporated 220
Interface Incorporated 222
International Automotive Components Group 226
INVISTA Sarl, see Koch Industries
J&J Industries Incorporated 227
Koch Industries Incorporated 231
Kraus Carpet Mills Limited 235
Mannington Mills Incorporated 239
Masland Carpets and Rugs LLC, see Dixie Group
Milliken & Company 241
Mohawk Industries Incorporated 245
NatureWorks LLC, see Cargill
Nourison Rug Corporation 250
Oriental Weavers Group 253
Pacificrest Mills Incorporated, see Royalty Carpet Mills
Rieter Holding Limited 257
Royalty Carpet Mills Incorporated 259
Shaw Industries Incorporated, see Berkshire Hathaway
Sphinx, see Oriental Weavers
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Strudex Fibres Limited, see Kraus Carpet Mills
SYNLAWN, see Astroturf
Tandus Flooring Incorporated 261
Tarkett SAS 264
Textile Rubber & Chemical Company Incorporated 267
3M Company 270
UGN Incorporated, see Autoneum Holding
LIST OF TABLES
SECTION I -- EXECUTIVE SUMMARY
Summary Table 3
SECTION II -- MARKET ENVIRONMENT
1 Macroeconomic Indicators 8
2 Personal Consumption Expenditures 11
3 Consumer Financing Environment, 2000-2010 15
4 Population & Households 20
5 Building Construction Expenditures 23
6 Residential Building Construction Expenditures 25
7 Housing Completions 29
8 Single-Family Home Sales 30
9 Residential Floor Space 32
10 Residential Improvement & Repair Expenditures 34
11 Nonresidential Building Construction Expenditures 37
12 Nonresidential Building Floor Space 39
13 Nonresidential Building Improvement & Repair Expenditures 40
14 Motor Vehicle Indicators 44
15 Other Transportation Equipment Indicators 47
16 Carpet & Rug Pricing Trends 49
17 Carpet & Rug Market, 2000-2010 51
18 Carpet & Rug Foreign Trade 66
19 Floor Covering Demand 70
SECTION III -- MATERIALS
1 Carpet & Rug Material Consumption 73
2 Face Fiber Consumption 76
3 Nylon Face Fiber Consumption 79
4 Polyester Face Fiber Consumption 83
5 Polypropylene Face Fiber Consumption 85
6 Wool & Other Face Fiber Consumption 88
7 Primary Backing Consumption 90
8 Secondary Backing Consumption 92
9 Adhesives Consumption 94
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SECTION IV -- PRODUCTS
1 Carpet & Rug Supply & Demand 99
2 Tufted Carpet & Rug Supply & Demand 102
3 Broadloom Carpet & Rug Shipments 106
4 Vehicular Carpet & Rug Shipments 109
5 Carpet Tile Shipments 111
6 Scatter Rug & Bath Mat Shipments 113
7 Artificial Grass Shipments 115
8 Woven Carpet & Rug Supply & Demand 117
9 Other Carpet & Rug Supply & Demand 120
SECTION V -- MARKETS
1 Carpet & Rug Demand by Market 126
2 Residential Carpet & Rug Demand 130
3 New Residential Carpet & Rug Demand 132
4 Residential Replacement Carpet & Rug Demand 134
5 Single-Family Housing Carpet & Rug Demand 137
6 Multifamily Housing Carpet & Rug Demand 139
7 Manufactured Housing Carpet & Rug Demand 140
8 Nonresidential Building Carpet & Rug Demand 142
9 New Nonresidential Carpet & Rug Demand 144
10 Nonresidential Replacement Carpet & Rug Demand 146
11 Nonresidential Carpet & Rug Demand by Building Type 147
12 Office & Commercial Building Carpet & Rug Demand 151
13 Institutional Building Carpet & Rug Demand 153
14 Industrial Building Carpet & Rug Demand 154
15 Other Nonresidential Building Carpet & Rug Demand 155
16 Transportation Equipment Carpet & Rug Demand 157
17 Motor Vehicle Carpet & Rug Demand 158
18 Other Transportation Equipment Carpet & Rug Demand 160
SECTION VI -- INDUSTRY STRUCTURE
1 Carpet & Rug Sales by Company, 2010 165
2 Selected Acquisitions & Divestitures 178
3 Selected Cooperative Agreements 180
LIST OF CHARTS
SECTION II -- MARKET ENVIRONMENT
1 Carpet & Rug Market, 2000-2010 52
2 Carpet & Rug Imports by Source, 2010 67
3 Carpet & Rug Exports by Destination, 2010 68
SECTION III -- MATERIALS
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1 Carpet & Rug Material Consumption, 2010 73
2 Face Fiber Consumption by Type, 2010 77
SECTION IV -- PRODUCTS
1 Carpet & Rug Shipments by Type, 2010 100
2 Tufted Carpet & Rug Shipments, 2010 103
SECTION V -- MARKETS
1 Carpet & Rug Demand by Market, 2010 127
2 Residential Carpet & Rug Demand by Housing Type, 2010 135
SECTION VI -- INDUSTRY STRUCTURE
1 US Carpet & Rug Market Share, 2010 166
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