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TABLE OF CONTENTS

Section 1 U.S. Wood Flooring Industry Trends...................................................... 1

  Executive Summary ................................................................................

Wood Flooring Sales Trends And Factors Driving Demand............................

Price Trends And Introduction Of Value Added Products...............................

Consumers Seeking Wider Choices............................................................

Wood Flooring's Growing Position In The U.S. Floor Coverings Market...........

Growing End-Use Markets..........................................................................

Changing Retail Distribution Channels.........................................................

Increased Competitive Pressures................................................................

Industry Profit Margins And The Material Cost Situation................................

Outlook....................................................................................................
1

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11

     
Table 1-1 Value Of U.S. Wood Flooring Market Sales, 1977-2008 (dollars)....................
12

Figure 1-1 Value Of U.S. Wood Flooring Market Sales, 1993-2008 (dollars)....................
13

Table 1-2 Quantity U.S. Wood Flooring Market Sales And Average Value Per Square Foot Supplied, 1992-2008 (board feet and dollars).........................................

14

Table 1-3 Wood Flooring's Position In The U.S. Floor Coverings Market, 1992-2008 (dollars, square yards, and percent)............................................................

15

Figure 1-2 Wood Flooring’s Share Of The Total U.S. Floor Coverings Market, 1997-2003 (percent)...................................................................................................

16

Table 1-4 Wood Floorings' Position In The U.S. Hard Surface Floor Coverings Market, 1992-2008 (dollars, square feet, and percent)..........................................

17

Table 1-5 U.S. Wood Flooring Shipments, Exports, And Imports, 1992-2008 (dollars, square feet, and percent): Shipments, Exports, Exports Percent Shipments, Imports, And Imports Percent Market Sales ................................................



18

Table 1-6 U.S. Market Sales For Hardwood And Softwood Flooring, 1992-2008 (square feet and dollars).........................................................................................


19

Table 1-7 U.S. Average Value Per Square Foot Of Floor Covering Supplied By Product Sector, 1992-2003 (dollars): Carpet And Area Rugs, Wood Flooring, Ceramic Floor And Wall Tile, Vinyl Sheet And Floor Tile, Rubber Sheet And Floor Tile, And Laminate Flooring...............................................................................

20

Table 1-8 U.S. Producer Price Trends For Hardwood Flooring And Competing Floor Coverings, 1987-2003 (index): Hardwood Flooring, Carpet And Area Rugs, Resilient Floor Coverings, Ceramic Tile, And Rubber Mats And Stair Treads......................................................................................................



21

Table 1-9 Monthly U.S. Producer Price Trends For Hardwood Flooring, 2001-2003 (index)......................................................................................................


22

Table 1-10 Gross Plant Profit Margins For Hardwood Flooring Plants And The U.S. Floor Coverings Industry Average, 1982-2003 (percent)...................................................................................................

23

SCOPE AND METHODOLOGY.................................................................................. 24
Section 2 U.S. Wood Flooring Shipments............................................................ 27

 

Summary Of Major Findings.......................................................................

Manufacturer Shipments............................................................................

Pricing Trends..........................................................................................

Solid Versus Engineered Products..............................................................

Prefinished Products.................................................................................

Species Shipment Mix...............................................................................

Growth Of Exotics.....................................................................................

Rustic Look..............................................................................................

Glueless Technology.................................................................................

27

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29

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31

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33

34
Table 2-1 Value Of Total U.S. Wood Flooring Shipments, 1972-2008 (dollars)............ 36

Table 2-2 Wood Flooring's Position In The U.S. Floor Coverings Industry, 1972-2008 (dollars and percent): Floor Coverings Product Shipments, Percent GDP, And Wood Percent Total..................................................................................

37

Table 2-3 Quantity Total U.S. Wood Flooring Shipments And Average Value Per Square Foot Shipped, 1972-2008 (board feet and dollars).........................................
38

Table 2-4 Value Of U.S. Hardwood And Softwood Flooring Shipments, 1972-2008 (dollars)....................................................................................................
39

Table 2-5 Quantity U.S. Hardwood And Softwood Flooring Shipments And Average Value Per Square Foot Shipped, 1972-2008 (board feet and dollars)..............
40

Table 2-6 Value Of U.S. Hardwood Flooring Shipments By Product Type, 1972-2008 (dollars): Strip Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck And Railroad Flooring, And Other Hardwoods.....................................

42

Table 2-7 Distribution Of U.S. Hardwood Flooring Dollar Shipments By Product Type, 1972-2008 (percent): Strip Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck And Railroad Flooring, And Other Hardwoods..........................

43

Table 2-8 Quantity U.S. Hardwood Flooring Shipments By Product Type, 1972-2008 (board feet): Strip Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck And Railroad Flooring, And Other Hardwoods.....................................

44

Table 2-9 Distribution Of U.S. Hardwood Flooring Quantity Shipments By Product Type, 1972-2008 (percent): Strip Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck Trailer And Railroad Oak Flooring, And Other Hardwoods...............................................................................................


45

Table 2-10 U.S. Average Value Per Square Foot Shipped By Hardwood Flooring Product Type, 1972-2008 (dollars): Strip Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck And Railroad Flooring, And Other Hardwoods............. 46

Table 2-11 U.S. Producer Price Trends For Hardwood Flooring Products By Type, 1985-2003 (index): Strip Oak Flooring and Maple Flooring.....................................

47

Table 2-12 Product Definitions And Terms................................................................. 48

  Solid Wood Flooring ..............................................................................

Parquet.................................................................................................

Engineered Wood Flooring......................................................................

Acrylic Impregnated Wood Flooring..........................................................

Custom Wood Floors..............................................................................

Mixed Media And Mixing Species............................................................

Customized Paint Designs......................................................................

Unfinished Wood Flooring........................................................................

Prefinished Wood Flooring.......................................................................

Nail Strip Or Plank Floor..........................................................................

Glue-Down Floor.....................................................................................

Floating Floor.........................................................................................

Wood Species.......................................................................................

Wood Flooring Cuts................................................................................

Recycled And Reclaimed Wood Flooring..................................................

Wood Floor Finishes...............................................................................
48

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48

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49

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51

     
Section 3 U.S. Wood Flooring Imports.................................................................. 53

  Summary Of Major Findings.......................................................................

Import Shipment........................................................................................

Hardwood Versus Softwood Imports............................................................

Exotic Product Offerings...........................................................................

Imports By Country..................................................................................

Companies Stimulating U.S. Imports...........................................................

53

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54

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54

55

Table 3-1 U.S. Solid Wood Flooring Imports, 1992-2008 (square feet and dollars).....................................................................................................
57

Table 3-2 U.S. Solid Wood Flooring Imports By Material, 1992-2003 (square feet and dollars): Softwood, Maple, Birch, And Other Hardwood.................................
58

Table 3-3 Imports' Share Of U.S. Wood Flooring Market Sales By Material, 1992-2003 (percent): Softwood And Hardwood .............................................................
59

Table 3-4 U.S. Solid Wood Flooring Imports For The Top Fourteen Countries Of Origin, 1997-2003 (square feet and dollars).............................................................
60

     
Section 4 U.S. Wood Flooring End-Use Markets And Distribution Channels.......... 62

 

Summary Of Major Findings.......................................................................

New Residential Construction Market..........................................................

Residential Remodeling Market..................................................................

Nonresidential Markets..............................................................................

Retail Distribution......................................................................................

The Distributor Channel..............................................................................

Installation Contractor Revenues.................................................................

Solid Wood Flooring Export Shipments.......................................................

 

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68
Table 4-1 Value Of U.S. Hardwood Flooring Purchases By Major End-Use Market, 1997-2003 (dollars): New Residential Construction, Residential Replacement And Repair, Factory-Built Housing, New Nonresidential Construction, Commercial Contract, And Transportation Equipment...................................


70

Table 4-2 Hardwood Flooring’s Share Of Total Dollar Floor Coverings Purchases By Major U.S. End-Use Market, 1997-2002 (percent): New Residential Construction, Residential Replacement And Repair, Factory-Built Housing, New Nonresidential Construction, Commercial Contract, And Transportation Equipment ...............................................................................................



71

Table 4-3 Value Of Hardwood Flooring Purchases Per U.S. Contractor-Built Housing Unit Completed And Factory-Built Housing Unit Shipped, 1997-2003 (dollars).

72

Table 4-4 U.S. Wood Flooring Contractor Revenues And Share Of Total U.S. Construction Spending, 1977-2003 (dollars and percent)...............................
73

Table 4-5 Contractor Business By Type Of Job And Products Sold, 1999-2002 (percent): New Home Versus Remodel, Installation Versus Finishing, And Products, Species, Finishes Sold...............................................................

74

Table 4-6 U.S. Contractor Revenue Per Square Foot Of Wood Flooring Installed, 1992-2003 (dollars)............................................................................................
75

Table 4-7 Number Of U.S. Hardwood Flooring Retailers And Sales By Type Of Outlet, 1997 And 2002 (number, dollars, and percent): Retail Sales, Hardwood Percent Total Floor Covering Sales, Number Of Retailers Carrying Line, And Average Sales Per Retailer.........................................................................

76

Table 4-8 Distributor Business By Type Of Product, Species, And Finish Sold, 1999-2002 (percent)..........................................................................................


77

Table 4-9 U.S. Solid Wood Flooring Exports, 1992-2008 (square feet and dollars).....................................................................................................


78

Table 4-10 U.S. Solid Wood Flooring Exports By Material, 1992-2003 (square feet and dollars): Softwood And Hardwood.................................................................
79

Table 4-11 Exports' Share Of U.S. Solid Wood Flooring Shipments By Material, 1992-2003 (percent): Softwood, Hardwood, And Total............................................
80

Table 4-12 U.S. Exports Of Solid Hardwood Flooring For The Top Seven Countries Of Destination, 1997-2003 (square feet and dollars)...........................................
81

Table 4-13 U.S. Exports Of Solid Softwood Flooring For The Top Seven Countries Of Destination, 1997-2003 (square feet and dollars)..................................
82


     
Section 5 Factors Affecting U.S. Wood Flooring Domestic Demand And
Distribution...........................................................................................

83

  Summary Of Major Findings.....................................................................

Residential Remodeling Market..................................................................

New Residential Construction Market..........................................................

Retail Distribution...................................................................................

Nonresidential Market.............................................................................
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Table 5-1

U.S. Spending On Building Construction, 1977-2003 (dollars): Total Buildings, Residential Buildings, And Nonresidential Buildings......................



87

Table 5-2 U.S. Spending On Construction Put In Place By Market And Building Type, 1999-2003 (dollars)....................................................................................

88

Table 5-3 Total U.S. Housing Demand By Sector By Region, 1998-2003 (number): Northeast, Midwest, South, West, And Total..............................................
90

Table 5-4 New U.S. Privately Owned Housing Units Started And By Type Of Structure, 1980-2003 (number): Total Starts; In Structures With 1 Unit, 2 To 4 Units, And 5 Units Or More.................................................................................
92

Table 5-5 Monthly New Private U.S. Housing Units Authorized By 19,000 Building Permit Places By Region, 2002 And 2003 (number).....................................

93

Table 5-6 New Privately Owned Housing Units Authorized By 19,000 Building Permit Places By Region And State, 1997-2003 (number).......................................


94

Table 5-7 Characteristics Of New U.S. Housing Units Affecting Floor Covering Product Demand, 1990-2002 (units): Region, Number Of Bathrooms, Number Of Bedrooms, Garages, Number Of Stories For Single-Family, Multi-Family Structures, And Mobile Homes..................................................................
96

Table 5-8 Average Size Per New U.S. Housing Unit By Type Of Unit And Region, 1990-2003 (square feet).....................................................................................

99

Table 5-9 New U.S. Single-Family Houses Sold By Sales Price, 1985-2003 (number and dollars): Under $100,000, $100,000 To $149,999, $150,000 To $199,999, $200,000 To $299,999, And $300,000 And Over...........................................
100

Table 5-10 Average Value Per New Single-Family House Sold And Average Value Per Square Foot, 1985-2003 (dollars)................................................................
101

Table 5-11 U.S. Residential Property Owner Expenditures For Improvements, Additions, Alterations, And Repairs And Spending By Single-Family Homeowners, 1985-2003 (dollars)................................................................................... 102

Table 5-12 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, 1992-2001 (dollars).............................................

103

Table 5-13 U.S. Household Spending On Hard Surface Flooring And Installation By Demographic Characteristic, 1997 And 2001 (dollars): Household Income, Age Of Household Head, Size Of Household, And Region............................
104

Table 5-14 U.S. Household Spending On Hard Surface Flooring By Demographic
Characteristic, 1990-1999 (dollars): Household Income, Age Of Household
Head, Size Of Household, And Region......................................................


106

Table 5-15 U.S. Retail Floor Coverings Sales By Type Of Outlet, 1987-2002 (dollars): Floor Coverings Stores, Building Material Dealers And Home Centers, Furniture Stores, Department Stores And Mass Merchandisers, Paint Stores, Non-Store Retailers, All Other Retailers, And Total Sales........................................


108

Table 5-16 Monthly U.S. Floor Coverings Store Sales, 2000-2003 (dollars).....................


109

Table 5-17 U.S. Home Mortgage Interest Rates And Personal Income, 1980-2003 (percent and dollars).................................................................................
110

Table 5-18 Distribution Of U.S. Households By Demographic Characteristic, 1985-2002 (percent): Household Income, Age Of Household Head, Household Size, Region, And Total Households...................................................................

111

     
Section 6 Cost Structure Of U.S. Hardwood Flooring Plants And The Competitive
Environment .........................................................................................

112

 

Summary Of Major Findings......................................................................

Number Of Hardwood Flooring Manufacturers And Plants..............................

Other Manufacturers And Marketers............................................................

Market And Brand Shares..........................................................................

Industry Profit Margins...............................................................................

Material Situation......................................................................................

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Table 6-1 Number Of U.S. Hardwood Flooring Plants And Facility Revenues, 1972-2003 (dollars)...................................................................................................
119

Table 6-2 U.S. Hardwood Flooring Plant Operating Ratios And Gross Profit Margin, 1972-2003 (percent): Payroll, Material Costs, And Gross Profit Margin...........
120

Table 6-3 U.S. Producer Price Trends For Lumber, 1982-2003 (index): Total, Softwood, And Hardwood..........................................................................................
121

Table 6-4 Monthly U.S. Producer Price Trends For Oak And Maple Rough Lumber, 2001-2003 (index)......................................................................................
122

Table 6-5 U.S. Hardwood Lumber Production And Mill Stocks, 1980-2002 (board feet) ..
123

Table 6-6 U.S. Hardwood Flooring Plant Labor Situation, 1972-2003 (number, percent, and dollars): Number Of Employees, Shipments Per Employee, Production Workers Percent Total Employees, Average Hourly Wages, And Average Weekly Hours ..........................................................................................


124

Table 6-7 U.S. Hardwood Flooring Plant Capital Expenditures, 1972-2003 (dollars)....................................................................................................
125

Table 6-8 Number Of U.S. Hardwood Flooring Manufacturers By Product Type, 1987-1997 (number and dollars): Softwood Flooring, Oak Flooring, Oak Parquetry, Other Oak Flooring, Maple, Truck And Railroad Flooring, And Other Hardwoods...............................................................................................
126

Table 6-9 Share Of U.S. Wood Flooring Supply For Twelve Leading Manufacturers, 2002 (percent) ..........................................................................................


127

Table 6-10 Sales And Profit Trends For Armstrong's Wood Flooring Segment, 1999-2003 (dollars and percent)..................................................................................
128

Table 6-11 Top Twelve Hardwood Flooring Brands Used By New U.S. Home Builders And Remodeling Contractors Over The Past Twelve Months, 2002 (percent)...................................................................................................
129

Table 6-12 Top Six Hardwood Flooring Brands Used By New U.S. Home Builders By Region, Cost Of Home, Units Built, And Home Type, 2002 (percent)..............
130

Table 6-13 Top Six Hardwood Flooring Brands Used By Remodeling Contractors By Region, Cost Of Home, Units Remodeled, And Home Type, 2002 (percent)...................................................................................................
131

     
Section 7 CANADIAN AND EUROPEAN WOOD FLOORING MARKET ....................... 132

 

Summary Of Major Findings.......................................................................

Canadian Market Sales ............................................................................

Canadian Shipments And Capacity Expansion.............................................

Canadian Exports ....................................................................................

Canadian Imports .....................................................................................

Leading Canadian Manufacturers................................................................

European Market Trends...........................................................................

Leading European Manufacturers................................................................

 

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Table 7-1 Value Of Canadian Hardwood Flooring Market Sales, 1992-2002 (Canadian dollars)....................................................................................................

139

Table 7-2 Value Of Canadian Hardwood Flooring Shipments, Exports, And Imports, 1992-2002 (Canadian dollars) ....................................................................

140

Table 7-3 Canadian Shipments Of Hardwood Flooring And Average Value By Wood Type, 1990-1999 (Canadian dollars and cubic meters): Maple, Oak, Birch, Other, And Total ................................................................


141

Table 7-4 Wood Flooring Production For Twelve Leading Canadian Manufacturers, 2002 (square feet): Solid Wood, Engineered Flooring, Mosaic Parquet, And Percent Sales Exported.............................................................................

142

Table 7-5 Canadian Exports And Imports Of Hardwood Flooring And Related Products, 1992-2002 (Canadian dollars).....................................................................

143

Table 7-6 Value Of Canadian Building Permits And Canadian Housing Starts, 1993-2002 (number and Canadian dollars)...........................................................

144

Table 7-7 European Wood Flooring Market By Country And Leading Suppliers, 2002 (percent)...................................................................................................

145

Table 7-8 Sales And Profit Trends For Five Canadian And European Wood Flooring Suppliers, 2002 (dollars and percent)..........................................................

146

     
Section 8
Company Profiles .................................................................................. 148

  Aged Woods/Yesteryear Floorworks Co...................................................... 149
 

Wood Flooring Products............................................

149
  American Biltrite Inc............................................................................... 150
 

Janus Flooring ........................................................

150
  Anderson Hardwood Floors................................................................... 151
 

Wood Flooring Products ..........................................
New Products..........................................................
Sales And Market Sales ..........................................

151
151
152
  Anderson-Tully Lumber Co. ................................................................... 153
 

Wood Flooring Products ..........................................

153
  Armstrong Holdings, Inc......................................................................... 155
 

Wood Flooring Products............................................
Marketing And Distribution ........................................
New Products ..........................................................
Sales And Profit Trends ............................................
Market Shares .........................................................

155
155
156
156
158
  Award Hardwood Floors....................................................................... 159
 

Wood Flooring Products ...........................................
Manufacturing And Distribution...................................
Sales And Market Share ...........................................

159
159
160
  Boa-Franc............................................................................................. 161
 

Wood Flooring Products And Production....................
New Products And Distribution ................................

161
161
  Boen Hardwood Floors ......................................................................... 163
 

Wood Floor Products ...............................................
Distribution .............................................................
Brand Shares..........................................................

163
163
164
  BR-111 Imports & Exports, Inc. ........................................................... 165
 

Wood Flooring Products ...........................................

165
  Columbia Forest Products ..................................................................... 166
 

Wood Flooring Products ...........................................
New Products ..........................................................
Sales And Market Share ..........................................
Acquisition Of Millwood Specialty Flooring .................

166
166
167
167
  D & M Bamboo Flooring Co. ................................................................ 169
 

Wood Flooring Products ............................................

169
  Domco Tarkett, Inc. .............................................................................. 170
 

Wood Flooring Products And Manufacturing...................
New Products .............................................................
Sales And Profit Trends................................................
Market And Brand Shares .............................................
Name Change Planned .................................................

170
170
171
171
172
  Felix Huard . ............................................................................................ 173
 

Wood Flooring Products................................................

173
  Floorco International North America, Inc. .............................................. 174
 

Wood Flooring Products ............................................

174
  Forbo International SA .......................................................................... 176
 

Wood Flooring Products And Sales ............................

176
  Gammapar ................................................................. 177
 

Wood Flooring Products...............................................
Acquisition Of PermaGrain Products.............................

177
177
  Johnson Premium Hardwood Flooring......................................................... 179
 
Wood Flooring Products..............................................
179
  F. Junckers Industrier A/S ..................................................................... 180
 
Wood Flooring Products And Sales...............................
Junckers Hardwood Subsidiary.....................................
180
180
  Kentucky Wood Floors, Inc. ................................................................. 182
 

Wood Flooring Products...............................................
New Products...............................................................
Brand Shares...............................................

182
182
183
  Lauzon Hardwood Flooring................................................................... 184
 

Wood Flooring Products.................................................
Manufacturing Output And Sales ....................................
Acquisitions And Partnership..........................................

184
185
185
  Linden Lumber Co. LTD ............................................................................ 186
 

Wood Flooring Products And Sales ................................

186
  Mannington Mills....................................................................................... 187
 

Wood Flooring Products And Market Share.....................
Market And Brand Shares .............................................

187
187
  Memphis Hardwood Flooring Co. ............................................................... 189
 

Wood Flooring Products And Sales .................................

189
  Mercier Wood Flooring ............................................................................. 190
 

Wood Flooring Products...................................................

190
  Mohawk Industries, Inc. ...................................................................... 191
 

Wood Flooring Products...................................................

191
  Mullican Flooring ................................................................................. 192
 

Wood Flooring Products....................................................
Manufacturing And Sales..................................................
Acquisitions....................................................................

192
192
193
  Nybron Flooring International ............................................................... 194
 

Wood Flooring Subsidiaries And Sales..............................
Bauwerk.........................................................................
Kährs.............................................................................
Marty.........................................................................

194
194
195
196
  Preverco .................................................................................................. 198
 
Wood Flooring Subsidiaries ...............................................
198
  Satin Finish Hardwood Flooring ............................................................ 199
 
Wood Flooring Products ...................................................
199
  Shaw Industries, Inc. ............................................................................ 200
 
Wood Flooring Products ...................................................
200
  Tarkett Sommer AG ............................................................................ 201
 

Wood Flooring Subsidiaries................................................
European Hardwood Floor Sales .......................................

201
201
  Tembec, Inc. ........................................................................................ 202
 

Wood Flooring Products And Sales....................................

202
  Upofloor Oy..... ........................................................................................ 203
 

Wood Flooring Products....................................................

203
  Weyerhaeuser Co..................................................................................... 204
 

Wood Flooring Products....................................................

204