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Examine the US Refractories Market

February 22, 2008

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US Refractories Market

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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

US Refractories Market

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