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US Refractories Market, Freedonia

  • June 2015
  • -
  • Freedonia
  • -
  • 238 pages

US demand to grow 3.3% annually through 2019
US demand for refractories is forecast to increase 3.3 percent per year through 2019 to $3.1 billion. This will represent a deceleration from robust 2009-2014 gains, as crude steel production in the US slows. Sales will also be limited by moderating output in a number of other durable goods manufacturing industries, many of which utilize refractories to at least some extent. Furthermore, a shift in demand toward better performing refractories, while providing an initial boost to sales based on their premium prices, will cause market growth to slow in the long run as replacement cycles are extended. However, continued increases in the price of raw refractory materials will support value gains. Additionally, the nonmetallic minerals market, which is expected to grow the fastest, utilizes some of the highest cost refractories, boosting overall dollar growth.

Nonmetallic minerals to post fastest market growth

When measured in volume terms, demand increases will be much more sluggish, averaging under one percent per year through 2019, when sales will total 2.3 million tons. Improvements in refractory designs have enabled end users to utilize less weight per ton of output, adversely affecting demand. Among specific markets, nonmetallic minerals will record the fastest demand advances through 2019, supported by an acceleration in shipments of cement and mineral, and ceramic products. Overall refractory market advances will be limited by the modest increases in iron and steel production in the US. The health of the iron and steel industry, which comprises the largest share of refractory demand by volume, has a major impact on overall refractory demand.

Nonclay refractories to outpace clay types

Growth opportunities for suppliers of nonclay refractories will be greater than those for clay refractories in dollar terms. Nonclay refractories typically present a number of performance advantages that boost their usage in more demanding applications, and nonclay refractory prices will rise faster than those for clay products, boosting value gains. However, the lower cost of clay refractories ensures their continued usage, especially when the performance advantages of nonclay refractories are not required.

US producers to gain from technological edge

Although the US has a small trade surplus in refractories in dollar terms, the country is both a large importer and exporter of refractories. The US typically imports lower cost commodity type products, while exporting higher value, advanced refractories. As a result, the nation is a small net importer of refractories in volume terms; the US had a trade deficit of 22,000 tons in 2014, equivalent to one percent of domestic demand. Shipments of refractories are expected to rise 2.7 percent yearly in value terms to $3.1 billion, while in volume terms shipments will grow less than one percent per year to 2.3 million tons in 2019. As is the case with demand, domestic production gains will be limited by the modest gains expected for iron and steel production in the US. Domestic producers of refractories will continue to see competition from low cost sources of supply, notably China and Mexico. Despite this, the technological advantage that US refractory producers have will continue to pose opportunities for growth, as the global trend toward usage of better performing refractories will favor output by US manufacturers.

Study coverage

This upcoming industry study, Refractories, presents historical demand data (2004, 2009 and 2014) plus forecasts (2019 and 2024) by refractory form, material and market. The study also considers market environment factors, assesses the industry structure, evaluates company market share and profiles 25 competitors in the US industry.

Table Of Contents

US Refractories Market, Freedonia
TABLE OF CONTENTS
INTRODUCTION viii
I. EXECUTIVE SUMMARY 1
II. MARKET ENVIRONMENT 4
General 4
Macroeconomic Trends 5
Fixed Investment Trends 9
Manufacturing Outlook 12
Refractory Technology 16
Basic Refractory Properties 18
Refractory Shapes and Forms 21
Refractory Materials 22
Other Technological Developments 24
Pricing Trends 25
Historical Market Trends 28
International Environment 31
World Supply and Demand 32
Foreign Trade 35
Imports 36
Exports 39
III. FORMS 42
General 42
Refractory Supply and Demand by Value 43
Refractory Supply and Demand by Volume 46
Refractory Bricks and Shapes 49
Standard Bricks 52
Preformed Shapes 54
Monolithic Refractories 57
Castables 60
Plastic and Ramming Mixes 62
Gunning Mixes 64
Bonding and Other Mortars 67
Other Refractory Forms 69
IV. MATERIALS 72
General 72
Refractory Supply and Demand by Value 73
Refractory Supply and Demand by Volume 75
Nonclay Refractory Products 78
Magnesite and Chrome 82
Zircon and Zirconia 86
Extra-High Alumina 88
Ceramic Fibers 91
Silicon Carbide 94
Graphite and Carbon 96
Mullite 98
Silica 100
Dolomite and Other Nonclay Refractories 103
Clay Refractory Products 106
High-Alumina 110
Fireclay 111
Insulating 114
V. MARKETS 117
General 117
Metals Industries 122
Outlook 122
Iron and Steel 124
Nonferrous Metals 125
Metal Casting and Fabrication 127
Refractory Market 127
Iron and Steel 129
Nonferrous Metals 134
Metal Casting and Fabrication 137
Nonmetallic Mineral Processing Industries 139
Outlook 139
Refractory Market 141
Ceramics 142
Glass 144
Cement, Lime, and Other Mineral Processing 146
Engineering Contractors 149
Nonmanufacturing Industries 151
Petroleum and Chemicals 153
Other Manufacturing Industries 156
VI. INDUSTRY STRUCTURE 159
General 159
Industry Composition and Restructuring 160
Market Share 163
Leading Refractory Suppliers 164
Significant Raw Material Suppliers 168
Product Development and Manufacturing 169
Marketing and Distribution 172
Company Profiles 175
Alcoa Incorporated 176
Allied Mineral Products Incorporated 177
Almatis GmbH 179
Alteo Holding 182
AluChem Incorporated 183
American Precast Refractories, see Allied Mineral
Products
ANH Refractories, see HarbisonWalker International
Asbury Carbons Incorporated 185
BNZ Materials Incorporated 186
Calderys, see Imerys
CerCo LLC 188
Cookson Group, see Vesuvius
Corning Incorporated 189
HarbisonWalker International 190
Imerys SA 193
Kerneos SA 199
Lhoist SA 201
Luossavaara-Kiirunavaara AB 202
Magneco/Metrel Incorporated 203
Magnesita Refratários SA 205
Metallurgica, see Vesuvius
Minerals Technologies Incorporated 207
Minteq International, see Minerals Technologies
Morgan Advanced Materials plc 210
Plibrico Company LLC 214
Refractory Specialties, see Unifrax
Resco Products Incorporated 216
RHI AG 218
Saint-Gobain 220
Specialty Ceramics, see Unifrax
TYK Corporation 224
Unifrax I LLC 225
VacuForm, see Unifrax
Veitsch-Radex America, see RHI
Vesuvius plc 228
Other Companies Mentioned in the Study 232

LIST OF TABLES
SECTION I -- EXECUTIVE SUMMARY
Summary Table 3
SECTION II -- MARKET ENVIRONMENT
1 Macroeconomic Indicators 9
2 Nonresidential Fixed Investment 12
3 Manufacturers' Shipments 16
4 Selected US Manufacturer Refractory Pricing 27
5 Refractory Demand, 2004-2014 30
6 US Foreign Trade in Refractories 36
7 US Refractory Imports by Source, 2004-2014 38
8 US Refractory Exports by Destination, 2004-2014 40
SECTION III -- FORMS
1 Refractory Supply and Demand by Form in Value Terms 45
2 Refractory Supply and Demand in Volume Terms 48
3 Refractory Brick and Shape Supply and Demand 51
4 Standard Brick Refractory Shipments 54
5 Preformed Shape Refractory Shipments 57
6 Monolithic Refractory Supply and Demand 60
7 Castable Refractory Shipments 62
8 Plastic and Ramming Mix Refractory Shipments 64
9 Gunning Mix Refractory Shipments 66
10 Bonding and Other Mortar Refractory Shipments 68
11 Other Refractory Form Supply and Demand 71
SECTION IV -- MATERIALS
1 Refractory Supply and Demand by Material in Value Terms 74
2 Refractory Supply and Demand by Material in Volume Terms 77
3 Nonclay Refractory Supply and Demand 80
4 Magnesite and Chrome Refractory Shipments 85
5 Zircon and Zirconia Refractory Shipments 88
6 Extra-High Alumina Refractory Shipments 91
7 Ceramic Fiber Refractory Shipments 94
8 Silicon Carbide Refractory Shipments 96
9 Graphite and Carbon Refractory Shipments 98
10 Mullite Refractory Shipments 100
11 Silica Refractory Shipments 102
12 Dolomite and Other Nonclay Refractory Shipments 105
13 Clay Refractory Supply and Demand 108
14 High-Alumina Clay Refractory Shipments 111
15 Fireclay Refractory Shipments 114
16 Insulating Clay Refractory Shipments 116
SECTION V -- MARKETS
1 Refractory Demand by Market 120
2 Metals Industry Indicators 124
3 Metals Industry Refractory Market 129
4 Iron and Steel Production Refractory Market 130
5 Nonferrous Metal Production Refractory Market 137
6 Metal Casting and Fabrication Refractory Market 138
7 Nonmetallic Mineral Product Shipments 140
8 Nonmetallic Mineral Product Refractory Market 141
9 Ceramics Refractory Market 144
10 Glass Refractory Market 146
11 Cement, Lime, and Other Mineral Processing Refractory Market 149
12 Engineering Contractor Refractory Market 151
13 Nonmanufacturing Industries Refractory Market 153
14 Petroleum and Chemical Refractory Market 155
15 Other Manufacturing Industries Refractory Market 158
SECTION VI -- INDUSTRY STRUCTURE
1 US Refractory and Raw Material Sales by Company, 2014 162
2 Capital Spending Patterns: Selected Refractory Manufacturers 172

LIST OF CHARTS
SECTION II -- MARKET ENVIRONMENT
1 Melting Points of Industrial Materials and Refractories 20
2 Selected US Manufacturer Refractory Pricing, 2004-2024 28
3 Refractory Demand, 2005-2014 31
4 World Refractory Demand by Region, 2014 34
5 US Refractory Imports by Source, 2014 39
6 US Refractory Exports by Destination, 2014 41
SECTION III -- FORMS
1 Refractory Demand by Form in Value Terms, 2004-2024 46
2 Refractory Demand by Form in Volume Terms, 2004-2024 49
SECTION IV -- MATERIALS
1 Refractory Demand by Material in Value Terms, 2004-2024 75
2 Refractory Demand by Material in Volume Terms, 2004-2024 78
3 Nonclay Refractory Shipments by Material, 2014 81
4 Clay Refractory Shipments by Material, 2014 109
SECTION V -- MARKETS
1 Refractory Demand by Market, 2014 121
SECTION VI -- INDUSTRY STRUCTURE
1 US Refractory Market Share, 2014 164

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