The 2004/2005 Outlook For The U.S. Soft-Surface Floor Coverings Industry (With Long-Term Forecasts Through 2013)

This publication has been discontinued on July 19, 2011.

Introduction

TABLE OF CONTENTS

SECTION I: THE U.S. FLOOR COVERINGS MARKET

Analysis and Summary:

• Overview. 1
• Industry Consolidation. 1
• Building Market Share. 2
• U.S. Manufacturers - Sales 2
• Market Segmentation 3

Tables:

• U.S. Manufacturers - Dollar Sales of Floor Coverings 4
• U.S. Manufacturers - Dollar Sales of Floor Coverings, by Type. 5
• Product Mix of U.S. Manufacturers - Dollar Sales of Floor Coverings 6
• Graph: Product Mix of U.S. Manufacturers - Dollar Sales of Floor Coverings 7
• Growth in U.S. Manufacturers - Dollar Sales of Floor Coverings, by Type. 8

SECTION II: THE U.S. MARKET FOR SOFT-SURFACE FLOOR COVERINGS

Analysis and Summary:

• Market Overview 9
• Tufted Carpets and Rugs 10
• Woven Carpets and Rugs. 10
• Other Carpets and Rugs. 11
• Leading Manufacturers 11
• Outlook 12

Tables:

• U.S. Manufacturers - Sales of Carpets and Rugs:
• Total Dollar Sales 13
• Dollar Sales, by Type 14
• Product Mix of Dollar Sales. 15
• Total Unit Sales. 16
• Unit Sales, by Type. 17
• Product Mix of Unit Sales. 18
• U.S. Manufacturers - Sales of Tufted Carpets and Rugs:
• Total Unit and Dollar Sales 19
• Graph: Distribution of Dollar Sales, by Fiber of Face Yarn. 20
• Graph: Distribution of Unit Sales, by Fiber of Face Yarn. 21
• Unit and Dollar Sales, by Type 22
• Unit and Dollar Sales of Scatter Rugs, Accent Rugs, Bath Mats, and Rugs 6' x 9' and Smaller. 24
• Graph: Distribution of Dollar Sales of Scatter Rugs, Accent Rugs, Bath Mats, and Rugs 6' x 9' and Smaller: Washable vs. Nonwashable. 25
• Graph: Distribution of Unit Sales of Scatter Rugs, Accent Rugs, Bath Mats, and Rugs 6' x 9' and Smaller: Washable vs. Nonwashable 26
• Unit and Dollar Sales of Roll Carpets and Rugs, Larger than 6' x 9'. 27
• Unit and Dollar Sales of Automobile and Aircraft Carpeting 28
• Unit and Dollar Sales of Tufted Artificial Grass for Nonathletic Surfaces. 29
• U.S. Manufacturers - Sales of Woven Carpets and Rugs:
• Total Unit and Dollar Sales 30
• Graph: Distribution of Dollar Sales, Man-Made vs. Other Fibers. 31
• Graph: Distribution of Unit Sales, Man-Made vs. Other Fibers. 32
• U.S. Manufacturers - Sales of Other Carpets and Rugs:
• Total Unit and Dollar Sales 33
• Unit and Dollar Sales, by Type 34
• Unit and Dollar Sales of Needle-Punched Carpets and Rugs. 35
• Unit and Dollar Sales of Knitted, Braided, Hooked, and Other Carpets and Rugs 36
• Graph: Estimated Company Market Shares in the U.S. Carpet and Rug Industry 37

SECTION III: FACTORS AFFECTING DEMAND FOR SOFT-SURFACE FLOOR COVERINGS

Part A: The Economy

Analysis and Summary:

• Overview. 38
• Gross Domestic Product. 38
• Per Capita Disposable Personal Income. 39
• Personal Consumption Expenditures 39
• Interest Rates 39

Tables:

• U.S. Gross Domestic Product 41
• U.S. Per Capita Disposable Personal Income. 42
• U.S. Personal Consumption Expenditures 43
• U.S. Personal Consumption Expenditures on Floor Coverings 44
• Interest Rates Charged by U.S. Banks 45

Part B: Housing Trends, Construction Activity, and Motor Vehicle Production

Analysis and Summary:

• Overview. 46
• Housing Market Benefits from Falling Mortgage Rates. 47
• Alternative Housing 48
• Home Improvement Expenditures 49
• Motor Vehicle Production 49

Tables:

• Privately Owned Housing Starts:
• By Type 50
• Distribution, by Type. 52
• By Region 53
• Distribution, by Region. 55
• Privately Owned Housing Units Completed:
• By Type 56
• By Region 58
• Average Sale Prices of New Houses Sold in the U.S. 60
• Average Square Feet of Floor Area in New Privately Owned One-Family Housing, by Region 61
• Number of Bedrooms in New Single-Unit Housing in the U.S.:
• Total 63
• Northeast 64
• Midwest 65
• South 66
• West. 67
• Housing Affordability 68
• First-Time Home Buyer Affordability 69
• Sales of New vs. Existing Single-Family Homes 71
• New Single-Family Home Sales, by Region. 72
• Existing Single-Family Home Sales, by Region. 73
• Number of Completed Multifamily Buildings. 74
• Existing Apartment, Condo, and Co-Op Sales, by Region. 75
• New Manufactured Homes, by Region 76
• Total Improvement Expenditures for All Residential Properties, by Region 77
• Value of New Construction in the U.S.:
• Total 78
• Private vs. Public. 79
• Private, by Type. 80
• Private Residential Building Construction, by Type 81
• Private Nonresidential Building Construction, by Type. 82
• Public Building Construction, by Type 84
• U.S. Motor Vehicle Production. 86

Part C: Population and Spending Trends

Analysis and Summary:

• Overview. 87
• Population Trends 87
• Consumer Spending 88
• How Value Determines Carpet Purchases. 89

Tables:

• U.S. Resident Population Trends and Projections. 90
• U.S. Population and Household Trends and Projections 91
• U.S. Population Trends and Projections:
• By Age Group 92
• Age Distribution 93
• By Region 94
• By State 95
• Distribution, by State 97
• Average Annual Expenditures on Soft-Surface Floor Coverings, Detailed by Type of Expenditure 99
• Average Annual Expenditures on Soft-Surface Floor Coverings, Detailed by Key Demographic Characteristics 100
• Average Annual Expenditures by Homeowners on Replacement Wall-to- Wall Carpeting, Detailed by Key Demographic Characteristics 101
• Average Annual Expenditures on Nonpermanent Floor Coverings, Detailed by Key Demographic Characteristics 102
• Standards for Budgeting Carpet Purchases. 103

SECTION IV: PRICE TRENDS IN THE SOFT-SURFACE FLOOR COVERINGS INDUSTRY

Analysis and Summary:

• Overview. 104
• Producer Prices. 104
• Consumer Prices. 106

Tables:

• Producer Price Trends:
• Carpets and Rugs. 107
• Carpets and Rugs, by Type. 108
• Tufted Carpets and Rugs, by Type 109
• Average Factory Prices:
• Carpets and Rugs. 110
• Woven Carpets and Rugs 111
• Tufted Carpets and Rugs. 112
• Tufted Carpets and Rugs, by Type 113
• Other Carpets and Rugs 115
• Other Carpets and Rugs, by Type. 116
• Consumer Price Trends for Floor Coverings 117

SECTION V: ADVERTISING IN THE SOFT-SURFACE FLOOR COVERINGS INDUSTRY

Analysis and Summary:

• Overview. 118
• Media Expenditures. 118
• Leading Advertising Spenders. 119

Tables:

• Media Expenditures for Soft-Surface Floor Coverings:
• Total 120
• By Leading Companies. 121
• By Leading Brands. 122
• By Company and Brand. 123
• Media Expenditures for Carpet Fibers and Materials, by Company and Brand. 124
• Circulation of Selected Home Decorating/Lifestyle Publications. 125
• Circulation of Selected Professional Decorating/Home Furnishings Publications 127

SECTION VI: DISTRIBUTION OF SOFT-SURFACE FLOOR COVERINGS

Analysis and Summary:

• Overview. 129
• Leading Carpet and Rug Retailers 129
• Growth of Floor Coverings Retailers 130
• Distribution Channels for Rugs. 130

Tables:

• Total Number of Floor Coverings Stores. 132
• Number of Floor Coverings Stores, by Employment Size. 133
• Distribution of Floor Coverings Stores, by Employment Size. 134
• Number of Employees and Payroll in Floor Coverings Stores. 135
• Graph: Distribution of Retail Sales of Machine-Made Rugs, by Marketing Channel. 136
• Graph: Distribution of Retail Sales of Handmade Rugs, by Marketing Channel. 137
• Graph: Distribution of Retail Sales of Washable Rugs, by Marketing Channel. 138
• Graph: Distribution of Retail Sales of Accent Rugs, by Marketing Channel. 139

SECTION VII: FOREIGN TRADE OF SOFT-SURFACE FLOOR COVERINGS

Part A: Overall Trends

Analysis and Summary:

• Overview. 140
• Rising Trade Deficit for Soft-Surface Floor Coverings 141
• Overall Trade of Floor Coverings. 141

Tables:

• Foreign Exchange Rates 142
• Fixed Euro Conversion Rates 143
• U.S. Apparent Consumption of Soft-Surface Floor Coverings. 144
• U.S. Balance of Trade for Floor Coverings. 145
• Total U.S. Exports of Floor Coverings. 146
• U.S. Exports of Floor Coverings: Soft vs. Hard. 147
• Total U.S. Imports of Floor Coverings 148
• U.S. Imports of Floor Coverings: Soft vs. Hard 149

Part B: U.S. Imports

Analysis and Summary:

• Overall Imports 150
• Leading Source Countries 150
• Persian Carpets and Rugs. 151
• Belgium Shines in Cloudy European Market 151
• Leading Import Product Categories 152
• Outlook 152

Tables:

• Top 20 U.S. Import Sources for Soft-Surface Floor Coverings: Value. 153
• Dollar Market Shares of the Top 20 U.S. Import Sources for Soft-Surface Floor Coverings 154
• Graph: Dollar Market Shares of the Leading U.S. Import Sources for Soft-Surface Floor Coverings. 155
• U.S. Imports of Soft-Surface Floor Coverings, by Type: Value 156
• Product Mix of U.S. Imports of Soft-Surface Floor Coverings: Value 158
• U.S. Imports of Soft-Surface Floor Coverings, by Country of Origin and by Type:
• Knotted Carpets and Rugs, Whether or Not Made Up:
• Of Wool or Fine Animal Hair. 160
• Of Other Textile Materials, Pile Inserted and Knotted During Weaving or Knitting 161
• Of Other Textile Materials, Hand-Hooked. 163
• Hand-Woven Rugs, Including �gKelem, - �gSchumacks, - and �gKaramanie - 165
• Woven Carpets and Rugs, Not Tufted or Flocked:
• Made Up, of Coconut Fibers 167
• Of Pile Construction, Not Made Up:
• Of Wool or Fine Animal Hair 169
• Of Man-Made Textile Materials. 171
• Of Other Textile Materials. 173
• Of Pile Construction, Made Up:
• Of Wool or Fine Animal Hair 175
• Of Man-Made Textile Materials. 177
• Of Other Textile Materials. 179
• Not of Pile Construction, Not Made Up:
• Of Wool or Fine Animal Hair 181
• Of Man-Made Textile Materials. 183
• Of Other Textile Materials. 185
• Not of Pile Construction, Made Up:
• Of Wool or Fine Animal Hair 187
• Of Man-Made Textile Materials. 189
• Of Other Textile Materials. 191
• Tufted Carpets and Rugs, Whether or Not Made Up:
• Of Wool or Fine Animal Hair. 193
• Of Nylon or Other Polyamides 195
• Of Other Man-Made Textile Materials 197
• Of Other Textile Materials 199
• Felt Carpets and Rugs, Not Tufted or Flocked, Whether or Not Made Up:
• Tiled. 201
• Other 203
• Other Carpets and Rugs, Whether or Not Made Up:
• Of Coir. 205
• Of Wool or Fine Animal Hair, Cotton, Man-Made Fibers, or Other Materials. 207

Part C: U.S. Exports

Analysis and Summary:

• Overall Exports. 209
• Leading Destination Countries. 209
• Leading Export Product Categories 210
• Outlook 210

Tables:

• Top 20 U.S. Export Destinations for Soft-Surface Floor Coverings: Value 211
• Dollar Market Shares of the Top 20 U.S. Export Destinations for Soft- Surface Floor Coverings. 212
• Graph: Dollar Market Shares of the Leading U.S. Export Destinations for Soft-Surface Floor Coverings. 213
• Top 20 U.S. Export Destinations for Soft-Surface Floor Coverings:
• Quantity. 214
• Unit Market Shares of the Top 20 U.S. Export Destinations for Soft- Surface Floor Coverings. 215
• Graph: Unit Market Shares of the Leading U.S. Export Destinations for Soft-Surface Floor Coverings. 216
• U.S. Exports of Soft-Surface Floor Coverings, by Type:
• Value 217
• Product Mix: Value. 218
• Quantity 219
• Product Mix: Quantity. 221
• U.S. Exports of Soft-Surface Floor Coverings, by Country of Destination and by Type:
• Knotted Carpets and Rugs, Whether or Not Made Up:
• Of Wool or Fine Animal Hair. 223
• Of Other Textile Materials 225
• Hand-Woven Rugs, Including �gKelem, - �gSchumacks, - and �gKaramanie - 227
• Woven Carpets and Rugs, Not Tufted or Flocked:
• Made Up, of Coconut Fibers 229
• Of Pile Construction, Not Made Up:
• Of Wool or Fine Animal Hair 231
• Of Man-Made Textile Materials. 233
• Of Other Textile Materials. 235
• Of Pile Construction, Made Up:
• Of Wool or Fine Animal Hair 237
• Of Man-Made Textile Materials. 239
• Of Other Textile Materials. 241
• Not of Pile Construction, Not Made Up:
• Of Wool or Fine Animal Hair 243
• Of Man-Made Textile Materials. 245
• Of Other Textile Materials. 247
• Not of Pile Construction, Made Up:
• Of Wool or Fine Animal Hair 249
• Of Man-Made Textile Materials. 251
• Of Other Textile Materials. 253
• Tufted Carpets and Rugs, Whether or Not Made Up:
• Of Wool or Fine Animal Hair. 255
• Of Nylon or Other Polyamides 257
• Of Other Man-Made Textile Materials 259
• Of Other Textile Materials 261
• Felt Carpets and Rugs, Not Tufted or Flocked, Whether or Not Made Up:
• Tiled. 263
• Other 265
• Other Carpets and Rugs, Whether or Not Made Up. 267

SECTION VIII: STRUCTURE OF THE U.S. SOFT-SURFACE FLOOR COVERINGS INDUSTRY

Analysis and Summary:

• Overview. 269
• Industry Economics 269
• Employment Trends. 270
• Capital Expenditures. 271
• Manufacturing Facilities 271

Explanation of Terms 272

Tables:

• The Carpet and Rug Industry:
• Operating Structure. 278
• Gross Operating Margin. 279
• Value Added by Manufacture 280
• Vertical Integration Index 281
• Employment Structure 282
• Total Labor Costs. 283
• Average Hourly Earnings of Production Workers 284
• Cost of Living Index for Production Workers 285
• Labor Productivity. 286
• Indexes of Real Labor Productivity 287
• New Capital Expenditures. 288
• Plant vs. Equipment Expenditures 289
• Ending Inventories. 290
• Number of U.S. Manufacturing Facilities 291

The Plant Manager?s Workbook:

• How to Use This Section. 292
• Gathering Your Data 293
• Developing Your Ratios. 294
• How Does Your Plant Stack Up?. 295

SECTION IX: RAW MATERIALS IN THE SOFT-SURFACE FLOOR COVERINGS INDUSTRY

Analysis and Summary:

• Overview. 300
• Yarn Production 300
• Raw Material Prices 301

Tables:

• Yarn Production for the Carpet and Rug Industry:
• Total 303
• By Type 304
• Spun Yarn, by Type. 305
• Spun Yarn, by Spinning System 306
• Textured Yarn, by Type. 307
• Producer Price Trends:
• Spun Yarn, by Type. 308
• Textured Yarn, by Type. 310
• Average U.S. Wool Prices 311

SECTION X: COMPANY PROFILES

Introduction. 312

Tables:

• Financial Profile of the Carpet and Rug Industry:
• Total 313
• Sorted by Sales. 314
• Sorted by Assets. 315

Company Profiles:

• Armstrong World Industries, Inc.:
• Overview 316
• Armstrong Floor Products 316
• Distribution. 317
• Brands 317
• Manufacturing 318
• Outlook. 318
• Financial Summary and Analysis 319
• Graph: Distribution of Armstrong Floor Product Net Sales, by Segment. 320
• Beaulieu of America, LLC. 321
• The Dixie Group, Inc.:
• Overview 322
• Fabrica. 322
• Masland Carpets. 323
• Restructuring Through Divestiture. 323
• Outlook. 324
• Financial Summary and Analysis 325
• Interface, Inc.:
• Overview 326
• Products. 326
• Manufacturing 327
• InterfaceFLOR. 327
• Outlook. 328
• Financial Summary and Analysis 329
• Joy Carpets, Inc 330
• L?Art du Temps Inc. 331
• Mannington Mills, Inc.:
• Overview 332
• Commercial Products. 332
• Residential Products 333
• Partnership with DuPont. 333
• Joint Venture 334
• Outlook. 334
• Mohawk Industries, Inc.:
• Overview 335
• Mohawk 335
• Dal-Tile. 336
• Manufacturing 336
• Distribution. 337
• News. 338
• Outlook. 338
• Financial Summary and Analysis 339
• Royalty Carpet Mills, Inc 340
• Shaw Industries, Inc.:
• Overview 341
• Brands 341
• Distribution. 342
• News. 342
• Outlook. 343
• Berkshire Hathaway 344

Superior Floor Company, Inc. 345

SECTION XI: INDUSTRY DIRECTORY

Introduction 346

Directory of Selected U.S. Manufacturers of Carpets and Rugs 347

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