Americas Products & Distribution faced a challenging year
with the sharp decline in new residential construction and
financial market turmoil from mid-year. Against this backdrop, our
Products businesses delivered a resilient performance with
continued growth in nonresidential activity mitigating the impact
of residential weakness, leaving full-year US$ operating profit
only slightly below the record 2006 outcome. In Distribution,
strong acquisition contributions were unable to compensate for an
organic profit decline as residential demand weakened and Florida
demand fell sharply from 2006 peak levels. Regionally, our Products
& Distribution operations in the western and southern states
performed relatively better; while the midwest and northeastern
operations were noticeably weaker than 2006. Significant cost
reduction measures were implemented in our residential-orientated
businesses which mitigated the impact of volume declines. Overall,
the Division recorded a 5% increase in sales and a 6% decline in
operating profit before translation adjustments. We believe that
this represents a very positive outcome and once again demonstrates
the merits of the Division’s broad sectoral exposure and
product diversity.
Architectural Products (APG)
APG, with 234 locations in 39 states and two Canadian provinces,
is the leading North American producer of concrete products for the
commercial masonry, professional landscaping and consumer DIY
markets. The group is also a regional leader in clay brick,
packaged dry-mixes, packaged decorative stone, mulches and
soils.
APG faced difficult trading conditions in 2007 due to the sharp
and continuing slowdown in the residential construction sector and
weaker demand from the homecenter channel. These negative
influences were partially offset by strong non-residential
construction which limited the decline in like-for-like sales to
approximately 10%. Despite the reduction in turnover, strong margin
management, a significant turnaround in our Lawn & Garden
bagged soil and mulch activities and a strong performance from our
Canadian operations resulted in broadly maintained profits and an
improved overall operating margin compared with 2006.
APG completed 12 acquisitions in 2007. These included the
purchase of concrete block operations, masonry distribution
businesses and other bolt-on acquisitions in masonry, packaged
soils and mulches, and packaged specialty concrete products.
Precast
The Precast group is a leading manufacturer of precast,
prestressed and polymer concrete products, small plastic box
enclosures and concrete pipe in North America. The group operates
from 81 locations in 26 states and the province of
Québec.
The continued strength of the non-residential construction
sector during the year was offset by a very weak residential
sector. However, margins were sustained by good cost control and
effective price management and profits were only slightly behind a
record 2006. Backlog volumes and margins heading into 2008 are
similar to 2007. Management’s focus will be on internal
improvements and cost reduction as we move into a more challenging
environment.
Internal developments completed during 2007 included the
commissioning of the new concrete pipe production plant in the
Panhandle region of Florida and the completion of two major
concrete pipe plant expansions in eastern Pennsylvania and Utah.
Together these investments will result in increased capacity and
lower manufacturing costs in three key markets.
Precast completed two acquisitions in 2007 – the
acquisition of a plastic and polymer box manufacturer with plants
in California, Kentucky and Ohio, expanding our national leadership
position in concrete, polymer and concrete small box enclosures,
and the purchase of a concrete manhole producer in Southern
California, adding to our strong market position in that
region.
Glass
The Glass group custom manufactures high-performance
architectural glass and engineered aluminium glazing systems for
multistorey commercial, institutional and residential
construction.
In June the Glass group acquired the Vistawall Group. With
annual sales of US$323 million, Vistawall is a leading
vertically-integrated manufacturer of a broad range of
architectural aluminium glazing systems, including storefront
systems, curtain wall, glass skylights, translucent roof and wall
systems and operable windows. Headquartered in Terrell, Texas,
Vistawall has 26 locations and a national footprint with sales in
all 50 states. The acquisition of Vistawall provides scale and
critical mass for Glass group’s growth strategy to assemble a
unique product and service bundle of architectural glass and
architectural aluminium glazing systems. With an expanded network
of 73 locations in 26 states and four Canadian provinces, the Glass
group continues to be the largest supplier of high-performance
glazing products and services in North America.
Trading conditions in the architectural glass market weakened in
the second half of the year, although continued demand for
high-performance energy-efficient architectural glass products and
value-added fabrication services resulted in similar like-for-like
sales and operating profit. This, combined with an excellent
firsttime contribution from Vistawall due to strong demand for
storefront, curtain wall systems and operable windows, enabled the
group to achieve a record performance in 2007.
MMI
MMI, acquired in April 2006, has 17 manufacturing plants and 59
distribution centres across 29 states plus a plant in Mexico.
Sales and profitability in its fencing division (which depends
to an important degree on residential applications) declined
significantly due to the dramatic fall in residential construction
activity and price development which failed to keep up with
increasing steel costs. The residential downturn also impacted
certain product categories in the welded wire reinforcement
division and this weakness was not sufficiently offset by demand
from the commercial and infrastructure sectors. Although
disappointing volumes and pricing were also factors for the
construction accessories division (especially in the state of
Florida), it performed relatively well for the year particularly in
those products used in tilt-up wall construction and as anchoring
systems for building facades and structural components. In light of
market conditions, strong management actions are underway to
rationalise MMI’s cost structure and improve operating profit
margins.
Distribution
Oldcastle Distribution, trading primarily as Allied Building
Products (“Allied”), has 200 branches in 30 US states
and 2 Mexican states, focused on major metropolitan areas. It
comprises two divisions which supply contractor groups specialising
in Roofing/Siding and Interior Products (wallboard, steel studs and
acoustical ceiling systems).
Roofing/Siding is the group’s traditional business and
Allied is one of the top three distributors in this segment in the
United States. Demand is largely influenced by residential
replacement activity with the key products having an average life
span of roughly 20 years. In 2005, we organised our fast-growing
Interior Products operations, focused equally on the commercial and
residential construction markets, into a separate division. We have
significantly expanded this segment and, with the recent
acquisition of Acoustical Materials Services in the western United
States and Baja California, Mexico, Interior Products accounts for
approximately 47% of annualised Distribution sales and we are now
the third largest Interior Products distributor in the United
States. Key to Oldcastle Distribution’s success is its
well-trained, highly motivated workforce and strategically-focused
organisational structure, supported by superior IT.
2007 was a challenging year for Americas Distribution in both
its business sectors. Roofing/Siding demand declined in almost all
areas reflecting the downturn in both new and remodel activity.
Florida was particularly impacted due to the absence of extensive
2006 roofing/siding repair activity which followed active hurricane
seasons in both 2004 and 2005. Hawaii and the Pacific Northwest
were the bright spots for the year. Interior Products performed
well despite a generally weakening background and significant price
deflation in gypsum wallboard and, with the benefits of good
contributions from acquisition activity in recent years
particularly in Hawaii, Texas and North Carolina, profits were
maintained. Against this backdrop, full year operating profit for
Americas Distribution declined by 26% before translation effects;
while down from the record 2006 level, the operating margin of 5.3%
was resilient in the circumstances.
South America
Our operations in Argentina and Chile had another record year in
a robust regional economic environment. In Argentina, the recent
capacity expansion made in our ceramic tile business resulted in
further strong gains in sales and profits. Our Chilean glass
business performed extremely well and the new state-of-the-art
laminating facility remains on track for start up in March
2008.
Outlook 2008
New United States residential demand is forecast to show further
declines in 2008 and the timing and pace of a recovery is not clear
given the continued uncertainty in credit markets. Residential
repair, maintenance and improvement activity is historically less
cyclical and is expected to remain close to 2007 levels. Following
good momentum in 2007, non-residential construction looks likely to
moderate later in 2008. Benefits from acquisitons, improvements
made in 2007, and further targeted cost reductions measures will
mitigate the effects of an overall weaker market, and we look to a
slightly lower US$ outcome for our Products and Distribution
activities.
The Americas Products & Distribution Division operates
primarily in the United States and has a significant presence in
Canada. Its product groups – Architectural Products, Precast,
Glass, MMI and Distribution – all have leading positions in
national and regional markets. The Division is also a leading
producer of clay tile products in Argentina and operates glass
fabrication businesses in Argentina and Chile. Employees total
approximately 24,000 at almost 600 locations.
Activities
Market leadership positions
Concrete masonry, patio products, pavers
and rooftiles
Canada, United States
13.4m tonnes*
No. 1 in masonry, paving and patio in United
States
No. 1 in paving and patio in Canada
Prepackaged concrete mixes United States
2m tonnes*
No. 2 United States
Clay bricks, pavers and tiles
Argentina, United States
1.3m tonnes*
No. 1 brick producer in northeast and midwest United
States
No. 1 in rooftiles in Argentina
No. 2 wall and floor tiles in Argentina
Precast concrete products
Canada, United States
2.4m tonnes*
No. 1 United States
Glass fabrication
Argentina, Canada, Chile, United States
12.5m square metres*
No. 1 in architectural glass fabrication in North
America
Aluminium Glazing Systems
Canada, United States
n/a
No. 1 in custom-engineered aluminium glazing systems in North
America
Construction accessories
United States
n/a
No. 1 United States
Welded wire reinforcement
United States
n/a
No. 2 fencing distributor and manufacturer United
States