Composites in Building & Construction
A Market Exploration
Prepared by Annette J. Carroll
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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 OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Market at a Glance – 2005 - Fiberglass
Thermoset –once polymers are formed and linked to polymer chain, can’t be reformed
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Market at a Glance – 2006 - Fiberglass
Thermoset –once polymers are formed and linked to polymer chain, can’t be reformed
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Market at a Glance – 2004 – Fiberglass – Thermoset & Thermoplastic
Thermoplastic –polymers linear (not joined); can be reheated and reformed
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Market at a Glance – FRP compared to Metals
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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)
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
A look at composites by market segments:
Infrastructure
Housing
Architectural /
Commercial Structures
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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…
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Infrastructure
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing
Residential Temporary
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential – Windows & Skylights
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential – Windows & Skylights
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential – Windows & Skylights
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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)
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential – Doors
Benefits include: Low maintenance, never
needs repainting Repels water Not attractive to insects
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Potential Tape Applications:
Venting – for foam core blown doors
Door sweep
Bottom rail decorative and protective panels
Glass glazing / muntin bars
Composites in Building & Construction
Housing – Residential – Doors
Wood Combo Doors:
Mortise and tennon joints secured with fasteners
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Glazing Bar – ADL (Actual Divided Light Bar)
Muntin Bar – SDL (Simulated Divided Light Bar)
Composites in Building & Construction
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)
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential – Doors
Tape Potential: Up to $20M
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential – Garage Doors
Garage door manufacturers now offering products comprised of wood fibers + resins + insulation.
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
1 – Laminated support rails
2 – Polystyrene insulation
3 – Engineered thermoset resin / cellulose door skin
4 – Composite skin and trim boards
Composites in Building & Construction
Housing – Residential – Garage Doors
Some Manufacturers:
Jeld-wen – www.jeld-wen.com
Amarr – www.amarr.com
Aspen Garage Doors – www.aspengaragedoors.com
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
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
Tape Potential: Up to $5M
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential – Decks, Fencing / Railings
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential – Decks, Fencing / Railings
www.timbertech.com
www.correctdeck.com
Tape / Adhesive Applications:
Perhaps some transit surface protection; little to no fastening needs
Tape Potential: Less than $10M
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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.
Tape Potential: Less than $5M
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential –
Decks, Fencing / Railings, Siding
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Just an interesting tidbit
Composites in Building & Construction
Housing – Residential – Siding
Some Composite Siding Manufacturers:
Revolution Siding – www.revolutionsiding.com
Boston Cedar – www.bostoncedar.com
LP Corporation – www.lpcorp.com
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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.
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential –Bathtub / Shower / Jacuzzi / Hot Tub
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
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
Tape Potential: Up to $15M
Composites in Building & Construction
Housing – Residential –Bathtub / Shower / Jacuzzi / Hot Tub
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
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
Composites in Building & Construction
Housing – Residential – Plumbing Pipes / Fixtures
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
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
Composites in Building & Construction
Housing – Residential – Plumbing Pipes / Fixtures
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Some composite pipe makers: Express Rooter - www.expressrooter.ca
Kitec Industries – www.kitecindustries.com
US Fabrics Inc – www.usfabricsinc.com
Tape / Adhesive Applications:
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
Tape Potential: Less than $1M
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Tape Potential: Up to $10M
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing – Residential – Countertops
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
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
Composites in Building & Construction
Housing – Residential – Roofing
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
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
Composites in Building & Construction
Housing – Residential – Roofing
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Tape / Adhesive Applications:
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
Composites in Building & Construction
Housing – Residential – Roofing
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
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
Tape Potential: Up to $10M
Composites in Building & Construction
Housing
Residential Temporary
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Housing - Temporary
Reference 5: Picture taken from CCV Corp – www.ccvbc.com
Reference 5
Wall Panel Constructions
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Common Honeycomb Material:
polycarbonate
aluminum
polypropylene
Common Facing Material:
aluminum
plastic
Composites in Building & Construction
Housing - Temporary
Some Wall Panel Manufacturers for Housing:
1. CCV – www.ccvbc.com
2. Duraplate – www.duraplateproducts.com
3. Permatherm - www.permatherm.net
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Tape / Adhesive Applications: Needs practical exploration, but:
adhering panel walls (facing material) to inner core
potential glass glazing
Tape Potential: Up to $5M
Composites in Building & Construction
Architectural Structures – Commercial Buildings
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Architectural Structures – Commercial Buildings
Composite Applications:
Wall panels / curtain walls
Studs
Beams / joists
Trusses
Mounts / supports
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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.
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Tape / Adhesive Applications:
Glass glazing
Panel attachment
Stiffener trim attachment (behind cladding panels) –Bruce reports this is a global focus area for ACX+
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
Architectural Structures – Commercial Buildings –Wall Panels
Tape Potential (Glazing Curtain Walls and Wall Panels): $20M+
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites in Building & Construction
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
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
Composites
Composites – Non-B/C - Floor Panels
Market OverviewComposite Types & ProcessesSegment – InfrastructureSegment – Housing - ResidentialSegment – Housing - TemporarySegment - Architecture
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