Executive Report

Study of the U.S. Market For Windows, Doors and Skylights

Copyright 2006 - Co-published April 2006 by:

American Architectural Manufacturers Association (AAMA) 1827 Walden Office Square, Suite 104 Schaumburg, Illinois 60173 Tel: (847) 303-5664/Fax: (847) 303-5774 www.aamanet.org

Window & Door Manufacturers Association (WDMA) 1400 East Touhy Avenue, Suite 470 Des Plaines, Illinois 60018 Tel: (847) 299-5200/Fax: (847) 299-1286 www.wdma.com

Researched by: Ducker Research Company, Inc. 1250 Maplelawn Drive, Troy, MI 48084 (248) 644-0086 www.ducker.com

TABLE OF CONTENTS
Section A. Description INTRODUCTION AND METHODOLOGY 1. Methodology 2. Purpose 3. Methodology and Time Line 4. Terminology U.S. CONSTRUCTION ACTIVITY 1. U.S. Summary 2. U.S. Residential Starts 3. Nonresidential Floor Area DOOR MARKET 1. Summary 2. Market Size by Application 3. Segmentation by Material 4. Wood Doors by Application 5. Wood Doors Segmented by Type 6. Residential Wood Flush Doors 7. Architectural (Nonresidential) Flush Doors 8. Wood Stile and Rail Doors 9. Historic and projected Growth Page 1

B.

C.

16

D.

WINDOW MARKET 39 1. Summary 2. Residential-Type Market Size by Application 3. Residential-Type Window Segmented by Application and Material 4. Residential-Type Wood Windows in Conventional Applications 5. Residential-Type Vinyl Windows in Conventional Applications 6. Historic and Projected Growth 7. U.S. Nonresidential Glass and Windows Market Size 8. Nonresidential Historic and Projected Growth PATIO DOOR MARKET 1. Summary 2. Market Size by Application 3. Segmentation of Wood Units SKYLIGHT MARKET 1. Summary 2. Market Size by Application U.S. STORM WINDOW AND DOOR MARKET 82

E.

F.

92

G.

100

APPENDICES: A. B. C. D. E.
F.

Eleven U.S. Census Regions

U.S. Entry and Interior Door Market U.S. Conventional Residential Window Market Nonresidential Vision Area Models U.S. Patio Door Market U.S. Glass Usage

LIST OF EXHIBITS
Section A Number & Type A.1 Time Line Description Program Time Line 2005 2006 Program Approval Draft Review Committee Review Report Publication U.S. New Residential Construction Segmented by Type of Structure 2001-2005 Manufactured Homes Multi-Family Single Family U.S. Conventional Housing Starts by Geographic Region 2005 11 Regions Forecasted U.S. Residential Construction Segmented by Type of Structure 2006 2009F Manufactured Homes Multi-Family Single Family U.S. Residential Housing Starts by Region 2005 South West Midwest Northeast U.S. Residential Housing Starts by Region 2009 Forecasted South West Midwest Northeast Expenditures and Growth Over Prior Year 2000 2009F Total U.S. Residential Improvement Expenditures Billions of Dollars Page 2

B.1 Bar Graph

B.2 Map

B.3 Bar Graph

B.4 Pie Chart

10

B.5 Pie Chart

10

B.6 Table

10

B.7 Bar Chart

11

B (cont.)

B.8 Table

New U.S. Housing by Type of Structure Private and Public, Including Farm 2000 2009F Total Shelter Manufactured Housing Total Conventional Single Family Multi-Family New U.S. Conventional Housing by Geographical Region Private and Public, Including Farm 2000 2009F Northeast Midwest South West U.S. Manufactured Housing Shipments to Dealers by Geographical Region Private and Public, Including Farm 2000 2009F Northeast Midwest South West Forecasted Nonresidential Contract Awards by Floor Area Segmented by Major Building Category 2003 2009F Manufacturing/Warehouse Office/Hotel/Institutional Store/Mercantile New U.S. Nonresidential Contract Awards by Geographical Region 2005 11 Regions

11

B.9 Table

12

B.10 Table

12

B.11 Bar Chart

13

B.12 Map

14

B.13 Pie Chart

Nonresidential Contracts by Region 2005 South West Midwest Northeast Nonresidential Contracts by Region 2009 Forecasted South West Midwest Northeast

13

B.14 Pie Chart

13

B (cont.)

B.15 Table

Nonresidential Contract Awards (Reported) by Selected Building Types and Regions 2000 2009F Manufacturing/Warehouse Office/Hotel/Institutional Store/Mercantile

15

C.1 Table

Total Market for U.S. Doors by Application 2005 Residential Entry Residential Interior Nonresidential Entry Nonresidential Interior Total U.S. Market for Doors by Construction Type and Application 2005 New Construction Remodeling Replacement U.S. Residential Entry Doors by Material 2005 Steel Wood Fiberglass Residential Interior Doors by Material 2005 Wood Other Nonresidential Entry Doors by Material 2005 Steel Aluminum Wood Other Nonresidential Interior Doors by Material 2005 Wood Aluminum Steel Other

18

C.2 Table

19

C.3 Pie

20

C.4 Pie Chart

21

C.5 Pie Chart

22

C.6 Pie Chart

23

C (cont.)

C.7 Table

U.S. Market for Wood Doors by Application 2005 Residential Entry Residential Interior Nonresidential Entry Nonresidential Interior U.S. Market for Wood Doors by Construction Type and Application 2005 New Construction Remodeling Replacement U.S. Market for Wood Doors Flush Versus Stile and Rail Construction 2005 Residential Entry Residential Interior Nonresidential Entry Nonresidential Interior Wood Residential Interior Doors by Type 2005 Flush Stile and Rail Wood Nonresidential Interior Doors by Type 2005 Flush Stile and Rail 2005 Wood Flush Door Market by Core Construction Hollow Core Solid Core Fire Door Residential Core Materials by Type Solid and Fire Rated Wood Flush Doors 2005 Particle Board MDF Mineral Core Other

24

C.8 Table

24

C.9 Table

25

C.10 Pie Chart

26

C.11 Pie Chart

26

C.12 Table

27

C.13 Pie Chart

28

C (cont.) C.14 Pie Chart Residential Wood Flush Doors by Material 2005 Molded Hardboard Flush Veneer Flush Hardboard Residential Wood Flush Veneer Doors by Ply Construction 2005 7 Ply 9 Ply Other Interior Flush Veneer Doors by Wood Species Used 2005 Red Oak Birch Maple Lauan/Related Cherry White Oak Mahogany Walnut Ash Other Hardwoods Softwoods Other Architectural Wood Passage Flush Door Shipments by Core Construction 2005 Hollow Core Solid Core Fire Door Solid Core and Fire Rated Wood Architectural Flush Passage Doors by Core Types 2005 Particleboard Mineral SCL Stave Fire Rated Wood Architectural Flush Passage Doors by Rating 2005 90 Minutes 60 Minutes 45 Minutes 20 Minutes 29

C.15 Pie Chart

29

C.16 Pie Chart

30

C.17 Table

31

C.18 Pie Chart

31

C.19 Pie Chart

32

C (cont.) C.20 Pie Chart Architectural Wood Flush Doors by Face Material 2005 Wood Veneer Laminates MDO/Others Architectural Flush Veneers by Wood Species Used 2005 Red Oak Birch Maple Lauan/Related Cherry White Oak Mahogany Walnut Ash Other Hardwoods Architectural Wood Veneer Flush Doors by Ply Construction 2005 5 Ply 7 Ply Architectural Wood Flush Doors by Door Height 2005 70 68 90 80 710 72 Other Wood Stile and Rail Doors by Application 2005 Residential Entry Residential Interior Nonresidential Entry Nonresidential Interior 32

C.21 Pie Chart

33

C.22 Pie Chart

34

C.23 Table

34

C.24 Table

35

C (cont.) C.25 Table Stile and Rail Wood Species Used 2005 Ponderosa Pine Radiata/Imported White Pine Other Pines Fir/Hemlock Other Softwoods Oak Cherry Mahogany Lauan Walnut Maple Poplar Other Hardwoods Sales of U.S. Doors by Material and Application 2000-2009F Steel Wood Fiberglass 36

C.26 Table

38

D.1 Table

Total Market for Residential-Type Window Units by Application 2003 and 2005 Residential New Construction Residential Remodel Residential Replacement Manufactured Housing Nonresidential New Construction Nonresidential Remodel Nonresidential Replacement

41

D (cont.) D.2 Table Total U.S. Market for Residential-Type Window Units by Application and Framing Material 2003 and 2005 Residential, Nonresidential and Manufactured Housing Window Units Wood and Clad Wood Vinyl Aluminum Other Total U.S. Conventional Residential Window Demand Historic and Forecasted Window Usage by Framing Material 2001 2009 F Wood and Wood Clad Aluminum Vinyl Other U.S. Conventional Residential Window Usage by Framing Material Segmented by Construction Type 2003 and 2005 New, Remodel, and Replacement Wood and Clad Wood Vinyl Aluminum Other Conventional Residential Window Usage Segmented by Framing Material 2003 and 2005 Wood Aluminum Clad Wood Vinyl Clad Wood Aluminum with Thermal Break Aluminum without Thermal Break Vinyl Other 43

D.3 Bar Graph

44

D.4 Table

45

D.5 Table

46

D (cont.)

D.6 Table

Conventional Residential Window Usage Segmented by Configuration 2003 and 2005 Wood, Vinyl and Aluminum/Other Double Hung Single Hung Casement Gliding/Slider Awning Fixed Specialty Conventional Residential Window Volumes Segmented by Customization 2003 and 2005 Standard Stock Windows Customized Windows Conventional Residential Window Glass Usage Segmented by Framing Material 2003 and 2005 Single Lite, Two Lite, Non-Sealed, Two Lite, Sealed IG, Two Lite, Sealed IG W/Storm, and Triple Lite, Sealed IG Wood Vinyl Aluminum Other Conventional Residential Windows Insulating Glass Segmented by Type of Spacer 2003 and 2005 Rigid Warm Edge Non-Rigid Warm Edge Aluminum Spacer Conventional Residential Windows With Sealed IG Segmented by Seal Configuration 2003 and 2005 Single Sealed Double Sealed Conventional Residential Windows Secondary Sealant Segmented by Seal Type 2003 and 2005 Polyurethane Silicone Polysulfide Hot Melt

47

D.7 Pie Chart

49

D.8 Table

50

D.9 Pie Chart

51

D.10 Pie Chart

52

D.11 Pie Chart

53

D (cont.)

D.12 Pie Chart

Conventional Residential Windows Hurricane Resistant Florida, All Other Regions Non Hurricane Hurricane Impact Glazing Hurricane Non-Impact Glazing Conventional Residential Windows Segmented by Glass Type 2003 and 2005 Wood, Vinyl, Aluminum, and Other Clear Tinted Reflective Low-E Conventional Residential Windows Low-E Segmented by Coating Type 2003 and 2005 Sputtered Pyrolytic Conventional Residential Windows Energy Ratings Segmented by Rating Type 2003 and 2005 Wood, Vinyl, Aluminum/Other NFRC Rating Energy Star Rating No Rating Conventional Residential Wood Window Units Segmented by Configuration 2003 and 2005 Clad Wood and Non-Clad Double Hung Single Hung Casement Gliding/Slides Awning Fixed Specialty Conventional Residential Wood Window Units Window Sash and Frame Segmented by Wood Species Used 2005 Ponderosa Pine Southern Yellow Pine Radiata Pine White Pine Fir/Hemlock Other Softwoods Oak Other Hardwoods

54

D.13 Table

54

D.14 Pie Chart

56

D.15 Pie Chart

57

D.16 Table

58

D.17 Table

59

D (cont.) D.18 Pie Chart Conventional Residential Wood Window Units Non-Clad Segmented by Exterior Finish 2005 Primed/Prefinished Natural No Finish Conventional Residential Wood Window Units Segmented by Type of Insulating Spacer 2003 and 2005 Rigid Warm Edge Spacer Non-Rigid Warm Edge Aluminum Spacer Conventional Residential Wood Window Units Segmented by Low-E Usage and Technology 2003 and 2005 Sputtered Pyrolytic Conventional Residential Vinyl Window Units Segmented by Configuration 2003 and 2005 Double Hung Single Hung Casement Gliding/Slider Awning Fixed Specialty Conventional Residential Vinyl Window Units Segmented by Type of Insulating Spacer Rigid Warm Edge Spacer Non-Rigid Warm Edge Aluminum Spacer Residential Vinyl Window Units Segmented by Fabrication Method 2003 and 2005 Fully Welded Frame Mechanically Fastened Frame Hybrid of Mechanically Fastened Frame and Fully Welded Frame Conventional Residential Vinyl Window Units Segmented by Solid Extrusion Color 2003 and 2005 White Tan Other 60

D.19 Pie Chart

61

D.20 Pie Chart

61

D.21 Table

62

D.22 Pie Chart

63

D.23 Pie Chart

63

D.24 Pie Chart

64

D (cont.) D.25 Table Conventional Residential Windows Usge 2003-2009 Forecast New Construction, Remodel/Replacement and Total Construction Wood Aluminum Vinyl Fiberglass Composite Other New Nonresidential Construction and Major Additions Segmented by Type of Wall Construction 2003 and 2005 Curtainwall, Storefront, Site Fabricated Windows, and Shop Fabricated Windows Office and Bank Stores, Other Mercantile Manufacturing/Warehouses Educational Hospital/Health Care (incl. Government) Public/Government Religious Amusement/Recreational Hotel/Motel/Dormitory Miscellaneous Total Nonresidential Vision Area Segmented by Type of Construction 2003 and 2005 New Building, Major Additions, and Remodel Curtainwall Storefront Site Fabricated Windows Shop Fabricated Windows Framing Materials Used in Nonresidential Construction 2003 and 2005 Curtainwall, Storefront, Site Fabricated Windows, and Shop Fabricated Windows Aluminum with Thermal Break Aluminum without Thermal Break Wood Vinyl, Other Nonresidential Aluminum Framing Segmented by Finish Material 2003 and 2005 Anodized Finish Standard Paint High End paint 65

D.26 Table

68

D.27 Table

69

D.28 Table

70

D.29 Pie Chart

71

D (cont.) D.30 Table Calculations New High-Rise Construction 2001 and 2003 Wall Area, Ratio High-Rise, High-Rise Wall Area, Vision Glass Area Office/Bank All Other Total U.S. Nonresidential Glass Usage Segmented by Glazing Configuration Single Lite Two-Lite, Not Sealed Two-Lite, Sealed Two-Lite Sealed IG, with Stormlite Triple Glazed, Sealed IG, other Glass Usage Nonresidential Windows Clear Tint Reflective Low-E Usage of Low-E Segmented by Coating Technology 2003 and 2005 Sputter and Suspended Film Pyrolytic Usage of Reflective Glass Segmented by Coating Technology 2003 and 2005 Sputter Pyrolytic Conversion: Total Insulated Vision Glass Area Insulating Glass, Sealed Square Feet to Lineal Feet Insulating Glass Sealants Segmented by Sealant Configuration 2001 and 2003 Double Sealed Single Sealed Double Sealed Insulating Glass - Secondary Sealant Usage 2003 and 2005 Polysulfide Silicone Polyurethane Non Residential Glazing Hurricane Resistant Florida, All Other Regions Non Hurricane Hurricane Impact Glazing Hurricane Non Impact Glazing 72

D.31 Table

73

D.32 Table

73

D.33 Pie Chart

74

D.34 Pie Chart

74

D.35 Picture

75

D.36 Table

75

D.37 Table

76

D.38 Pie Chart

77

D (cont.) D.39 Picture U.S. Market for Commercial Windows Segmented by Window Type 2005 Site Fabricated Shop Fabricated U.S Market for Architectural Rated Shop-Fabricated Windows by Rating Segmented by Window Rating Type AW C H/C U.S. Shop-Fabricated Windows Segmented by Window Configuration 2003 and 2005 Hung Slider Projected Fixed Sliding Door Specialty/Other U.S Shop-Fabricated Patio and Terrace Doors Segmented by Door Type Hinged Sliding U.S. Window Usage in Nonresidential Buildings 2003-2009F New Construction Remodeling & Replacement 78

D.40 Pie Chart

78

D.41 Table

79

D.42 Pie Chart

80

D.43 Table

81

E.1 Table

Total U.S. Market for Residential Patio Doors Segmented by Framing Material 2005 Wood Aluminum Vinyl Steel Fiberglass Others

83

E (cont.) E.2 Table Total U.S. Market for Residential Patio Doors Segmented by Construction Type and Framing Material 2003 and 2005 New Construction, Remodel, and Replacement Wood Aluminum Vinyl Steel Fiberglass Other Patio Doors by Framing Material 2003 and 2005 Wood Aluminum Vinyl Steel Fiberglass Other 84

E.3 & E.4. Pie Charts

85

86 E.5 Table Total U.S. Market for Residential Patio Doors Segmented by Application and Framing Material 2003 and 2005 Hinged and Sliding Wood Aluminum Vinyl Steel Fiberglass Others Total U.S. Sliding and Hinged Patio Doors Segmented by Number of Panels 2003 and 2005 One Panel, Two Panel, and Three or More Panels Wood Aluminum Vinyl Steel Fiberglass Others 87

E.6 Table

E (cont.) E.7 Table Total U.S. Market for Residential Patio Doors Segmented by Low-E Usage and Technology 2003 and 2005 Clear, Tinted, Reflective and Low-E Wood Vinyl Aluminum Steel Fiberglass Others Wood Patio Doors Segmented by Cladding and Type of Door 2003 and 2005 Hinged and Sliding Clad Non-Clad Non-Clad Wood Patio Doors Segmented by Finish Type 2005 Primed/Painted No Finish Natural Finish Wood Patio Door Lumber Type Segmented by Wood Species 2005 Ponderosa Pine Southern Yellow Pine Radiata Pine White Pine Fir/Hemlock Other Softwoods Oak Other Hardwoods Residential Patio Door Market 2000 2009F New Construction Remodel Replacement 88

E.8 Table

89

E.9 Pie Chart

90

E.10 Table

91

E.11 Table

91

F.1 Table

Residential-Type Skylights (Including Light Commercial) 2000 2005 NewConstruction Remodel Replacement Skylights by Type and Application 2005 Plastic Glazed Skylight and Glass Glazed Skylight Residential Light Commercial Total Market for Skylights by Type 2003 and 2005 Glass Glazed Skylights Plastic Glazed Skylights Plastic Glazed Skylights by Type 2005 Acrylic Polycarbonate Fiberglass Plastic Glazed Skylights by Type 2005 Translucent/Diffusing Tinted/Colored Clear Glass Glazed Skylights by Type 2005 Low E Clear Tinted Reflective Residential-Type Skylights by Framing Material 2005 Vinyl and Aluminum Vinyl Aluminum Wood and Clad wood Frameless Residential-Type Skylights by Type and Application 2005 Plastic Glazed Skylights and Glass Glazed Skylights Fixed Venting Venting Motorized/Operable

93

F.2 Table

94

F.3 Pie Chart

94

F.4 Pie Chart

95

F. 5 Pie Chart

96

F.6 Pie Chart

96

F.7 Pie

97

F.8 Table

98

F (cont.) F.9 Table Forecast of Residential-Type Skylights 2005 2009F New Remodel Replace 99

G.1 Table

U.S. Historic Storm Window and Door Shipments 2000 2004 Windows Doors Forecasted U.S. Storm Window and Door Shipments 2005 2009F Windows Doors Eleven U.S. Census Regions Four to Eleven Region Conversion and Abbreviation Definitions U.S. Entry and Interior Door Market Segmented by Application and Estimated Geographic Segmentation 2005 Residential Nonresidential U.S. Conventional Residential Window Market Segmented by Application and Estimated Geographic Segmentation 2005 New Construction Remodeling and Replacement

100

G.2 Table

101

Appendix A Appendix B

Map Table Table

Appendix C

Table

Appendix D

APDX-D.1 Graphic APDX-D.2 Graphic APDX-D.3 Table

Conversion: Total Vision Glass Area

Model: Total Vision Glass Area

United States Nonresidential Contract Awards 2002 Contract Awards Office and Bank Stores, other Mercantile Manufacturing/Warehouse Educational Hospital/Health Care (incl. Government) Public/Government Religious Amusement/Recreational Hotel/Motel/Dormitory Miscellaneous U.S. Nonresidential Total Wall Area New and Additions 2003 Floor Area and Wall-to-Floor Ratio Office and Bank Stores, other Mercantile Manufacturing/Warehouse Educational Hospital/Health Care (incl. Government) Public/Government Religious Amusement/Recreational Hotel/Motel/Dormitory Miscellaneous U.S. New Nonresidential Vision and Opaque Wall Area New and Additions Segmented by Building Category Total Wall Area and Vision Glass Office and Bank Stores, other Mercantile Manufacturing/Warehouse Educational Hospital/Health Care (incl. Government) Public/Government Religious Amusement/Recreational Hotel/Motel/Dormitory Miscellaneous

APDX-D.4 Table

APDX-D.5 Table

Appendix E

Table

U.S. Patio Door Market Segmented by Application and Estimated Geographic Segmentation 2003 New Construction Remodeling and Replacement U.S. Glass Usage Segmented by Glass Type and Estimated Geographic Segmentation 2003 Clear Tinted Reflective Low E Combination

Appendix F

Table

Copyright 2006 AAMA and WDMA All rights reserved. This report or any part thereof, may not be reproduced in any form without the written permission of the publisher.

A.

INTRODUCTION AND METHODOLOGY

Ducker Research Company (DRC) has been conducting the study of the U.S. residential and nonresidential window and door markets for WDMA (Window & Door Manufacturers Association) in combination with AAMA (American Architectural Manufacturers Association) since October 1994. This study details market volumes and trends in the U.S. for 2005, forecasted through 2009. Ducker Research has been conducting residential and nonresidential market studies continuously since 1982 for AAMA. Prior to that, studies were conducted for the Sealed Insulating Glass Manufacturers Association (SIGMA) since 1978. This association is now called the Insulating Glass Manufacturers Association (IGMA) Additionally, our database goes back to 1972 when we first developed a demand model for flat glass usage in the United States. Ducker further produces many syndicated and custom market research studies for the fenestration market annually. These include the annual studies of the North American Flat Glass Market and bi-annual study of the Northern American Fabricated Glass Market. This following report is the result of a combined market study and a database analysis funded by AAMA and WDMA in a cooperative effort. The intent in combining these studies is to develop a full database and a comprehensive report on the window and door market. The database is designed to be utilized for studies into the foreseeable future.

1.

Methodology The role of Ducker Research is to combine primary and secondary market research efforts with its own body of knowledge to profile and track residential and nonresidential fenestration market volume. As a major input to the research, Ducker receives confidential disclosures from AAMA and WDMA members and non-members. However, multiple industry sources, such as demand models, raw material and component suppliers, and internal databases, are necessary and consistently used to triangulate market statistics. Public databases are also utilized, such as the U.S. Bureau of Census and other statistics sources.

In addition, Ducker interviewed several hundred home builders, contractors, installers and distributors, which helped develop indicative product usage factors and channel flow as a cross reference to manufacturers sales figures. Please note that there have been several important revisions to data from 2003 due to new and improved data received at both national and local levels. Current numbers reflect the adjustment and all historical numbers have been restated accordingly. The overall participation from manufacturers in general was significantly higher for the latest study, and this coupled with additional insight gained from related Ducker work over the past 2 years has provided better insight into the following areas: Residential windows: The wood window market in particular was found to have been overstated for several years, with both vinyl and aluminum conversely understated. Patio doors: Similar to residential windows, the wood patio door market was found to have been overstated. Skylights: The total market was found to be overstated previously and has been revised down. Distribution: While the numbers were not restated as such, we eliminated a distributor category, Wholesale Retailers, and reallocated this volume primarily to lumberyards, but also somewhat to specialty retailers. This was done partly to simplify and to better align with the definitions used by most manufacturers, and partly because trends in the market were leading to the blurring of lines between wholesale retailers and other categories .

The following report represents our research and analytical efforts beginning in the Fall of 2005. 2. Purpose The purpose of this study is to provide a comprehensive single report detailing the window and door market for WDMA and AAMA. Methodology and Time Line Study findings are based upon disclosures from window and door manufacturers, secondary data and our experience in providing this information for several years. Study findings are segmented by geographic region as illustrated in Appendix A to this report. The research program for the WDMA and AAMA spans from September 2005 through April 2006. A detailed timeline is provided, below, as Exhibit A.1.
2

3.

Exhibit A.1 Program Time Line 2005 2006 Program Approval

Kick-off meeting Initiate fieldwork

Draft Review

Committee Review

Report Publication

Present draft results Fieldwork complete

Review draft reports with WDMA/AAMA advisory committees

September, 2005

late-March, 2006

early-April, 2006

mid-April, 2006

For purposes of presenting data in this report, the term Exhibits will be used to display all graphics and tables. 4. Terminology Certain terms are used throughout the report which require definition. Also, in our analysis, assumptions are made regarding units and construction activity. The following is a list of definitions and assumptions used in the development of this report. Bifold Door: An interior application utilizing two or more individual door leafs, conjoined with hinges, which operate on a sliding track. A bifold door is primarily a form of a closet door. However, bifold doors do not include folding doors or overlapping sliding doors. Bifold door volume counted on a per leaf basis. Included in interior door volume. Closet Doors: An interior door used for passage from room or hallway to closet. Included in interior door volume. Doors: Units are defined as actual door slabs and panels, rather than openings where one or more slabs would be used. Excluded from door units are closet doors, bifold doors and service and industrial doors.
3

Entry Doors: A door opening that allows passage from the exterior of a building or home to the interior. In the residential market, hinged rear entrance doors connecting an attached garage to a home are included, while patio doors are excluded and reported separately. In the nonresidential market, entry doors include vestibule doors. Flush Door Construction: A method of door construction whereby a thin face material is attached to a light internal frame (often made of wood). Face material may include high density fiberboard, steel, wood veneer, MDO, or other products. Framing: Metal, wood, fiberglass, vinyl, or composite members comprising the window. In operable windows, framing members include both a operational portion and fixed portion of the window. Insulating Glass: Two- or three-lite, sealed. Distinct from twolites, not sealed and distinct from storm windows. Interior Door: Includes both Passageway and Closet doors. Nonresidential: Nonresidential construction is defined as all commercial buildings, from small to large, that are not meant for residence. Hotels, motels, and dormitories are included in nonresidential figures. Patio Doors: Units are defined as openings at the manufacturer level, to avoid double counting units due to multiple operable, or inoperable panels. For example, a double French door and a triple panel sliding door are all considered one unit. Figures in this report identify units with single panels and multiple panels alike as one singular unit. Further segmentation by number of panels in detailed in the Patio Door section of this report. Passageway Doors: An interior door used for passage from room or hallway to room. Excluded from this are garage hinged and service doors. Residential: Residential construction is defined as dwelling units: single-family attached, single-family detached, multi-family and mobile homes. Apartment buildings, although considered commercial construction, are included in our residential figures. Stile and Rail Door Construction: A traditional method of construction for wood doors whereby the structural components are

exposed. Structural components include wood stiles (vertical beams) and rails (horizontal beams), which encompass wood panels. Stiles and rails are held together using glue and dowel pins, while panels often float within channels grooved into the stile and rail components. Skylights: Standardized unit specified by product. Not included in window volumes. Sloped Glazing: Nonstandard specification, also called custom skylights or monumental glazing. This product is captured in curtainwall data, but not segmented out. Does not include sunrooms, which are a separate category. Study Regions: Eleven geographic regions are used throughout the report. Appendix A to this report illustrates the definition of these regions. Sunrooms: Separate classification from sloped glazing. included in window volumes. Not

Vision Glass Area: Unless otherwise noted, glass area figures are surface measure of vision glass area. Figures for spandrel glass materials also are surface measured. Windows: Units are defined as openings at the manufacturer level. However, the definition of a unit differs among manufacturers (e.g., a bay window to some may be three openings while to others it may be one). This does not account for multiple windows that are nailed together at the distributor level for one opening. Figures in this report more closely reflect units at the manufacturer level, rather than openings at the job site.

***

Executive Report

U.S. Industry Statistical Review and Forecast

Copyright 2006 - Co-published April 2006 by:

American Architectural Manufacturers Association (AAMA) 1827 Walden Office Square, Suite 104 Schaumburg, Illinois 60173 Tel: (847) 303-5664/Fax: (847) 303-5774

Window & Door Manufacturers Association (WDMA) 1400 East Touhy Avenue, Suite 470 Des Plaines, Illinois 60018 Tel: (847) 299-5200/Fax: (847) 299-1286

www.aamanet.org

www.wdma.com

Researched by: Ducker Research Company, Inc. 1250 Maplelawn Drive, Troy, MI 48084 (248) 644-0086 www.ducker.com

Introduction Market estimates in the U.S. Industry Statistical Review and Forecast are driven not only by statistics published by the Census Bureau and other organizations, but also from primary interviews with leading manufacturers of windows, doors and skylights, as well as component suppliers. All forecasts are based on projections of construction activity as of February and appropriate usage factors developed by Ducker Research Company, which is solely responsible for the data. Any questions on the Review, or its contents should be directed to Ducker Research Company. Ducker has been conducting residential and nonresidential market studies continuously since 1982 for the American Architectural Manufacturers Association (AAMA). From 1978 to 1981, studies were conducted for the Sealed Insulating Glass Manufacturers Association (SIGMA(currently referred to as IGMA). Ducker has been conducting the update study of the U.S. residential and nonresidential window and door markets for the Window and Door Manufacturers Association (WDMA) in combination with AAMA since October of 1994. The U.S. Industry Statistical Review and Forecast is published annually. Additional and much more detailed information on window, door and skylight markets is contained in the updated (2005) Study of the U.S. Market for Windows, Doors and Skylights, and The Distribution of Residential and Non-Residential Windows and Doors in the 2005 U.S. Market, as well as individual Statistical Review and Forecast market overview reports for each of the 11 major U.S. regional markets. All reports are available from AAMA, WDMA, or Ducker. Contents Residential Construction Activity Privately owned housing New housing by type of structure Residential construction activity Improvement expenditures Manufactured housing shipments Existing home sales Residential Product Statistics Prime windows Storm windows/doors Skylights Patio doors Entry and passage door usage Door Forecast Nonresidential Product Statistics Entry and passage door usage Door Forecast Insulating glass statistics Nonresidential Construction Activity Contract awards Regional construction Window usage U.S. Map of Geographic Division 13-14 15 16-17 18 10 11 12 5-6 7 7 8 9-10 11 1 1 2 3 4 4

Executive Report

The Distribution of Residential and Nonresidential Windows and Doors in the 2005 U.S. Market

Copyright 2006 - Co-published April 2006 by:

American Architectural Manufacturers Association (AAMA) 1827 Walden Office Square, Suite 104 Schaumburg, Illinois 60173 Tel: (847) 303-5664/Fax: (847) 303-5774

Window & Door Manufacturers Association (WDMA) 1400 East Touhy Avenue, Suite 470 Des Plaines, Illinois 60018 Tel: (847) 299-5200/Fax: (847) 299-1286

www.aamanet.org

www.wdma.com

Researched by: Ducker Research Company, Inc. 1250 Maplelawn Drive, Troy, MI 48084 (248) 644-0086 www.ducker.com

TABLE OF CONTENTS Section I. II. Description Page

EXECUTIVE SUMMARY....................................................................1 INTRODUCTION AND METHODOLOGY..........................................3 A. Introduction B. Study Objectives C. Study Methodology CHANNEL MEMBER DEFINITIONS AND PROFILES......................6 A. Characteristics of Channel Members B. Characteristic Definitions C. Distributor Profiles PRODUCT FLOW ANALYSIS .........................................................23 A. Market Size B. Distribution Discussion C. Windows D. Patio Doors E. Entry Doors F. Interior Doors ISSUES AND TRENDS....................................................................63 A. Channel Member Trends B. Regional Trends NONRESIDENTIAL WINDOWS AND DOORS................................71 A. Nonresidential Windows and Glazing B. Nonresidential Windows and Glazing Supply Channel Chain Definitions C. Nonresidential Window Distribution Analysis D. Nonresidential Door Channel Member Definitions E. Nonresidential Door Distribution Analysis

III.

IV.

V.

VI.

Appendix A

............................................................................................85

Executive Summary

April, 2006

INDEX OF EXHIBITS Exhibit II.1 III.1 III.2 III.3 III.4 III.6 III.7 III.8 IV.1 IV.2 IV.3 IV.4 IV.5 IV.6 IV.7 IV.9 IV.10 IV.11 IV.12 IV.13 IV.14 IV.15 IV.16 IV.17 IV.18 IV.20 IV.21 IV.22 IV.23 IV.24 Title Page Number

Interviews Conducted - Respondent Type ..................................................... 5 Definitions Categorizing Process ................................................................ 8 Millwork Wholesaler Profile .......................................................................... 11 Big Box Profile.............................................................................................. 14 Lumberyard Profile....................................................................................... 16 Shortline Distributor Profile........................................................................... 18 Specialty Retailer Profile .............................................................................. 20 Summary of Distribution Definitions ............................................................. 22 2005 Market Size - Residential .................................................................... 23 2005 Windows Manufacturer Direct .......................................................... 26 2005 Windows Secondary Distribution Channels...................................... 27 2005 Windows - Total Volume by Channel Distribution ............................... 28 2005 Millwork Wholesaler Actual Window Purchases and Sales .............. 29 2005 Big Box Actual Window Purchases and Sales ................................. 30 2005 Lumberyard Actual Window Purchases and Sales........................... 31 2005 Shortline Distributor Actual Window Purchases and Sales .............. 32 2005 Specialty Retailer Actual Window Purchases and Sales .................. 33 2005 Summary of Window Volumes Segmented by End User ................. 34 2005 Summary of Window Volumes Segmented by Construction Type ... 35 2005 Patio Doors Manufacturer Direct ...................................................... 36 2005 Patio Doors Major Distribution Channels.......................................... 37 2005 Patio Doors Total Volume by Channel of Distribution....................... 38 2005 Millwork Wholesaler Actual Patio Door Purchases and Sales.......... 39 2005 Big Box Actual Patio Door Purchases and Sales ............................. 40 2005 Lumberyard Actual Patio Door Purchases and Sales....................... 41 2005 Shortline Distributor Actual Patio Door Purchases and Sales .......... 42 2005 Specialty Retailer Actual Patio Door Purchases and Sales.............. 43 2005 Summary of Patio Door Volumes Segmented by End User ............. 44 2005 Summary of Patio Door Volumes Segmented by Construction Type44 2005 Entry Doors Manufacturer Direct ...................................................... 45

Executive Summary

April, 2006

INDEX OF EXHIBITS (continued) Exhibit IV.25 IV.26 IV.27 IV.28 IV.29 IV.30 IV.31 IV.32 IV.33 IV.34 IV.35 IV.36 IV.37 IV.38 IV.39 IV.40 IV.41 IV.42 IV.43 Title Page Number

2005 Entry Doors Secondary Distribution Channels ................................. 46 2005 Entry Doors Total Volume by Channel of Distribution ...................... 47 2005 Millwork Wholesaler Actual Entry Door Purchases and Sales.......... 48 2005 Big Box Actual Entry Door Purchases and Sales ............................. 49 2005 Lumberyard Actual Entry Door Purchases and Sales ...................... 50 2005 Shortline Distributor Actual Entry Door Purchases and Sales .......... 51 2005 Specialty Retailer Actual Entry Door Purchases and Sales.............. 52 2005 Summary of Entry Door Volumes Segmented by End User ............. 53 2005 Summary of Entry Door Volumes Segmented by Construction Type53 2005 Interior Doors Manufacturer Direct ................................................... 54 2005 Interior Doors Secondary Distribution Channels .............................. 55 2005 Interior Doors Total Volume by Channel of Distribution.................... 56 2005 Millwork Wholesaler Actual Interior Door Purchases and Sales ....... 57 2005 Big Box Actual Interior Door Purchases and Sales .......................... 58 2005 Lumberyard Actual Interior Door Purchases and Sales.................... 59 2005 Shortline Distributor Actual Interior Door Purchases and Sales ....... 60 2005 Specialty Retailer Actual Interior Door Purchases and Sales........... 61 2005 Summary of Interior Door Volumes Segmented by End User .......... 62 2005 Summary of Interior Door Volumes Segmented by Construction Type ............................................................................................................. 62

V.1 V.2 V.3

Historic View of Window and Door Product Distribution Channel Characteristics ............................................................................................. 66 Forecasted View of Window and Door Product Distribution Channel Characteristics ............................................................................................. 67 Historic and Expected Changes in Window and Door Product Distribution Flow 2003-2009...................................................................... 68

VI.1 VI.2 VI.3 VI.4

Nonresidential Construction Specification Process and Cycle....................... 71 Architectural Glazing Products Supply Chain ................................................ 78 Shop Fabricated Commercial Window Supply Chain .................................... 81 Nonresidential Door Product Flow ................................................................. 84

Executive Summary

April, 2006

INDEX OF EXHIBITS (continued) Exhibit Title Page Number

Appendix A Exhibit I 2003 Window Distribution Restated Manufacturer Direct........................................................................ 85 Appendix A Exhibit II 2003 Patio Door Distribution and Volume Restated Manufacturer Direct .......................................................... 85

Executive Summary

April, 2006

Executive Report

Summary of Findings Regarding Installation Practices and Procedures 2005 U.S. Market

Copyright 2006 - Co-published April 2006 by:

American Architectural Manufacturers Association (AAMA) 1827 Walden Office Square, Suite 104 Schaumburg, Illinois 60173 Tel: (847) 303-5664/Fax: (847) 303-5774

Window & Door Manufacturers Association (WDMA) 1400 East Touhy Avenue, Suite 470 Des Plaines, Illinois 60018 Tel: (847) 299-5200/Fax: (847) 299-1286

www.aamanet.org

www.wdma.com

Researched by: Ducker Research Company, Inc. 1250 Maplelawn Drive, Troy, MI 48084 (248) 644-0086 www.ducker.com

TABLE OF CONTENTS Section I. II. Description Page

INTRODUCTION AND METHODOLOGY..........................................1 MANUFACTURER INPUT .................................................................2 A. Installation Support Materials B. Installation Crews C. Installation Materials INSTALLER INPUT............................................................................5 A. Window Installations B. Window Flashings C. Window Sealants

III.

INDEX OF EXHIBITS

Exhibit I.1 II.1 II.2 II.3 II.4 II.5 II.6 III.1 III.2 III.3 III.4 III.5 III.6 III.7 III.8 III.9

Title

Page Number

Number of Respondents by Region ..................................................................1 Manufacturer Inclusion of Printed Installation Instructions ............................... .2 Printed Instructions Follow AAMA Installation Masters or ASTM 2112 Guidelines ................................................................................ .2 Manufacturers With Own Installation Crews..................................................... .3 Manufacturer Contracts With Exclusive Installers ............................................ .3 Flashing Materials: Manufacturer Involvement with Customers ....................... .4 Sealant Materials: Manufacturer Involvement with Customers......................... .4 Window Installations With/Without Fins - Overall ............................................ .5 Window Installations With/Without Fins Regional Segmentation ..................5 Window and Door Installations Involving Sill Pans Overall 6 Window Installations Involving Sill Pans Regional Segmentation ..................6 Door Installations Involving Sill Pans Regional Segmentation...7 Window and Door Installations Involving Sill Pans Regional Segmentation7 Flexible Flashing Segmented by Type ............................................................. .8 Flexible Flashing Use Segmented by Region....................................................8 Flexible Flashing Type Segmented by Region ..................................................9

III.10 Incidence of Building Inspectors Checking Flashing Installations ..................... .9 III.11 Instruction Guide Utilized for Window and Door Flashing ................................ .10 III.12 Reported Utilization of Sealant in Window Installations ................................... .11 III.13 Reported Sealant Utilization for Window Installation......................................... 11 III.14 Reported Sealant Utilization for Window Installation - By Region .................... 12