a market exploration prepared by annette j. carroll€¦ · a market exploration prepared by...

Composites in Building & Construction

A Market Exploration

Prepared by Annette J. Carroll

Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture


At a Glance

Building / construction considered mature market; composites in b/c fairly new (last 20 years or so)

JEC Composites (int’l composites org) estimates global composites market to be 53B Euro

B/C estimated to represent 21% = 11.1B – 11.4B Euro

30% of the material volume



At a Glance

In the US…

Estimated B/C market (2007 – 2008) - $1.2 – 1.6 Trillion (US Census)

Estimated composites market within B/C1:

2007 - $4.740 Billion (based on reported shipments)

2008 - $4.769 Billion (based on reported shipments)

Estimated raw composite material inputs1:

2007 - $1.310 Billion

2007 – 1.418 Billion Pounds (based on shipments)

2008 – Estimated 1.6 Billion Pounds (reference ACMA2)

Reference 1: Researchandmarkets.com – Article Excerpts – Opportunities for Composites in the North American Construction Market 2008 –2013: Trends, Forecast, and Opportunity Analysis

Reference 2: American Composite Manufacturers Association



At a Glance Composites in B/C encompass many entities, including:

Doors, garage doors, windows

Decks

Roofing

Rebar (hybrid steel bar using for concrete reinforcement)

Utility poles

Bridge decks

Grating systems (road, run-off drains, etc.)

Cooling towers (heat removal devices to transfer process waste heat to atmosphere)

Bathtubs / sinks / hot tubs / jacuzzis

Countertops

Swimming pools

Wall and floor panels

Architectural structuresAnd the List Goes On!!!



Market at a Glance – 2005 - Fiberglass

Thermoset –once polymers are formed and linked to polymer chain, can’t be reformed



Market at a Glance – 2006 - Fiberglass

Thermoset –once polymers are formed and linked to polymer chain, can’t be reformed



Market at a Glance – 2004 – Fiberglass – Thermoset & Thermoplastic

Thermoplastic –polymers linear (not joined); can be reheated and reformed



Market at a Glance – FRP compared to Metals



Common Types of Composites: Fiberglass:

Glass fiber reinforced concrete (GFRC)

Glass reinforced plastic (GRP)

Fiberglass reinforced polymer (FRP) - polyester, plastic -commonly used in wall panels

Carbon fiber reinforced polymer (CFRP) – clusters of carbon atoms commonly used to reinforce plastic and fabric

Plywood (layers of wood veneer bonded with adhesive glue)

Fiberboard - extruded wood / glue combinations (HDF, MDF, LDF)

Plastic-covered wood

Cladding (dissimilar metals and alloys bonded together – typically by an extrusion process)

Foam and adhesive glue

Honeycomb (in limited instances)



Production Methods at a Glance

Open Molding

Hand Lay-Up Manual Resin Application Mechanical Resin Application

Chopped Laminate Process Atomized Spray-Up Non-Atomized Application

Filament Winding

Closed Molding

Compression molding Sheet Molding Compound (SMC) Bulk Molding Compound (BMC) Thick Molding Compound (TMC) Low Pressure Molding Compound (LPMC) Wet Lay-Up Compression Molding

Pultrusion Reinforced Reaction Injection

Molding (RRIM) Resin Transfer Molding (RTM) Vacuum Bag Molding

Wet Lay-Up Prepreg

Vacuum Infusion Processing Centrifugal Casting Continuous Lamination

Reference: ACMA – American Composite Manufacturers Association



A look at composites by market segments:

Infrastructure

Housing

Architectural /

Commercial Structures



InfrastructureDefined as:

Roadways

Temporary and permanent bridges / overpasses (over 578,000 in US on public roads)

Utility poles, grids, and distribution systems

Flag poles

Parking garages and like structures

Civil engineers beginning to compare traditional materials to composites based on3:

Extending service life of existing structures

Building for weather and seismic resistance

Protecting from bomb blasts and other terrorist acts

Ease of installation / portablenessReference 3: ASCE – American Society of Civil Engineers – www.asce.org



Infrastructure

Some composite bridge makers:

Composite Advantage - FRP technology –www.compositeadvantage.com

Vectorply – www.vectorply.com

Zellcomp – www.zellcomp.com

Hardcore Composites

Common composite materials:

Steel-reinforced concrete – but problems with exposed steel when concrete crumbles or deteriorates

Plastic reinforced with fibers – gaining momentum as a solution for repair and replacement of substandard bridges



Infrastructure

Quote from Article in Composites Technology dated 1/26/2009If CT is the preacher of the composites faith, consider yourself the choir: There is a whole universe of contractors, road builders, bridge builders and government transportation managers who not only don’t know a spool of glass fiber from a spool of thread, but also have unrelenting faith in the traditional materials that are now in such dire need of repair…

Tape Relevance / Potential: Little evidenced at this point, very nuts and bolts oriented – less than $15M, but…



Infrastructure



Housing

Residential Temporary



Housing - Residential

Composite materials are playing a fragmented role in portions of residential housing and ancillary structures.

Focus areas include: Windows and skylights Doors Garage doors Decks, fencing, and railings Decorative trims & moldings Bathtubs / showers / jacuzzis / hot tubs Plumbing fixtures Countertops Swimming pools Flooring Roofing systems



Housing – Residential –Common Composite Components

Fiberglass

PVC

Glass reinforced plastics

Wood / plastic

Steel / aluminum / metal combinations

Clay / polymer combinations

Composite Benefits Over Wood:

Low to no maintenance

Moisture resistant

Energy efficiency

Reference: Builder Magazine – www.builderonline.com



Housing – Residential – Windows & Skylights

Window and Door Mfr Association reports sales of composites still relatively small, but manufacturers are continuing to experiment with materials

Composite types being tested / used:

PVC (lion’s share)

Aluminums / vinyl

Fiberglass

Wood / plastic

Composite Benefits Over Wood:

Low to no maintenance

Moisture resistant

Energy efficiency




Potential Tape Applications Include: Glazing - Sealing glass into window or skylight frame Sealing elements (windows, skylights, etc) around / on

sheathing- first wall or roof board system attached to structural frame

Surface protection – during transport and installation; for glass and framing elements (e.g. Novacel Inc.)

General masking




Tape Potential: $20M+

Some Window & Skylight Manufacturers:

Fibertec Window & Door Mfg. – www.fibertec.com

Traco – www.traco.com

CW Ohio Inc. – www.cwohio.com

Euro-tech Window Ind. – www.eurotechwindows.ca

Inline Fiberglass – www.inlinefiberglass.com

Peachtree Doors and Windows – www.peachtreedoor.com

Pella – www.pellacommercial.com

Armortex – www.armortex.com – interesting bullet and blast-resistant windows




Some Tape Providers:

3M – www.mmm.com

Permacel – www.permacel.com

St. Gobain (foams, teflons, glass cloths) -www.saint-gobain-corporation.com

Gaska Tape, Inc. (foams) – www.gaska.com

Norton (foams) – www.nortonfoam.com(div. of St. Gobain)

Hardcast / Carlisle – www.hardcast.com –TGM-3300, TPO-2265

Tamlyn – www.tamlyn.com –WS25 Product Series, PNS Product Series

Cofair Products – www.cofair.com

Scapa – www.scapa.com



Housing – Residential – Doors

Some movement toward composite doors as replacements for wood doors

Common composite combinations include:- aluminum - PVC- steel- fiberglass- GRP (Glass Reinforced Plastic) top-coat skin

Common cores:- MDF - polyurethane foam- honeycomb (can be cardboard)




Benefits include: Low maintenance, never

needs repainting Repels water Not attractive to insects


Potential Tape Applications:

Venting – for foam core blown doors

Door sweep

Bottom rail decorative and protective panels

Glass glazing / muntin bars



Wood Combo Doors:

Mortise and tennon joints secured with fasteners


Glazing Bar – ADL (Actual Divided Light Bar)

Muntin Bar – SDL (Simulated Divided Light Bar)


Housing – Residential – DoorsSome Composite Door Makers (includes some windows):

ASI Technologies, Inc. (Milwaukee WI)

Arcoplast, Inc. (Saint Peters MO)

Ceco Door Products (Milan TN)

Chem-Pruf Door Co., Inc. (Brownsville TX)

Dunbarton Door and Entry Systems (Dothan AL)

Duraplate Products

Europe's Best Windows & Doors (Chesapeake VA)

Fib-R-Dor (Maumelle AR)

Fibertec Window Mfg Ltd (Concord ON)

Inline Fiberglass Ltd (Toronto ON)

JELD-WEN, Inc. (Klamath Falls OR)

Lynden Door Inc. (Lynden WA)

MI Windows & Doors, Inc. (Gratz PA)

Markar Architectural Products, Inc. (Lancstr NY)

Milgard Windows, Inc. (Tacoma WA)

Newmar Window Mfg Inc (Mississauga ON)

Pease Inds., Inc. (Fairfield OH)

Rusco Window Co., Inc. (Roanoke VA)

Scatton Manufacturing Co. (North Wales PA)

Special-Lite, Inc. (Decatur MI)

Supa Doors Inc. (Universal City TX)

Supa Doors Inc. (Universal City TX)

Taylor Building Products (West Branch MI)

Therm-O-Lite (South Bend IN)

Therma-Tru Corp. (Maumee OH)

Warminster Fiberglass (Southampton PA)




Tape Potential: Up to $20M



Housing – Residential – Garage Doors

Garage door manufacturers now offering products comprised of wood fibers + resins + insulation.


1 – Laminated support rails

2 – Polystyrene insulation

3 – Engineered thermoset resin / cellulose door skin

4 – Composite skin and trim boards


Housing – Residential – Garage Doors

Some Manufacturers:

Jeld-wen – www.jeld-wen.com

Amarr – www.amarr.com

Aspen Garage Doors – www.aspengaragedoors.com


Benefits: Resists dents, rusting, and warping Skins and trim boards made from recycled materials

Tape / Adhesive Applications: Applying weather stripping to bottom of door

(rubber, other) Possibly applying decorative handles / trims Vent tape (for blown insulation) Possible transit surface protection



Housing – Residential – Decks, Fencing / Railings

A 2005 study by The Freedonia Group concluded that wood accounted for 97 percent of volume in the decking market with alternative decking materials showing minimal penetration.

Composite decking will provide the strongest growth opportunities, posting 15 percent annual growth through 2009 to almost 900 million board feet,” the report concluded. (Article: On Deck Hitters – builderonline.com – July, 2007)

www.timbertech.com




Common composites are a blend of woods(LDF, MDF, HDF3) with some form of plastic coverings (such as PVC).

Another common composite is “plastic lumber”, which consists of a variety of recycled plastics reinforced with fiberglass; contains no wood elements.

Debate continues over durability and structural integrity of wood verses composite materials.

Fastening / joining systems seem to still be very hardware intensive.

www.timbertech.com

www.correctdeck.comReference 3: LDF – Low density fiber; MDF – Medium density fiber; HDF – high density fiber




www.timbertech.com

www.correctdeck.com

Tape / Adhesive Applications:

Perhaps some transit surface protection; little to no fastening needs

Tape Potential: Less than $10M



Housing – Residential – Siding

www.revolutionsiding.com

Man-made boards for use as exterior siding from various combinations of wood fibers, fillers, fiber cement, binders and glue. These mixtures are heated and compressed into composite wood products. To simulate the “wood look”, embossed overlayments are added.

Vertical joining system fastens planks together, so many boards do not require adhesives, although trim work seems to need fasteners – see next section on Trims / Moldings.

Tape Applications: Limited with the possible exception of exterior trims / moldings (later reference) and possible transit surface protection.




Housing – Residential –

Decks, Fencing / Railings, Siding


Just an interesting tidbit


Housing – Residential – Siding

Some Composite Siding Manufacturers:

Revolution Siding – www.revolutionsiding.com

Boston Cedar – www.bostoncedar.com

LP Corporation – www.lpcorp.com



Housing – Residential – Trims & Moldings

Tape Applications:

Traditional fasteners (nails, glues) are currently being used to attach trims and molds; although exterior trims need stainless steel fasteners to prevent rusting.

Tape Potential: $20M+ Definite fastening tape potential here, along with some transit surface protection opportunities.

Interior and exterior composite trims / moldings becoming common and popular.

Common composite types include wood fibers + resins + glues plastics + wood fibers

Common manufacturing process includes sealed press injected with steam; bonded under heat and pressure.



Housing – Residential – Trims & Moldings

Some Composite Trim Manufacturers:

Azek – www.azek.com

Fypon – www.fypon.com

IQM Trim Boards by Mid-America – www.iqmtrimboards.com

MiraTEC Treated Exterior Composite Trim – www.miratectrim.com

Royal Group Technologies – www.royalgrouptech.com

Royal Mouldings – www.royalmouldings.com



Housing – Residential –Bathtub / Shower / Jacuzzi / Hot Tub

Common composites:

Acrylic (polymer fiber + 85% acrylonitrile)

mold made by heating enormous sections (sheets) of acrylic and then stretching the softened sheets over a mold to create the proper shape and size

Fiberglass – sprayed to fill mold

Engineered stones and ceramic

End products: bathtubs shower wall units shower / drain pans sinks hot tubs / jacuzzis





Adhesive / Tape Applications:

surface and edge protection (including full-body wrap)

trim and handle attachment – 3M VHB currently being used to attach metal trims to glass

masking around fiberglass mold edges

see next section for pipe and drain commentary

Note: some home healthcare items made of composites; needs further exploration





Some Manufacturers:

Lasco Bathware – www.lascobathware.com

Kohler – www.us.kohler.com

Aker Plastics – www.maax.com

Some Competitors:

Scapa - recently released a new product for mounting – Scapa 815

Lohmann


Housing – Residential – Plumbing Pipes / Fixtures


Composite piping systems were originally developed in Europe over 25 years ago.

Composites Types for Pipes and Drains:

aluminum tube / polyethylene inner and outer layers

aluminum combinations

metals / plastic resins

some fiber / resin combinations


Housing – Residential – Plumbing Pipes / Fixtures


Some composite pipe makers: Express Rooter - www.expressrooter.ca

Kitec Industries – www.kitecindustries.com

US Fabrics Inc – www.usfabricsinc.com


attaching layers of aluminum / PE pipes

Note: current tesa customer – Wellstream –using tesa® 4289 for this application

possible transit protection

Interesting site: www.plumbingworld.com



Housing – Residential – Swimming Pools

Manufacturing techniques:

wall panels joined by tongue-groove connectors (cemented at seams) Steel wall Polymers (GRP plastic) wall Vinyl wall / liners Gunite (plaster / cement)

one-piece units formed using a mold Fiberglass Ceramic / resins Injection and spray mold methods

multiple-unit modular molds – can be attached together to make distinctive shapes Fiberglass Ceramic / resins Injection and spray mold methods



Housing – Residential – Swimming PoolsAdhesive / Tape Applications

1. Adhering pool liner to pool base

2. Removing excess fiberglass (composites) from edges of sprayed mold – tesa® TPP tape currently being used at Stegmeier)

3. Attaching temporary cement forming devices around edges of pool to create decorative edges and ledges

• tesa® 4970 currently being used by Stegmeier to secure foam forms during concrete pouring application

4. Possibly securing above-ground drain liners

5. Wrapping exterior side of molds to protect them from damage (masking or long-term surface protection)

6. Sean reports that 3M 233+ is highly used by this audience



Housing – Residential – Swimming Pools

Other Adhesive Applications:

Glues and epoxies common for:

Sealing gaskets and o-rings

Setting and repairing spa jets, lights, pipes, plumbing, skimmers, drain lines

A Few Composite Pool Providers:

Viking Pools – www.vikingpools.net

Composite Pool Corp – www.ffpfirewater.com

Liberty Composite Pools – www.libertycompositepools.com




Housing – Residential – Countertops

Composite countertops offer expanded design options and functionality for residential and commercial counters.

Common Composite Types:

Paper-composite (post-consumer waste) –www.richlite.com

Wood pulp & paper – www.ecohomeimprovement.com

Paper concrete – mix of fly ash, recycled glass dust, mixed recycled paper, cement, and iron oxide pigments - www.ecohomeimprovement.com

Engineered stone – quartz composite mixed with pebbles, polymers, epoxies

Plastic laminates



Housing – Residential – Countertops


Adhesive Applications – adhering countertop onto frame and board structure

Common Adhesives:

Contact cement

Glues / liquid nails

Note: Bruce wants to explore this market further for potentialACX Plus opportunities.

Tape Potential: Between $5M and $10M


Housing – Residential – Roofing


New composites containing plastic elements are extending shingle lives up to 50 years.

Mold, mildew, hail, and insect resistant.

Composites:

New - plastic resins (some recycled) and limestone (laced with silica quartz and crystobalite)

Traditional - asphalt, limestone (laced with silica quartz and crystobalite), mineral granules, fiberglass, formaldehyde, polyester, felt, sand, and talc. 3M does make granules for shingles





Shingle packaging – cellophane tape being use to separate shingles that are stacked in packaging

Roof marking for shingle placement – refer to Reveal Tape (www.dciproducts.com)

Shingles attached with spray / liquid adhesives / glues

Note: tesa currently offers a roofing tape assortment in some markets. Applications include:

purlin buffer (isolation tape) – tesa® PVC tape acts as a buffer between metal, plastic, and objects below, thus preventing electrolysis and heat transfer

skylight tape – foam buffer between skylight and roof supports; allows for impact resistance and expansion / contraction of window unit

eave and ridge gap fillers

Purlin




Some composites roof manufacturers:Titan Mfrg Roof Systems – www.titanroofsystems.com

Tamko – www.tamko.com

Enviroshake – www.enviroshake.com

Tape Relevance: 15+ roofing companies already identified in ONC as active / prospective companies



Housing

Residential Temporary



Housing - Temporary

Composite materials are “appearing on the radar” for use in temporary and mobile structures4.

Focus includes:

Disaster relief housing

Mobile service units

Storm shelters

Applications include:

Wall panel systems (FRPs) – see next slide

Reference 4: Article on compositesworld.com – Standing up to Natural Disasters – Karen Wood – 9/22/2008



Housing - Temporary

Reference 5: Picture taken from CCV Corp – www.ccvbc.com

Reference 5

Wall Panel Constructions


Common Honeycomb Material:

polycarbonate

aluminum

polypropylene

Common Facing Material:

aluminum

plastic


Housing - Temporary

Some Wall Panel Manufacturers for Housing:

1. CCV – www.ccvbc.com

2. Duraplate – www.duraplateproducts.com

3. Permatherm - www.permatherm.net


Tape / Adhesive Applications: Needs practical exploration, but:

adhering panel walls (facing material) to inner core

potential glass glazing



Architectural Structures – Commercial Buildings




Types of Composites:

Steel / steel (two differing types of steel with differing weights of chromium, silicon, carbon, etc)

Fiber-reinforced cement

Metal / PVC

Aluminum – metal / foam core

Aluminum – metal / honeycomb core

Aluminum / polypropylene core – phenolic resins

Aluminum / tempered hardboard / foam core

Wood fibers




Composite Applications:

Wall panels / curtain walls

Studs

Beams / joists

Trusses

Mounts / supports



Architectural Structures – Commercial Buildings –Curtain Walls

Curtain Wall Definition: interior or exterior building facade that does not bear load; wind and gravity loads transferred to building structure5

Self-contained frame system (usually aluminum) that attaches to structural frame

Typical wall frame infill combinations:

Glass

Metal

Thin stone

FRPs (fiber-reinforced plastics)

Reference 5 – WBDG – Whole Building Design Guide – www.wbdg.org

Resource: www.ryanlinks.com – specification resource for architects and engineers



Architectural Structures – Commercial Buildings –Curtain Walls

Installation methods (determined by building height)

Stick system – wall frame and panels are installed piece by piece on-site

Unitized / modular system – frame and panels are assembled and glazed at the factory



Architectural Structures – Commercial Buildings –Curtain Walls – Types of Glazing

Pressure Plate Glazing - glass and infill panels of wall installed from exterior, typically against dry gaskets. Outer layer of gaskets is installed and gaskets are compressed against glass by the torque applied to fasteners,securing a continuous pressure plate.

Interior Dry Glazing - glass and infill panels are installed from the interior. Frame is fixed and exterior dry gaskets are installed. Glass unit is slid into a deep glazing pocket on one jamb far enough to allow clearing the opposite jamb and then slid back into the opposite glazing pocket and then dropped into the sill glazing pocket.

Structural Silicone Glazing - glass or infill unit is adhered to the frame with a bead of silicone. Outer silicone weather seals supplement the structural seal.

Butt-Glazing - True butt-glazing has no mullion or other back-up member behind the joint and relies solely on a sealant, typically silicone, between the glass units to provide a perfect barrier seal.



Architectural Structures – Commercial Buildings –Curtain WallsSome Curtain Wall Providers:

Alcoa – www.alcoa.com (Reynobond systems)

Portafab – www.portafab.com

Kawneer – www.kawneer.com

Avanti Systems – www.avantisystemsusa.com

Traco – www.traco.com


Glass glazing

Panel attachment

Stiffener trim attachment (behind cladding panels) –Bruce reports this is a global focus area for ACX+



Architectural Structures – Commercial Buildings –Wall Panels

Adhesive Providers:

Dow Corning – Structural Glazing Silicone & Other Sealants –www.dowcorning.com/content/publishedlit/62-0979c-01.pdf

3M – VHB

Wall Panel Definition: Typically interior walls serving as room dividers; non-load bearing

Tape Applications:

Attaching glass, metal, and other panel materials to the structural beams of a building



Architectural Structures – Commercial Buildings –Wall Panels

Tape Potential (Glazing Curtain Walls and Wall Panels): $20M+



Architectural Structures – Commercial BuildingsWall Panel Providers:

Plascore - www.plascore.com – wall / structure

First Class Building Products – www.firstclassbp.com

Laminators, Inc. – www.laminatorsinc.com

Centria Architectural Systems - www.centria.com

Kastner Metals (An Embury Company - www.emburyco.com

Metlspan LLC – www.metlspan.com

Bamco, Inc. – www.bamcoinc.org

Kanalco Ltd – www.kanalco.com

Tectum Inc. – www.tectum.com

Kingspan Insulated Panels Ltd – www.kingspanpanels.com

Trespa – www.trespa.com

Crane Composites, Inc. – www.cranecomposites.com

Resolite, Inc. – www.resolite.com

Citadel Architectural Products, Inc. – www.citadelap.com

Mapes Industries, Inc. – www.mapes.com


Composites

Composites – Non-B/C - Floor Panels


Flooring systems for a variety of venues:

Vehicles: Van Boat Delivery truck Emergency vehicle Bus

Trade show booth Modular shelter Dance floors

Honeycomb or foam core + adhesive + facing materials


A Market Explored

by Annette J. Carroll


a market exploration prepared by annette j. carroll€¦ · a market exploration prepared by...

Documents