Polystyrene and Polyurethane Foam Products in U.S. Building and Construction

Table of Contents

Executive Summary

• Polystyrene Foam Market Is Worth $7.2 Billion
• Table 1-1 U.S. Market for Polystyrene Foam by Shipment and Import-Export Values, 2002-2007 (in million $)
• Canada is Largest Exporter
• Consumer Products Comprise Half Polystyrene Foam Market
• Polyurethane Foam Market Is Valued at $6.4B
• Table 1-2 U.S. Market for Polyurethane Foam by Shipment and Import-Export Values, 2002-2007 (in million $)
• Germany is Largest Import Source
• Canada Has Highest Exports Value
• Building and Construction Foam Comprises 8% of the Total Market
• Figure 1-1 Total U.S. Market for Polyurethane Building and Construction Foam 2002-2007 (in million $)
• Total Building and Construction Foam Market Valued at $1.7B
• Table 1-3 U.S. Market for Polyurethane and Polystyrene Foam for Building and Construction 2002-2007 (in million $)
• Insulation Shipments
• Total Market Growth Due to Three Factors
  • Energy Costs Skyrocket
• The Products
  • Polyurethane Foam Products
• Producer Prices Rise
• Insulation Market Opportunities
• Thermal Insulation Products for the Construction Industry
• Foam Market at a Critical Juncture
  • Controlling Greenhouse Gas
  • Regulatory Control Measures Proposed
• USGBC and the LEED Program
• Implications for Sellers of Green Insulation
• Communicating Green Initiatives with Customers
• Market Value to Reach $18.7B by 2012

Chapter 2: Market Size and Growth

• Report Scope
• Methodology
• The U.S. Market
  • Polystyrene Foam Market Is Worth $7.2 Billion
  • Table 2-1 U.S. Market for Polystyrene Foam by Shipment and Import-Export Values, 2002-2007 (in million $)
  • Figure 2-1 Imports and Exports of Polystyrene Foam, Expressed as Percent of the Total Market, 2002-2007 (in million $)
  • Figure 2-2 Total U.S. Market for Polystyrene Foam, 2002-2007 (in million $)
  • Canada is Largest Exporter
  • Table 2-2 U.S. Imports of Polystyrene Foam, by Country of Shipment Origin, 2002-2007 (in million $)
  • Table 2-3 U.S. Exports of Polystyrene Foam, by Country of Destination, 2002-2007 (in million $)
  • Figure 2-3 Share of Total Market for U.S. Imports of Polystyrene Foam, by Country of Shipment Origin, 2002-2007 (in million $)
  • Consumer Products Comprise Half Polystyrene Foam Market
  • Table 2-4 U.S. Shipments of Polystyrene Foam, by Type of Product, 2002-2007 (in million $)
  • Building and Construction Polystyrene Foam Market Worth $1.2B
  • Table 2-5 U.S. Market for Polystyrene Building and Construction Foam by Shipment and Import-Export Values, 2002-2007 (in million $)
  • Figure 2-4 Total U.S. Market for Polystyrene Foam Used for Building and Construction, 2002-2007 (in million $)
  • Illinois is Largest Producer of Polystyrene Foam for Construction
  • Table 2-6 U.S. Shipments of Polystyrene Building & Construction Foam, by State, 2002-2007 (in billion $)
  • Polyurethane Foam Market Is Valued at $6.4B
  • Table 2-7 U.S. Market for Polyurethane Foam by Shipment and Import-Export Values, 2002-2007 (in million $)
  • Table 2-8 Total Value of the U.S. Market for Polyurethane Foam, 2002-2007 (in million $)
  • Germany is Largest Import Source
  • Canada Has Highest Exports Value
  • Table 2-9 U.S. Imports of Polyurethane Foam, by Country of Origin, 2002-2007 (in million $)
  • Table 2-10 U.S. Exports of Polyurethane Foam, by Country of Destination, 2002-2007 (in million $)
  • Figure 2-4 U.S. Imports of Polyurethane Foam, by Country of Origin, 2002-2007 (in million $)
  • Building and Construction Foam Comprises 8% of the Total Market
  • Table 2-11 U.S. Shipments for Polyurethane Foam by Product Category, 2002-2007 (in million $)
  • Table 2-12 U.S. Market for Polyurethane Building and Construction Foam by Shipment and Import-Export Values, 2002-2007 (in million $)
  • Polyurethane Foam for Construction Worth $492M
  • Figure 2-5 Total U.S. Market for Polyurethane Building and Construction Foam 2002-2007 (in million $)
  • Total Building and Construction Foam Market Valued at $1.7B
  • Table 2-13 U.S. Market for Polyurethane and Polystyrene Foam for Building and Construction 2002-2007 (in million $)
  • Insulation Shipments
  • Table 2-14 U.S. Market for Foam Insulation Compared to Other Foam Products for Building and Construction, 2002-2012 (in million $)
  • Figure 2-6 U.S. Market Share of Plastic Foam Insulation and Other Foam Products, 2002, 2007, and 2012
• Factors Influencing the Market
  • Manufacturing Sectors Grow
    • Table 2-15 Growth in U.S. Manufacturing Sectors, 1Q2007 vs. 1Q200830
  • Energy Consumption Affects Insulation Market
    • Growth in HVAC and Water Heating Systems
  • Total Market Growth Due to Three Factors
    • Energy Costs Skyrocket
    • Housing and Commercial Building Construction Slows
    • Table 2-16 Annual U.S. New Home Sales and Average Annual New Sales Price, 2000-2006
    • Home Renovation Market Declining
    • Table 2-17 U.S. Home Improvement Market, 2007-2012
    • Figure 2-7 U.S. Housing Market Index, by Region, 2007 to January 2008
    • Housing Starts and Home Sales Rebounding in 2009
    • Table 2-18 U.S. Housing Activity and Forecast, 2004-2009 (in thousands)
    • Construction Spending
    • Table 2-19 U.S. Construction Spending: Total, Private, Public,
    • Residential and Nonresidential, March 2007 vs. March 2008 (seasonally adjusted and annualized in million $)
    • Construction Industry Labor Force Will Grow
    • Chemical Manufacturing Employment Will Decline
    • Insulation Contractor Employment Will Grow
    • Table 2-20 U.S. Employment Outlook for Insulation Contractors, 2006 vs. 2016
  • Market Value to Reach $18.7B by 2012
    • Table 2-21 Projected U.S. Shipments for Polystyrene and Polyurethane Foam, by Category (2007 to 2012, in million $)
    • Figure 2-8 Projected Market Share of U.S. Shipments of Polystyrene and Polyurethane Foam, by Category, 2012
    • Table 2-22 Projected U.S. Shipments for Polystyrene and Polyurethane
    • Building and Construction Foam, by Category (2007 to 2012 in million $)
    • Figure 2-9 Total U.S. Market for Polystyrene and Polyurethane Foam, (2007 to 2012 in million $)

Chapter 3: Market Dynamics and Product Innovation

• The Products
  • Polystyrene Foam
  • Structural Insulated Panels Compete with ICF Market
  • Table 3-1 Comparison of Labor Hours and Cost of Labor for SIP-Built and 2" x 4" Batt Insulation
  • Polyurethane Foam Products
• Producer Prices Rise
  • Figure 3-1 PPI for Polyurethane Construction Foam is Higher than Packaging Foam
  • Figure 3-2 Producer Price Index of Polyurethane Foams Used for Packaging and Building & Construction, 2006 vs. 2007
  • Insulation Market Opportunities
  • Table 3-2 R-Value of Thermal Insulation Materials (Higher R Value Translates into Better Insulation)
  • Table 3-3 Thermal Insulation Levels for Homes Recommended by the U.S. Department of Energy
  • Table 3-4 Summary of Energy Prices, 2006 to 2009
  • Table 3-5 Historic Trends of Energy Consumption by Type of Fuel, 2002 to Jan. 2008
  • Figure 3-3 Annual Consumption of Energy Sources in the U.S. (quadrillion BTUs), 2002 to 2012
• Thermal Insulation Products for the Construction Industry
  • Thermal Concrete Insulation
  • Insulation Innovations Rapidly Emerging
  • Insulated Vinyl Siding

Chapter 4: Marketing and Distribution

• Foaming at the Mouth
  • Polyurethane Foam Manufacturers Cope with Negative Publicity
  • XPS Marketing Efforts Have been Slow
  • Controlling Greenhouse Gas
  • Regulatory Control Measures Proposed
  • Table 4-1 Annual Energy Savings and Greenhouse Gases Reduced from Using Foam Sheathing on External House Walls
  • Manufacturers Increase Green Output
  • USGBC and the LEED Program
    • Other Green Building Tools Emerge
  • LEED Project Trends
    • Table 4-2 LEED-Certified Projects, 2000-2007 (number and percent)
  • Implications for Sellers of Green Insulation
    • Figure 4-2 Estimated Growth of U.S. Green Insulation Market Revenues, 2002-2007 (in $ millions)
  • Communicating Green Initiatives With Customers
  • Retailers On Board - Lowe' s and Home Depot Test Their Strategies
    • Eco Options Branding
    • Lowe' s Leaves Product Claims to Third Parties
    • Direct Sales Teams
    • Distributors/Retailers
    • Dealer and Builder Programs
    • Websites

Chapter 5: Manufacturer Profiles

• BASF
  • Figure 5-1 Share of BASF Sales by Business Segment, 2007
  • Table 5-1 BASF Sales and Year-Over-Year Percent Growth, 2004-2007 (in billion $)
• Dow Chemical
  • Table 5-2 Dow Chemical and Year-Over-Year Percent Growth, 2004- 2007 (in billion $)
  • Dow Acquires Polyurethane Manufacturer
  • Table 5-3 Dow Chemical Insulation Product Line
• Bayer MaterialScience
  • Figure 5-2 Bayer Group Share of Company Revenue by Business Unit 83
  • Table 5-4 Bayer MaterialScience Revenues and Year-Over-Year Growth, 2004 to 2007 ($ billions)
• Chevron Phillips Chemical Co
  • Table 5-5 Chevron Phillips Chemical Revenues and Year-Over-Year Growth, 2004 to 2007 ($billions)
• Owens Corning
  • Table 5-6 Owens Corning Revenues and Year-Over-Year Growth, 2004 to 2007 ($ billions)
  • Table 5-7 Brand Portfolio of Owens Corning Company for Thermal Insulation
• Carlisle Companies
  • Table 5-8 Carlisle Companies Revenues and Year-Over-Year Growth, 2004 to 2007 ($billions)
  • Table 5-9 Brand Portfolio of Carlisle Companies Incorporated for Thermal Insulation
• Johns Manville Corporation
  • Table 5-10 Brand Portfolio of Johns Manville Corporation for Thermal Insulation

Chapter 6: End Users

• Housing Construction Activity Affects Foam Purchases
  • Table 6-1 Total Spending on Construction in the U.S., April 2008 vs. April 2007 ($ millions)
  • Type of Construction
  • Table 6-2 U.S. Consumer Spending on Household Improvements, Maintenance and Repairs ($ billions), 2003 to 2007
• Home Improvement Project Spending Will Grow
  • Figure 6-1 Quarterly Spending in Homeowner Remodeling ($ billions) and Year-Over-Year Growth, 2005 to 2008 (e)
  • Table 6-3 Projects Involving Interior and Exterior Replacements
• Remodeling Activity Increased In Early 2008
  • Figure 6-2 National Association of Home Builders Remodeling Market Index of Additions and Alterations, 2002 to 2007
  • Figure 6-3 National Association of Home Builders Remodeling Market Index by Region, 2001 to 2007
• Consumer Interest Increases in Energy-Efficiency Remodeling
  • Table 6-4 Types of Equipment or Fuel Used to Heat U.S. Homes, 1995 to 2005
• Owners of Older Homes More Vulnerable to Energy Cost Increases
  • Table 6-5 Amount Spent on Insulation Remodeling Improvements, by Age Group and Gender (past 12 months)
• Spending on Remodeling Projects Will Grow Through 2015
• Rising Demand of "Green" Products
• Consumer Spending On Green Will Double, Reach $500 Billion In 2008

Appendix