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US demand to reach $2.5 billion in 2011



US demand for refractory products is forecast to advance 1.8 percent per annum to $2.5 billion in 2011, accelerating from the 2001-2006 period. Gains will be driven by strong growth in shipments of nonmetallic mineral products, particularly cement, as nonresidential and nonbuilding construction expenditures are expected to accelerate. Growth will also be supported by the increasing use of better performing, more expensive refractories, which will bolster demand in value terms through 2011. Advances will be somewhat restrained, on the other hand, by slowing steel production growth and a weak outlook for fabricated metals.



Shipments of refractories are projected to rise 1.3 percent per year, a slower pace than demand, and the US is expected to slip into a trade deficit in refractory products by 2011. In volume terms, shipments are expected to decline, falling to 2.9 billion tons in 2011, as refractory products continue to become more efficient and thereby longer lasting. Imports will increase more rapidly than exports, in part the result of recent policy changes in China that tax the export of raw materials to promote the export of finished refractories.



Bricks, shapes to outpace monolithics



Among refractory forms, demand for bricks and shapes is expected to advance more rapidly than for monolithics, as preformed shapes continue to be increasingly utilized due to the performance advantages they offer, such as reduced heat-up time. However, demand for monolithic bonding and other mortars is projected to grow at an above-average pace, as the use of these products provides an economic advantage by extending the time-span between brick relinings. Clay refractories are expected to outperform nonclay refractories through 2011, benefiting from rising use of higher-value materials such as high alumina due to their superior performance attributes.



Nonmanufacturing markets to be fastest growing



Refractory demand from nonmanufacturing industries will grow at the fastest pace through 2011, supported by the increased use of stone-ovens in restaurants, as well as the growing popularity of outdoor fireplaces. The largest dollar gains are expected in the nonmetallic mineral products market, which will increase more in value terms than the considerably larger metal products market, despite its smaller size. Gains in this market will be spurred by strong growth in ceramics, cement and miscellaneous mineral product output, fueling demand for associated refractories.



Study coverage



It presents historical demand data for the years 1996, 2001 and 2006 and forecasts for 2011 and 2016 by refractory form, material and market. The study also considers market environment factors, evaluates company market share and profiles leading industry competitors.

INTRODUCTION

I. EXECUTIVE SUMMARY 1

II. MARKET ENVIRONMENT 4
General 4
Macroeconomic Trends 5
Capital Spending/Fixed Investment Trends 9
Manufacturing Sector Outlook 12
Durable Goods 14
Nondurable Goods 14
Technology 15
Basic Refractory Properties 17
Refractory Shapes & Forms 20
Refractory Materials 21
Other Technological Developments 23
Pricing Trends 24
Refractory Market Trends 27
International Environment 30
World Supply & Demand 31
Trends in US Foreign Trade 34
Imports 36
Exports 39

III. FORMS 42

General 42
Refractory Bricks & Shapes 45
Standard Bricks 47
Preformed Shapes 50
Monolithic Refractories 52
Castables 54
Plastics & Ramming Mixes 56
Gunning Mixes 58
Bonding & Other Mortars 60
Other Refractory Forms 61


IV. MATERIALS 64

General 64
Nonclay Refractory Products 67
Magnesite & Chrome 71
Zircon & Zirconia 74
Extra-High Alumina 77
Ceramic Fibers 79
Silicon Carbide 82
Graphite & Carbon 84
Silica 86
Mullite 88
Dolomite & Other Nonclay Refractories 90
Clay Refractory Products 93
High-Alumina 98
Fireclay 100
Insulating 102

V. MARKETS 105

General 105
Metal Industries 109
Outlook 110
Iron & Steel 111
Nonferrous Metals 114
Metal Casting & Fabrication 115
Refractory Market 116
Iron & Steel 118
Steelmaking Technology 119
Steel Refractory Manufacturers & Products 122
Nonferrous Metals 122
Metal Casting & Fabrication 125
Nonmetallic Mineral Processing Industries 127
Outlook 128
Refractory Market 129
Ceramics 130
Glass 133
Cement, Lime & Other Mineral Processing 136
Engineering Contractors 138
Nonmanufacturing Refractory Market 140
Petroleum & Chemicals 142
Other Manufacturing Industries 144


VI. INDUSTRY STRUCTURE 147

General 147
Industry Composition & Restructuring 148
Market Share 152
Leading Refractory Producers 153
Significant Raw Material Suppliers 156
Product Development & Manufacturing 158
Marketing & Distribution 162
Mergers, Acquisitions & Industry Restructuring 164
Company Profiles 167
Alcoa Incorporated 168
Allied Mineral Products Incorporated 169
Almatis GmbH 171
AluChem Incorporated 173
American Precast Refractories, see Allied Mineral Products
ANH Refractories Company 175
Asbury Carbons Incorporated 178
BNZ Materials Incorporated 179
CALDERYS, see Imerys SA
C-E Minerals Incorporated, see Imerys SA
CerCo LLC 181
Chemical Lime Company, see Lhoist SA
Chicago Fire Brick, see Allied Mineral Products
Cookson Group plc 182
Corning Incorporated 185
Harbison-Walker Refractories, see ANH Refractories
Imerys SA 187
Kerneos Incorporated, see Materis Holding Luxembourg SA
Kyanite Mining Corporation 191
Lhoist SA 192
LWB Refractories GmbH & Company KG 193
Magneco/Metrel Incorporated 195
Materis Holding Luxembourg SA 196
Matrix Refractories, see Allied Mineral Products
McDanel Advanced Ceramic Technologies LLC 198
Minerals Technologies Incorporated 199
Minteq International, see Minerals Technologies
Monofrax Incorporated, see RHI AG
Morgan Crucible Company plc 202
Morganite Crucible Incorporated, see Morgan Crucible
New Castle Refractories Company, see Resco Products
North American Refractories, see ANH Refractories
Plibrico Company 206
Resco Products Incorporated 208
RHI AG 211
Rio Tinto Group 214
Saint-Gobain 216
Shenango Advanced Ceramics LLC, see Resco Products
Thermal Ceramics Americas, see Morgan Crucible
Timcal SA, see Imerys SA
Treibacher Schleifmittel North America, see Imerys SA
TYK Corporation 220
Unifrax I LLC 221
Vesuvius Group SA, see Cookson Group plc
World Minerals Incorporated, see Imerys SA
Worldwide Refractories Incorporated, see Resco Products
Other Refractory Manufacturers 224
Other Refractory Raw Material Suppliers 236

SECTION I -- EXECUTIVE SUMMARY
1 Summary Table 3

SECTION II -- MARKET ENVIRONMENT

1 Economic Indicators 9
2 Nonresidential Fixed Investment 11
3 Manufacturers’ Shipments by Industry 13
4 Selected Refractory Pricing 26
5 Refractory Market, 1996-2006 29
6 World Refractory Demand by Region 34
7 US Foreign Trade in Refractories 36
8 US Refractory Imports by Source 38
9 US Refractory Exports by Destination 40

SECTION III -- FORMS

1 Refractory Supply & Demand by Form 44
2 Refractory Brick & Shape Supply & Demand 47
3 Standard Brick Refractory Shipments 49
4 Preformed Shape Refractory Shipments 52
5 Monolithic Refractory Supply & Demand 54
6 Castable Refractory Shipments 56
7 Plastic & Ramming Refractory Shipments 58
8 Gunning Mix Refractory Shipments 59
9 Bonding & Other Mortar Refractory Shipments 61
10 Other Refractory Form Supply & Demand 63

SECTION IV -- MATERIALS

1 Refractory Supply & Demand by Material 66
2 Nonclay Refractory Supply & Demand 69
3 Magnesite & Chrome Refractory Shipments 74
4 Zircon & Zirconia Refractory Shipments 77
5 Extra-High Alumina Refractory Shipments 79
6 Ceramic Fiber Refractory Shipments 82
7 Silicon Carbide Refractory Shipments 84
8 Graphite & Carbon Refractory Shipments 86
9 Silica Refractory Shipments 88
10 Mullite Refractory Shipments 90
11 Dolomite & Other Nonclay Refractory Shipments 93
12 Clay Refractory Supply & Demand 96
13 High-Alumina Clay Refractory Shipments 99
14 Fireclay Refractory Shipments 102
15 Insulating Clay Refractory Shipments 104

SECTION V -- MARKETS

1 Refractory Demand by Market 107
2 Metal Industry Indicators 111
3 Metal Industry Refractory Market 117
4 Iron & Steel Production Refractory Market 118
5 Nonferrous Metal Production Refractory Market 125
6 Metal Casting & Fabrication Refractory Market 127
7 Nonmetallic Mineral Product Shipments 129
8 Nonmetallic Mineral Product Refractory Market 130
9 Ceramic Refractory Market 132
10 Glass Refractory Market 135
11 Cement, Lime & Other Mineral Processing Refractory Market 138
12 Engineering Contractor Refractory Market 140
13 Nonmanufacturing Refractory Market 141
14 Petroleum & Chemical Refractory Market 144
15 Other Manufacturing Industries Refractory Market 146

SECTION VI -- INDUSTRY STRUCTURE

1 Revenue Data: Selected Refractory & Raw Materials
Manufacturers, 2006 151
2 Capital Spending Patterns: Selected Refractory Manufacturers 161
3 Selected Acquisitions & Divestitures 166


LIST OF CHARTS

SECTION II -- MARKET ENVIRONMENT
1 Melting Points of Industrial Materials & Refractories 18
2 Selected Refractory Pricing, 1996-2016 27
3 Refractory Market, 1997-2006 30
4 US Refractory Imports by Source, 2006 39
5 US Refractory Exports by Destination, 2006 41
SECTION III -- FORMS
1 Refractory Demand by Form, 1996-2006 45
SECTION IV -- MATERIALS
1 Refractory Demand by Material, 1996-2016 67
2 Nonclay Refractory Shipments by Material, 2006:
Value Vs. Volume 70
3 Clay Refractory Shipments by Material, 2006:
Value Vs. Volume 97
SECTION V -- MARKETS
1 Refractory Demand by Market, 2006 108
2 Additional Refractory Demand by Market, 2006 Vs. 2011 108
SECTION VI -- INDUSTRY STRUCTURE
1 US Refractory Market Share by Company, 2006 153