usg AR_2005

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usg AR_2005

  1. 1. USG Corporation 2005 Annual Report
  2. 2. Dear Fellow Shareholders We have kept our promises, and a promising future lies ahead. In 200, when we filed for Chapter , we committed to: – Sustain our market leadership and operational excellence – Maintain a strong organization – Pay our creditors in full – Gain the best outcome for current shareholders – Put asbestos behind us, once and for all – Emerge as quickly as possible, without sacrificing our other goals Those commitments have been kept. On January 30th, 2006, we announced a watershed agree- ment that resolves all asbestos-related personal injury claims against USG. Protecting Your Interests Our years of effort, on many fronts, have succeeded. Our operations team continued to serve our customers with distinction—and lead our industry. Our finance staff assured that we had the capital required to negotiate from a position of strength. We communicated honestly and forthrightly with all key stakeholders, including shareholders, customers, suppliers, bankers and investors, and all bankruptcy committees. We worked hard to develop a broad, legislative solution to the asbestos crisis. And we succeeded in crafting an agreement that is fair, fast, final and affordable. The agreement is fair for everyone who has a stake in USG. People who suffer from an asbestos- related illness will begin receiving compensation soon after the plan is approved by the courts. All of our creditors will be paid in full, with interest—an amount totaling approximately $.4 billion. Employees can look ahead with confidence, secure in the knowledge that our enterprise USG Corporation 2005 Annual Report
  3. 3. 2 is stable, proud and vibrant. And for the first time ever in a major asbestos bankruptcy agree- ment, shareholders will retain their ownership of the company. After nearly five years in bankruptcy, the agreement offers a fast resolution. With the approval of the courts and the continued support of key stakeholder committees, we could leave Chapter “Now the House and the as early as July of this year. Senate need meaningful When the agreement is approved, we will gain a final settlement of our asbestos personal injury asbestos reform and they need to get it to my desk liability. We will be able to put the issue behind us once and for all and avoid the uncertainty of as soon as possible.” lengthy, contentious bankruptcy litigation. President George W. Bush, October 26, 2005 The agreement is affordable. We will finance it using funds from a number of sources, including our existing cash balances and a rights offering. Our record-setting operating performance over the past five years has enabled us to set aside almost $.6 billion in cash, which provides a substantial portion of the capital required. We plan to raise $.8 billion in new equity through a rights offering to our stockholders, who will have the opportunity to purchase one new share of stock for each share already owned. A backstop agreement will assure that we receive the full amount. Under the terms of the agreement, the final amount we will pay depends on the fate of the Fairness in Asbestos Injury Resolution Act, commonly known as the FAIR Act. The Senate debated the legislation in February of 2006, but an effort to overcome a technical issue related “It is a remarkable comeback for to the Act failed by one vote, stalling the legislation. the 104-year-old company – and When our plan of reorganization takes effect, we will pay $ 900 million into a special trust that an unprecedented recovery for the stock of a company that is would pay all asbestos personal injury claims against U.S. Gypsum, now and in the future. We still doing business under believe that $ 900 million is an equitable settlement. protection from creditors.” If the FAIR Act, which calls for the establishment of a $40 billion national trust fund to pay The Wall Street Journal, February 15, 2006 asbestos victims, is passed and signed into law by the President, $ 900 million is all that we would pay. Our trust would be consolidated into the national trust fund, and we would owe nothing more.
  4. 4. 3 If the FAIR Act fails, we are obligated to make two additional payments totaling $ 3.05 billion to our personal injury trust. Although it is a large sum and does not accurately reflect what we believe to be our true liability for asbestos, we are able to fund it, and doing so provides a clear path toward leaving Chapter with our shareholders’ equity largely intact. Should the two payments become necessary, we will raise about $ billion in new debt financing and add it to the funds raised by the rights offering. Making the full $ 3.95 billion contribution to the trust will result in a tax refund of about $. billion, which will also be used to fund the agreement. We are speaking with representatives of property damage claimants, but as of now, property damage claims are not a part of the agreement. Property damage claimants will retain the rights to any valid claims that remain unresolved when the bankruptcy is concluded. In the days and weeks ahead, we will continue to work to win passage of the FAIR Act, which we have actively supported from the beginning. It is good for USG, good for the country and good for people who suffer from asbestos-related illnesses. Yet even if the Act does not become law, the agreement to resolve our bankruptcy is one of the most significant events in our 04-year history. And it tops a year of stellar performance—one of the best we’ve ever had. A Record-Setting Performance Just as our restructuring team has worked to do what’s right for our shareholders, creditors and asbestos claimants, our operations team has made tremendous progress in serving our customers and preparing for the future. The U.S. housing market remained strong through the end of the year, and housing starts reached the highest level since 972. Our long-term strategies of investing in low-cost manufacturing and expanding our distribution business enabled us to meet the demand. After topping $4 billion USG achieved record sales of for the first time in 2004, our sales rose 4 percent to a record $ 5. billion in 2005. We shipped a more than $ 5 billion in 2005. record .3 billion square feet of wallboard, up three percent from 2004. We also shipped record volumes of joint compound and FIBEROCK products. L W Supply, our distribution company, achieved double-digit gains in both sales and profit. Sales in our worldwide ceilings business increased three percent, with much of the gain coming late in the year. USG Corporation 2005 Annual Report
  5. 5. 4 Net earnings for the year reached $ 50 million before the impact of a $.9 billion after-tax charge associated with the bankruptcy settlement and an $ million after-tax charge related to the adoption of a new accounting standard. After the charges, we reported a net loss of $.4 billion for the year. Building the Enterprise Even in the midst of Chapter , we never stopped working to improve our products and build our enterprise. In fact, since 200, we have invested more than $ 500 million to build the most productive and profitable operations in the industry. Improvements include new DUROCK cement board lines in Baltimore and Monterrey, Mexico, and new joint compound lines in Phoenix, Jacksonville and Baltimore. Expansions to our Aliquippa, Pennsylvania, and Jacksonville, Florida, facilities add more than 00 million square feet of new, low-cost wallboard production When it is completed in 2008, the new wallboard plant in capacity. Upgrades to our Bridgeport, Alabama, facility created the fastest wallboard line in the Washingtonville, Pa., will serve world, capable of producing more than a mile of wallboard in less than 0 minutes. New York, Philadelphia and other The investments we have made have dramatically improved our operating performance—our important East Coast markets. wallboard lines are now running an average of more than 40 percent faster than they did five years ago. High-volume, low-cost production provides a critical strategic advantage. It gives us the flexibility needed to be successful across market cycles—we can meet market demand during peak periods and we can weather the storm during the low points of the cycle. We continued to build our operations in 2005. In February, we announced plans to invest about $30 million to modernize and upgrade our Norfolk, Virginia, wallboard plant. When the work The new Washingtonville wall- is completed by mid-2007, it will more than double the plant’s capacity. In September, we an- board plant will use 800,000 nounced construction of a new, state-of-the-art wallboard plant in Washingtonville, Pennsylvania. tons of recaptured gypsum per Scheduled to begin operations in 2008, it will produce approximately one billion square feet of year produced by the scrubbers wallboard annually, while also setting new standards for environmental responsibility. The plant on a nearby power plant. will produce wallboard using recaptured gypsum, utilize 00 percent recycled paper, recycle 00 percent of its production waste and operate with zero discharges into nearby waterways.
  6. 6. 5 We also have continued to build our distribution business. Today, working under a number of locally recognized names, L W operates more than 200 locations, and is the only specialty distributor with a national presence. Thirty-six manufacturing plants earned a perfect The expansion of our production and distribution facilities is part of our long-term mission safety rating in 2005. to “Find a Better Way”—and continuously improve every aspect of our performance. We are especially proud of our safety performance, which remains one of the best in our own—or any— industry. In fact, 36 of our manufacturing plants achieved a perfect safety rating in 2005. A New Chapter Now, with the end of Chapter in sight, we are ready to open a bright new chapter in our history. USG has a long tradition of leadership, and leadership remains our objective today. We will achieve it by focusing on customer service and operational excellence. The loyalty and support of our customers, some of whom have done business with us for genera- tions, have sustained us during Chapter . We’re continuing to strengthen those relationships and build new ones with new products for new markets. SHEETROCK is already one of the best-known brands in the country. New marketing efforts are strengthening our brands even more. A new multi-year title sponsorship agreement with NASCAR USG signed a multi-year agree- puts our major brands – SHEETROCK, DUROCK, FIBEROCK and DONN - in front of thousands of our ment to sponsor the SHEETROCK customers and millions of viewers around the world. 400 and the DUROCK 300 races. NASCAR has more than 75 million We want to be known as a company that’s easy to do business with. We are continuing to imple- fans and is the No. 2 rated sport ment an enterprise-wide software system, called LinX, that will connect all of our operations, on television. reduce costs for USG and our customers, and provide better, more timely information. The new training and quality programs at our customer service center are allowing us to provide the “one-and-done” service that customers are looking for. Our industry-leading Web site provides a variety of tools to help customers easily design with and specify USG products. USG Corporation 2005 Annual Report
  7. 7. 6 Innovative products give customers even more reasons to do business with us. In 2005, we launched a number of new products that round out our product lines and expand our share of houses and commercial buildings. Created for commercial applications, new SECUROCK brand roof board offers superior fire, wind and moisture resistance, greater versatility and less envi- In 2005, United States Gypsum ronmental impact than conventional products. We expanded our line of DUROCK products with Company shipped enough wall- board to build 1.3 million homes. new mortars, mastics and grouts that help contractors deliver high-quality tile installations. A new family of LEVELROCK poured self-leveling cement underlayments, designed for flooring applications, was named one of the Top 00 Products of 2005 by Buildings magazine. Looking Ahead With leading brand names, leading market shares, and industry-leading production and distribu- tion operations, we can look ahead with confidence. Toward the end of 2005, the housing market began to show signs of cooling, but we expect it to remain strong by historical standards. We are ready, with a plan for all seasons. If demand slows, we have the option of idling or retiring older, higher-cost operations. We are committed to outperforming our competitors at every point in the cycle. We will continue to invest for the future. Along with adding to our low-cost production capacity, we will continue to grow LW’s distribution network. We have commissioned a new ship to carry gypsum from our mines to our plants. Later this year we will begin to move into a new headquar- ters in Chicago, which will aid efforts to control costs and improve productivity. We will continue to strengthen our service and our customer relationships. We will complete the implementation of our LinX system and intensify our quest for innovation. In addition to extend- ing our current product lines, our Research and Development staff is exploring a number of new product innovations, as well as breakthrough technologies that could revolutionize wallboard and ceilings production.
  8. 8. 7 We also will continue to build the best team in the industry. Increased emphasis on skills training and leadership development programs is helping to prepare the next generation of USG’s leader- ship. A number of organizational changes further strengthened our team. As the new president of USG Corporation, Jim Metcalf will lead our continuing pursuit of operational excellence by overseeing all of our North American operating subsidiaries. Ed Bosowski is now directing our overall growth plan and strategy, as well as our international operations. We also have added further experience to our board of directors with the election of Steven F. Leer, chairman and chief executive officer of Arch Coal, Inc. With the exception of myself, all of our directors are independent as defined by both USG and NYSE standards. In protecting the interests of shareholders throughout an asbestos-related restructuring, while leading our industry, we have achieved something few, if any, companies have ever accom- “It’s the most successful plished. This singular achievement is the direct result of staying focused on our goals and true managerial performance in to our convictions. It is a credit to the hard work and resolve of all of USG’s 4,000 employees, not bankruptcy that I’ve ever seen.” just over the past 2 months, but over the past five years. They all have played a role and applied Warren E. Buffett, Chairman of the Board, Berkshire Hathaway Inc. their strength to carry us through uncertain times. No one could be more proud of or grateful for The Wall Street Journal, what they have accomplished. For the record, however, I would like to single out Stan Ferguson February 15, 2006 and Rick Fleming for their valued counsel and untiring efforts to find a principled solution to an extraordinary challenge. USG—and I—owe them our deepest thanks. Your company is stronger than ever before. The path ahead is clear. We are moving forward. William C. Foote Chairman and Chief Executive Officer February 24, 2006 USG Corporation 2005 Annual Report
  9. 9. Business Over view 8 Businesses Products and Services Gypsum United States Gypsum Company Manufactures and markets gypsum CGC Inc. wallboard, joint treatments and tex- USG Mexico S.A. de C.V. tures, cement board, gypsum fiber panels, plaster, shaft wall systems and industrial gypsum products Ceilings USG Interiors, Inc. Manufactures and markets USG International acoustical ceiling panels, ceiling CGC Inc. suspension grid, specialty ceilings and other building products Distribution LW Supply Corporation Specializes in delivering construc- tion materials to job sites
  10. 10. 9 Best-Known Brand Names Geographical Areas Served Customers SHEE TROCK gypsum panels; United States, Canada, Mexico purchasers : specialty drywall SHEE TROCK H UMITEK gypsum pan- centers, distributors, hardware els; SHEE TROCK joint compounds; cooperatives, buying groups, DUROCK cement board; FIbEROCK home centers, mass merchandis- gypsum fiber panels; SECUROCK ers; influencers : architects, roof board; LE V ELROCK floor specifiers, building owners; underlayment; H Y DROCA L gypsum end users : contractors, builders, cement; IMPERIAL building plasters; do-it-yourselfers and DIAMOND building plasters ASTRO, ECLIPSE and R A DA R United States, Canada, Mexico purchasers : specialty acoustical ceiling panels; DONN DX, FINELINE and more than 125 other countries centers, distributors, hardware and CENTRICITEE ceiling grid; in all parts of the world: North, cooperatives, home centers, con- COMPäS SO suspension trim; Central and South America, the tractors; influencers : architects, CURVAT UR A 3-D ceiling system; Caribbean, Europe, the Middle specifiers, interior designers, GEOME TRI X ceiling panels; East, Asia, the Pacific Rim, Africa building owners, tenants, facility TOPO 3-dimensional system; managers; end users : contrac- and bILLO 3-dimensional panels tors, builders, do-it-yourselfers United States purchasers and end users : contractors, builders USG Corporation 2005 Annual Report
  11. 11. 0 Board of Directors Corporate Of ficers Rober t L . Barnet t Valerie B. Jarret t William C. Foote Dominic Dannessa ( 2*, 4, 5, 6 ) (*, 4, 5, 6) Former Executive Managing Director and Chairman and Vice President; Vice President, Executive Vice President, Chief Executive Officer Executive Vice President, Motorola Corporation The Habitat Company Manufacturing, building Systems James S. Metcalf President and Keith A . Brown Steven F. Leer Brendan J. Deely ( 2, 3, 4, 5 ) ( 3, 4, 6 ) President, Chairman and Chief Operating Officer Vice President; President Chimera Corporation Chief Executive Officer, and Chief Operating Officer, Edward M. Bosowski Arch Coal, Inc. LW Supply Corporation Executive Vice President James C. Cot ting ( 3, 4, 5 ) Former Chairman and and Chief Strategy Officer; Mar vin E. Lesser Fareed A . K han (, 2, 4, 6) Chief Executive Officer, Managing Partner, President, USG International Vice President; Navistar International Sigma Partners, L.P. Executive Vice President, Stanley L . Ferguson Corporation Sales and Marketing, Executive Vice President John B. Schwemm (, 2, 4) building Systems Former Chairman and and General Counsel Lawrence M. Crutcher ( 2, 3, 4*, 5, 6* ) Managing Director, Chief Executive Officer, Karen L . Leets Richard H. Fleming Veronis Suhler Stevenson R.R. Donnelley Sons Company Vice President and Treasurer Executive Vice President and Chief Financial Officer William C. Foote Judith A. Sprieser D. Rick Lowes (, 2, 3*, 4, 6) Chairman and Former Chief Executive Officer, Vice President and Controller Brian J. Cook Chief Executive Officer Transora, Inc. Senior Vice President, Peter K . Maitland Human Resources W. Douglas Ford (, 4, 5*) Vice President, Committees of the board of Directors Former Chief Executive, Compensation, benefits Compensation and Organization Marcia S. Kaminsk y Refining and Marketing, and Administration Committee Senior Vice President, bP Amoco p.l.c. 2 Audit Committee Communications Donald S. Mueller 3 Finance Committee 4 Governance Committee David W. Fox Vice President, (, 3, 4, 6) 5 Corporate Affairs Committee Former Chairman and Research and Development 6 Governance-Nominating Subcommittee Chief Executive Officer, * Denotes Chair Clarence B. Owen Northern Trust Corporation and Vice President and The Northern Trust Company Chief Technology Officer J. Eric Schaal Corporate Secretary and Associate General Counsel
  12. 12. Form 0-K USG Corporation 2005 Annual Report
  13. 13. UNITED STATES SECURITIES AND EXCHANGE COMMISSION Washington, D.C. 20549 _________________ FORM 10-K (Mark One) X ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 For the fiscal year ended December 31, 2005 OR TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 For the transition period from _______________ to _______________. Commission File Number 1-8864 USG CORPORATION (Exact name of Registrant as Specified in its Charter) Delaware 36-3329400 (State or Other Jurisdiction of (I.R.S. Employer Incorporation or Organization) Identification No.) 125 S. Franklin Street, Chicago, Illinois 60606-4678 (Address of Principal Executive Offices) (Zip Code) Registrant’s Telephone Number, Including Area Code: (312) 606-4000 Securities Registered Pursuant to Section 12(b) of the Act: Name of Exchange on Title of Each Class Which Registered New York Stock Exchange Common Stock, $0.10 par value Chicago Stock Exchange Preferred Share Purchase Rights (subject to New York Stock Exchange Rights Agreement dated March 27, 1998, as amended) Chicago Stock Exchange Preferred Stock Purchase Rights (subject to New York Stock Exchange Reorganization Rights Plan, dated January 30, 2006) Chicago Stock Exchange 8.5% Senior Notes, Due 2005 New York Stock Exchange Securities Registered Pursuant to Section 12(g) of the Act: None (Title of Class) Indicate by check mark whether the registrant is a well-known seasoned issuer, as defined in Rule 405 of the Securities Act. Yes No Indicate by check mark if the registrant is not required to file reports pursuant to Section 13 or 15(d) of the Exchange Act. Yes No Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days. Yes No Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of registrant’s knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K. Indicate by check mark whether the registrant is a large accelerated filer, an accelerated filer, or a non-accelerated filer. See definition of “accelerated filer and large accelerated filer” in Rule 12b-2 of the Exchange Act. Large accelerated filer Accelerated filer Non-accelerated filer Indicate by check mark whether the registrant is a shell company (as defined in Exchange Act Rule 12b-2) Yes No Indicate by check mark whether the registrant has filed all documents and reports required to be filed by Section 12, 13 or 15(d) of the Securities Exchange Act of 1934 subsequent to the distribution of securities under a plan confirmed by a court. Yes No The aggregate market value of the registrant’s common stock held by non-affiliates based on the New York Stock Exchange closing price as of June 30, 2005 (the last business day of the registrant’s most recently completed second fiscal quarter), was approximately $1,834,759,765. The number of shares outstanding of the registrant’s common stock as of January 31, 2006, was 44,683,671.
  14. 14. DOCUMENTS INCORPORATED BY REFERENCE Certain sections of USG Corporation’s definitive Proxy Statement for use in connection with the annual meeting of stockholders to be held on May 10, 2006, are incorporated by reference into Part III of this Form 10-K Report where indicated. TABLE OF CONTENTS PART I Page Item 1. Business .............................................................................................................................................. 3 Item 1a. Risk Factors......................................................................................................................................... 8 Item 1b. Unresolved Staff Comments................................................................................................................ 13 Item 2. Properties ............................................................................................................................................ 14 Item 3. Legal Proceedings ............................................................................................................................... 15 Item 4. Submission of Matters to a Vote of Security Holders ......................................................................... 15 PART II Item 5. Market for the Registrant’s Common Stock, Related Stockholder Matters and Issuer Purchases of Equity Securities ......................................................................................................................... 16 Item 6. Selected Financial Data ....................................................................................................................... 17 Item 7. Management’s Discussion and Analysis of Results of Operations and Financial Condition .............. 18 Item 7a. Quantitative and Qualitative Disclosures About Market Risks ........................................................... 40 Item 8. Financial Statements and Supplementary Data ................................................................................... 41 Item 9. Changes in and Disagreements With Accountants on Accounting and Financial Disclosure ............. 81 Item 9a. Controls and Procedures...................................................................................................................... 81 PART III Item 10. Directors and Executive Officers of the Registrant ............................................................................. 83 Item 11. Executive Compensation..................................................................................................................... 85 Item 12. Security Ownership of Certain Beneficial Owners and Management and Related Stockholder Matters ........................................................................................................................ 85 Item 13. Certain Relationships and Related Transactions ................................................................................. 85 Item 14. Principal Accounting Fees and Services ............................................................................................. 85 PART IV Item 15. Exhibits and Financial Statement Schedules ....................................................................................... 86 Signatures ................................................................................................................................................................. 90 2
  15. 15. PART I Item 1. BUSINESS General the Bankruptcy Court. Since the Filing, the Debtors have ceased making payments with respect to asbestos United States Gypsum Company (“U.S. Gypsum”) was lawsuits. incorporated in 1901. USG Corporation (the In late January 2006, the Debtors, the committee “Corporation”) was incorporated in Delaware on representing asbestos personal injury claimants (the October 22, 1984. By a vote of stockholders on “Official Committee of Asbestos Personal Injury December 19, 1984, U.S. Gypsum became a wholly Claimants” or “ACC”), and the legal representative for owned subsidiary of the Corporation, and the future asbestos personal injury claimants (the “Futures stockholders of U.S. Gypsum became the stockholders Representative”) reached an agreement to resolve of the Corporation, all effective January 1, 1985. Debtors’ present and future asbestos personal injury Through its subsidiaries, the Corporation is a liabilities and to cooperate in the confirmation of a plan leading manufacturer and distributor of building of reorganization consistent with that resolution (the materials, producing a wide range of products for use in “Asbestos Agreement”). The Asbestos Agreement was new residential, new nonresidential, and repair and approved by USG’s Board of Directors on January 29, remodel construction as well as products used in certain 2006, and was executed by the Futures Representative industrial processes. and each law firm representing a member of the ACC. The Asbestos Agreement also is supported by the VOLUNTARY REORGANIZATION UNDER CHAPTER 11 committee representing unsecured creditors (the On June 25, 2001, the Corporation and 10 of its United “Official Committee of Unsecured Creditors”) and the States subsidiaries (collectively, the “Debtors”) filed committee representing the Corporation’s shareholders voluntary petitions for reorganization (the “Filing”) (the “Official Committee of Equity Security Holders”). under Chapter 11 of the United States Bankruptcy Code The Asbestos Agreement does not include asbestos (the “Bankruptcy Code”) in the United States property damage claims, and the committee Bankruptcy Court for the District of Delaware (the representing asbestos property damage claimants (the “Bankruptcy Court”). The Chapter 11 cases of the “Official Committee of Asbestos Property Damage Debtors (the “Chapter 11 Cases”) have been Claimants”) has not taken a position on the Asbestos consolidated for purposes of joint administration as In Agreement. re: USG Corporation et al. (Case No. 01-2094). These As contemplated by the Asbestos Agreement, the cases do not include any of the Corporation’s non-U.S. Debtors expect to file a proposed plan of reorganization subsidiaries or companies that were acquired post- (the “Proposed Plan”) and a Disclosure Statement with petition by Debtor LW Supply Corporation. The the Bankruptcy Court in February 2006 incorporating Debtors initiated Chapter 11 proceedings to resolve the terms of the Asbestos Agreement and addressing the asbestos claims in a fair and equitable manner, to treatment of other claims and interests. Pursuant to the protect the long-term value of the Debtors’ businesses, Proposed Plan, a trust would be created and funded by and to maintain the Debtors’ leadership positions in Debtors pursuant to Section 524(g) of the Bankruptcy their markets. The Debtors are operating their Code, and this trust would compensate all qualifying businesses as debtors-in-possession subject to the present and future asbestos personal injury claims provisions of the Bankruptcy Code. against the Debtors. If confirmed by the courts, the U.S. Gypsum is a defendant in asbestos lawsuits Proposed Plan would contain an injunction channeling alleging both property damage and personal injury. all asbestos personal injury claims against the Debtors Other Debtors also have been named as defendants in a to the Section 524(g) trust for payment and precluding small number of asbestos personal injury lawsuits. As a any individual or entity from bringing an asbestos result of the Filing, all pending asbestos lawsuits personal injury claim against Debtors. This channeling against U.S. Gypsum and other Debtors are stayed, and injunction would include any asbestos personal injury no party may take any action to pursue or collect on claims against Debtors relating to A.P. Green such asbestos claims absent specific authorization of Refractories Co., a former subsidiary of U.S. Gypsum 3
  16. 16. and the Corporation. The amount that the Debtors and Note 18, Litigation. would be required to pay to the Section 524(g) asbestos OPERATING SEGMENTS personal injury trust would depend upon whether The Corporation’s operations are organized into three national legislation creating a trust for payment of operating segments: North American Gypsum, asbestos personal injury claims is enacted by the 10th Worldwide Ceilings and Building Products day after final adjournment of the 109th Congress. If the Distribution. Net sales for the respective segments Proposed Plan is confirmed and the legislation is accounted for approximately 54%, 12% and 34% of enacted by that date, the Debtors’ funding obligation to 2005 consolidated net sales. the Section 524(g) trust would be $900 million. If the Proposed Plan is confirmed and such legislation is not North American Gypsum enacted before that date, or such legislation is enacted but held unconstitutional, the Debtors’ funding BUSINESS North American Gypsum, which manufactures and obligation to the Section 524(g) trust would total $3.95 markets gypsum and related products in the United billion. States, Canada and Mexico, includes U.S. Gypsum in Under the Proposed Plan, allowed claims of all the United States, the gypsum business of CGC Inc. other creditors, including allowed claims of general (“CGC”) in Canada, and USG Mexico, S.A. de C.V. unsecured creditors, would be paid in full, with interest (“USG Mexico”) in Mexico. U.S. Gypsum is the largest where required. Disputed claims, including disputed manufacturer of gypsum wallboard in the United States asbestos property damage claims, would be resolved in and accounted for approximately one-third of total the bankruptcy proceedings or other forum, where domestic gypsum wallboard sales in 2005. CGC is the appropriate. Upon resolution of those disputed claims, largest manufacturer of gypsum wallboard in eastern the allowed amount of any such claims would also be Canada. USG Mexico is the largest manufacturer of paid in full, with interest where required. Shareholders gypsum wallboard in Mexico. of the Corporation as of the effective date of the Proposed Plan would retain their shares, and pursuant to a proposed shareholder rights offering, would have PRODUCTS North American Gypsum’s products are used in a the right to purchase, at $40.00 per share, one new variety of building applications to finish the interior common share of the Corporation for each share owned walls, ceilings and floors in residential, commercial and as of the effective date of the rights offering. institutional construction and in certain industrial There are important conditions to the Asbestos applications. These products provide aesthetic as well Agreement and conditions to confirmation and as sound-dampening, fire-retarding, abuse-resistance effectiveness of the Proposed Plan. One of the and moisture-control value. The majority of these conditions of the Asbestos Agreement is that the products are sold under the SHEETROCK® brand Proposed Plan must be confirmed and have an effective name. Also sold under the SHEETROCK® brand name date on or before August 1, 2006, absent written is a line of joint compounds used for finishing agreement among all parties to the Asbestos Agreement wallboard joints. The DUROCK® line of cement board to extend that time. There can be no assurance that the and accessories provides water-damage-resistant and Proposed Plan will be confirmed or, if confirmed, fire-resistant assemblies for both interior and exterior become effective by August 1, 2006. construction. The FIBEROCK® line of gypsum fiber Additional information about the Proposed Plan, panels includes abuse-resistant wall panels and floor the Section 524(g) asbestos personal injury trust underlayment as well as sheathing panels usable as a contemplated by the Proposed Plan, funding relating to substrate for most exterior systems and as roof cover the Proposed Plan, conditions and other factors relating board sold under the SECUROCK® brand name. The to the effectiveness of the Proposed Plan, and asbestos LEVELROCK® line of poured gypsum underlayments litigation involving the Debtors is set forth in Part II, provides surface leveling and enhanced sound Item 7, Management’s Discussion and Analysis of performance for residential, commercial and multi- Results of Operations and Financial Condition, and Part family installations. The Corporation produces a variety II, Item 8, Financial Statements and Supplementary of construction plaster products used to provide a Data - Notes to Consolidated Financial Statements, custom finish for residential and commercial interiors. Note 2, Voluntary Reorganization Under Chapter 11, 4
  17. 17. Like SHEETROCK® brand gypsum wallboard, these The Corporation owns and operates seven paper products provide aesthetic, sound-dampening, fire- mills located across the United States. Vertical retarding and abuse-resistance value. Construction integration in paper ensures a continuous supply of plaster products are sold under the trade names RED high-quality paper that is tailored to the specific needs TOP®, IMPERIAL® and DIAMOND®. The Corporation of the Corporation’s wallboard production processes. also produces gypsum-based products for agricultural The Corporation augments its paper needs through and industrial customers to use in a number of purchases from outside suppliers. About 7% of the applications, including soil conditioning, road repair, Corporation’s paper supply was purchased from such fireproofing and ceramics. sources during 2005. MANUFACTURING MARKETING AND DISTRIBUTION North American Gypsum’s products are manufactured Distribution is carried out through LW Supply at 42 plants located throughout the United States, Corporation (“LW Supply”), a wholly owned Canada and Mexico. subsidiary of the Corporation, other specialty wallboard Gypsum rock is mined or quarried at 14 company- distributors, building materials dealers, home owned locations in North America. In 2005, these improvement centers and other retailers, and locations provided approximately 70% of the gypsum contractors. Sales of gypsum products are seasonal in used by the Corporation’s plants in North America. the sense that sales are generally greater from spring Certain plants purchase or acquire synthetic gypsum through the middle of autumn than during the remaining and natural gypsum rock from various outside sources. part of the year. Based on the Corporation’s estimates Outside purchases or acquisitions accounted for 30% of using publicly available data, internal surveys and the gypsum used in the Corporation’s plants. The gypsum wallboard shipment data from the Gypsum Corporation’s geologists estimate that its recoverable Association, management estimates that during 2005 rock reserves are sufficient for more than 24 years of about 47% of total industry volume demand for gypsum operation based on the Corporation’s average annual wallboard was generated by new residential production of crude gypsum during the past five years construction, 39% of volume demand was generated by of 9.7 million tons. Proven reserves contain residential and nonresidential repair and remodel approximately 240 million tons. Additional reserves of activity, 8% of volume demand was generated by new approximately 148 million tons are found on four nonresidential construction, and the remaining 6% of properties not in operation. volume demand was generated by other activities such About 26% of the gypsum used in the as exports and temporary construction. Corporation’s plants in North America is synthetic gypsum, which is a by-product resulting from flue gas COMPETITION desulphurization carried out by electric generation or The Corporation accounts for more than 30% of the industrial plants burning coal as a fuel. The suppliers of total gypsum wallboard sales in the United States. In this kind of gypsum are primarily power companies, 2005, U.S. Gypsum shipped 11.3 billion square feet of which are required to operate scrubbing equipment for wallboard, the highest level in its history. U.S. industry their coal-fired generating plants under federal shipments (including imports) estimated by the Gypsum environmental regulations. The Corporation has entered Association were a record 37.2 billion square feet. into a number of long-term supply agreements that Competitors in the United States are: National Gypsum provide for the acquisition of such gypsum. The Company, BPB (through its subsidiaries BPB Gypsum, Corporation generally takes possession of the gypsum Inc. and BPB America Inc.), Georgia-Pacific at the producer’s facility and transports it to its user Corporation, American Gypsum (a unit of Eagle wallboard plants, by water where convenient using Materials Inc.), Temple-Inland Forest Products ships or river barges, or by railcar or truck. The supply Corporation, Lafarge North America, Inc. and PABCO of synthetic gypsum is continuing to increase as more Gypsum. Competitors in Canada include BPB Canada power generation plants are fitted with desulphurization Inc., Georgia-Pacific Corporation and Lafarge North equipment. Of the Corporation’s gypsum wallboard America, Inc. The major competitor in Mexico is Panel plants, 48% use some or all synthetic gypsum in their Rey, S.A. Principal methods of competition are quality operations. of products, service, pricing, compatibility of systems 5
  18. 18. and product design features. COMPETITION The Corporation estimates that it is the world’s largest Worldwide Ceilings manufacturer of ceiling grid. Principal competitors in ceiling grid include WAVE (a joint venture between Armstrong World Industries, Inc. and Worthington BUSINESS Worldwide Ceilings, which manufactures and markets Industries) and Chicago Metallic Corporation. The interior systems products worldwide, includes USG Corporation estimates that it is the second-largest Interiors, Inc. (“USG Interiors”), the international manufacturer/marketer of acoustical ceiling tile in the interior systems business managed as USG world. Principal global competitors include Armstrong International, and the ceilings business of CGC. World Industries, Inc., OWA Faserplattenwerk GmbH Worldwide Ceilings is a leading supplier of interior (Odenwald), BPB America Inc. and AMF ceilings products used primarily in commercial Mineralplatten GmbH Betriebs KG (owned by Gebr. applications. The Corporation estimates that it is the Knauf Verwaltungsgellschaft KG). Principal methods largest manufacturer of ceiling grid and the second- of competition are quality of products, service, pricing, largest manufacturer/marketer of acoustical ceiling tile compatibility of systems and product design features. in the world. Building Products Distribution PRODUCTS Worldwide Ceilings manufactures ceiling tile in the BUSINESS United States and ceiling grid in the United States, Building Products Distribution consists of LW Canada, Europe and the Asia-Pacific region. It markets Supply, the leading specialty building products both ceiling tile and ceiling grid in the United States, distribution business in the United States. In 2005, Canada, Mexico, Europe, Latin America and the Asia- LW Supply distributed approximately 11% of all Pacific region. Its integrated line of ceilings products gypsum wallboard in the United States, including provides qualities such as sound absorption, fire approximately 32% of U.S. Gypsum’s wallboard retardation and convenient access to the space above production. the ceiling for electrical and mechanical systems, air distribution and maintenance. USG Interiors’ MARKETING AND DISTRIBUTION significant trade names include the AURATONE® and LW Supply was organized in 1971. It is a ACOUSTONE® brands of ceiling tile and the DONN®, service-oriented organization that stocks a wide range DX®, FINELINE®, CENTRICITEE®, CURVATURA® of construction materials and delivers less-than- and COMPASSO® brands of ceiling grid. truckload quantities of construction materials to job sites and places them in areas where work is being done, thereby reducing the need for handling by MANUFACTURING Worldwide Ceilings’ products are manufactured at 15 contractors. LW Supply specializes in the distribution plants located in North America, Europe and the Asia- of gypsum wallboard (which accounted for 50% of its Pacific region. Principal raw materials used in the 2005 net sales), joint compound and other gypsum production of Worldwide Ceilings’ products include products manufactured by U.S. Gypsum and others. It mineral fiber, steel, perlite, starch and high-pressure also distributes products manufactured by USG laminates. Certain of these raw materials are produced Interiors such as acoustical ceiling tile and grid as well internally, while others are obtained from various as products of other manufacturers, including drywall outside suppliers. metal, insulation, roofing products and accessories. LW Supply leases approximately 90% of its facilities from third parties. Typical leases are five years and MARKETING AND DISTRIBUTION Worldwide Ceilings’ products are sold primarily in include renewal options. markets related to the construction and renovation of LW Supply remains focused on opportunities to commercial buildings. Marketing and distribution are profitably grow its specialty business as well as conducted through a network of distributors, optimize asset utilization. As part of its plan, LW installation contractors, LW Supply locations and Supply acquired eight locations in 2005. As of home improvement centers. December 31, 2005, LW Supply operated 192 6
  19. 19. locations in 36 states, compared with 186 locations and million, $17 million and $18 million in the years ended 183 locations as of December 31, 2004 and 2003, December 31, 2005, 2004 and 2003, respectively. respectively. ENERGY Primary supplies of energy have been adequate, and no COMPETITION LW Supply competes with a number of specialty curtailment of plant operations has resulted from wallboard distributors, lumber dealers, hardware stores, insufficient supplies. Supplies are likely to remain home improvement centers and acoustical ceiling tile sufficient for projected requirements. Currently, energy distributors. Competitors include Gypsum Management price swap agreements are used by the Corporation to Supply with locations in the southern, central and hedge the cost of a substantial majority of purchased western United States, Rinker Materials Corporation in natural gas. the southeastern United States (primarily in Florida), KCG, Inc. in the southwestern and central United SIGNIFICANT CUSTOMER States, The Strober Organization, Inc. in the On a worldwide basis, The Home Depot, Inc. accounted northeastern and mid-Atlantic states, and Allied for approximately 11% of the Corporation’s Building Products Corporation in the northeastern, consolidated net sales in 2005, 2004 and 2003. central and western United States. Principal methods of competition are location, service, range of products and OTHER pricing. Because orders are filled upon receipt, no operating segment has any significant order backlog. Executive Officers of the Registrant None of the operating segments has any special working capital requirements. See Part III, Item 10, Directors and Executive Officers Loss of one or more of the patents or licenses held of the Registrant - Executive Officers of the Registrant by the Corporation would not have a major impact on (as of February 14, 2006). the Corporation’s business or its ability to continue operations. Other Information No material part of any of the Corporation’s business is subject to renegotiation of profits or termination of contracts or subcontracts at the election RESEARCH AND DEVELOPMENT The Corporation performs research and development at of the government. the USG Research and Technology Innovation Center All of the Corporation’s products regularly require (the “Research Center”) in Libertyville, Ill. Research improvement to remain competitive. The Corporation team members provide product support and new also develops and produces comprehensive systems product development for the operating units of the employing several of its products. To maintain its high Corporation. With unique fire, acoustical, structural and standards and remain a leader in the building materials environmental testing capabilities, the Research Center industry, the Corporation performs ongoing extensive can evaluate products and systems. Chemical analysis research and development activities and makes the and materials characterization support product necessary capital expenditures to maintain production development and safety/quality assessment programs. facilities in good operating condition. Development activities can be taken to an on-site pilot- In 2005, the average number of employees of the plant level before being transferred to a full-size plant. Corporation was 14,100. Research is also conducted at two satellite locations See Part II, Item 8, Financial Statements and where industrial designers and fabricators work on new Supplementary Data - Notes to Consolidated Financial ceiling grid concepts and prototypes. Statements, Note 16, Segments, for financial In 2006, a new lab will be formed to give special information pertaining to operating and geographic focus to innovation, further enhancing the research segments. team’s commitment to the Corporation’s growth initiative. Research and development expenditures are charged to earnings as incurred and amounted to $17 7
  20. 20. Available Information substantially diluted or cancelled in whole or in part. Even if the Proposed Plan is confirmed, the The Corporation maintains a website at www.usg.com Corporation’s payments to the asbestos personal and makes available at this website its annual report on injury trust will vary substantially depending upon Form 10-K, quarterly reports on Form 10-Q, current whether federal asbestos trust fund legislation is reports on Form 8-K and all amendments to those enacted, or is enacted but found unconstitutional. reports as soon as reasonably practicable after such Passage of such legislation is extremely speculative material is electronically filed with or furnished to the and not within the control of the Corporation. Securities and Exchange Commission (the “SEC”). If you wish to receive a paper copy of any exhibit to the Pursuant to the Asbestos Agreement with the ACC and Corporation’s reports filed with or furnished to the the Futures Representative, the Debtors expect to file a SEC, such exhibit may be obtained, upon payment of Proposed Plan in February 2006 pursuant to which the reasonable expenses, by writing to: J. Eric Schaal, Debtors propose to resolve their present and future Corporate Secretary, USG Corporation, P.O. Box 6721, asbestos personal injury liabilities through the creation Chicago, IL 60680-6721. You may read and copy any and funding of an asbestos personal injury trust under materials the Corporation files with the SEC at the Section 524(g) of the Bankruptcy Code. If the Proposed SEC’s Public Reference Room at 100 F Street, N.E., Plan is confirmed, all present and future asbestos Washington, D.C. 20549. You may obtain information personal injury claims against the Debtors would be on the operation of the Public Reference Room by channeled to the trust, and no individual or entity may calling the SEC at 1-800-SEC-0330. thereafter bring an asbestos personal injury claim against Debtors. The amount that the Debtors must pay to the Section 524(g) asbestos personal injury trust Item 1a. RISK FACTORS would depend upon whether national legislation creating a trust for payment of asbestos personal injury claims is enacted into law by the 10th day after final Our business, operations and financial condition are adjournment of the 109th Congress. If the legislation is subject to various risks and uncertainties. You should carefully consider the risks and uncertainties described enacted by that date, the Debtors’ funding obligation to below, together with all of the other information in this the Section 524(g) trust would be $900 million. If such annual report on Form 10-K and in other documents legislation is not enacted before that date, or is enacted that we file with the SEC, before making any investment but held unconstitutional, the Debtors’ funding decision with respect to our securities. If any of the obligation to the Section 524(g) trust would total $3.95 following risks or uncertainties actually occur or billion. develop, our business, financial condition, results of The Asbestos Agreement is subject to numerous operations and future growth prospects could change. conditions. One of the conditions of the Asbestos Under these circumstances, the trading prices of our Agreement is that the Proposed Plan be confirmed and securities could decline, and you could lose all or part effective no later than August 1, 2006. There is no of your investment in our securities. guarantee that the Proposed Plan will be confirmed or become effective. If the Proposed Plan is not The Debtors expect to file a Proposed Plan to resolve confirmed, the Debtors will remain in chapter 11, the their present and future asbestos personal injury amount of Debtors’ present and future asbestos liabilities pursuant to an agreement with the Official personal injury liabilities will be unresolved, and the Committee of Asbestos Personal Injury Claimants (or terms and timing of any plan of reorganization ACC) and the Futures Representative. However, there ultimately confirmed in the Debtors’ Chapter 11 Cases is no guarantee that the Proposed Plan will be are unknown. In such a situation, it cannot be known confirmed. If the Proposed Plan, or a substantially what amount will be necessary to resolve Debtors’ similar plan, is not confirmed, the interests of the present and future asbestos personal injury liabilities, Debtors’ creditors and stockholders may be how the plan of reorganization ultimately approved will significantly and adversely affected by any plan of treat other pre-petition claims, whether there will be reorganization ultimately confirmed, and the interests sufficient assets to satisfy Debtors’ pre-petition of the Corporation’s stockholders may be liabilities, and what impact any plan of reorganization 8
  21. 21. Corporation’s ability to continue as a going concern. ultimately confirmed may have on the value of the Our plans concerning this matter also are described in shares of the Corporation’s common stock or other Note 2. The financial statements do not include any securities. The interests of the Corporation’s adjustments that might result from the outcome of this stockholders may be substantially diluted or cancelled uncertainty. in whole or in part. Our historical financial information will not be The Asbestos Agreement does not resolve asbestos indicative of our financial performance following property damage claims. Currently, approximately 900 approval of any plan of reorganization by the proofs of claim alleging asbestos property damage are Bankruptcy Court. Under American Institute of pending. Under the Proposed Plan, asbestos property Certified Public Accountants Statement of Position damage claims would be separately resolved in the 90-7, “Financial Reporting by Entities in bankruptcy proceedings or other forum, where Reorganization under the Bankruptcy Code,” all of our appropriate. outstanding debt is classified as liabilities subject to See Part II, Item 7, Management’s Discussion and compromise, and interest expense on this debt has not Analysis of Results of Operations and Financial been accrued or recorded since June 25, 2001 (the Condition, and Part II, Item 8, Financial Statements and “Petition Date”). From the Petition Date through Supplementary Data - Notes to Consolidated Financial December 31, 2005, contractual interest expense not Statements, Note 2, Voluntary Reorganization Under accrued or recorded on pre-petition debt totaled $337 Chapter 11, and Note 18, Litigation, for additional million. This calculation excludes the impact of any information on the bankruptcy proceeding, including compounding of interest on unpaid interest that may be the potential impacts of asbestos litigation on those payable under the relevant contractual obligations, as proceedings. well as any interest that may be payable under a plan of reorganization to trade or other creditors that are not As a result of the Chapter 11 Cases, our historical otherwise entitled to interest under the express terms of financial information will not be indicative of our their claims. future financial performance. In connection with the Chapter 11 Cases and the As a result of the Chapter 11 Cases, our capital development of any plan of reorganization, it is also structure may be significantly changed by any plan of possible that additional restructuring and similar reorganization. Under fresh start accounting rules that charges may be identified and recorded in future may, or may not, apply to us upon the effective date of periods. Such charges could be material to the any plan of reorganization, our assets and liabilities consolidated financial position and results of operations would be adjusted to fair values and retained earnings of the Corporation in any given period. would be restated to zero. Accordingly, if fresh start accounting rules apply, our financial condition and Debtor U.S. Gypsum has significant asbestos personal results of operations following our emergence from injury liabilities, and the ACC and Futures Chapter 11 would not be comparable to the financial Representative claim that other Debtors have condition or results of operations reflected in our significant asbestos personal injury liabilities as well. historical financial statements. The Proposed Plan will establish the possible amount The accompanying consolidated financial that Debtors would be required to pay into a Section statements have been prepared assuming that the 524(g) asbestos personal injury trust to satisfy all Corporation will continue as a going concern. As liabilities for present and future asbestos personal discussed in Part II, Item 8, Financial Statements and injury claims against Debtors, including claims Supplementary Data - Notes to Consolidated Financial against Debtors relating to A.P. Green Refractories, Statements, Note 2, Voluntary Reorganization Under Inc., a former subsidiary of U.S. Gypsum and the Chapter 11, there is significant uncertainty as to the Corporation. However, if the Proposed Plan is not resolution of our asbestos litigation, which, among confirmed, the amount of the Debtors’ asbestos other things, may lead to possible changes in the personal injury liabilities will not be resolved and will composition of our business portfolio, as well as be subject to substantial dispute and uncertainty. changes in the ownership of the Corporation. This uncertainty raises substantial doubt about the 9
  22. 22. Our future indebtedness could adversely affect our As a result of the Asbestos Agreement and Proposed financial condition. Plan, in the fourth quarter of 2005, the Corporation recorded a pretax charge of $3.1 billion ($1.935 billion, The optimum level of future indebtedness will be or $44.36 per share, after tax) for all asbestos-related contingent on the capital structure of the Corporation claims, increasing the reserve for all asbestos-related under a plan of reorganization or in connection with claims to $4.161 billion. This reserve includes the developments thereafter. Our indebtedness could have Debtors’ obligations to fund asbestos personal injury significant adverse effects on our business. Such claims as will be set forth in the Proposed Plan adverse effects could include, but are not limited to, the (recorded at $3.95 billion on the assumption that the following: Proposed Plan is confirmed but that the FAIR Act or substantially similar legislation is not enacted as set • make it more difficult for us to satisfy our debt forth in the Proposed Plan). This reserve also includes service obligations; the Debtors’ estimate of the cost of resolving asbestos property damage claims filed in its chapter 11 • increase our vulnerability to adverse economic proceedings, including estimated legal fees associated and industry conditions; with those claims; and the Debtors’ estimate of resolving other asbestos-related claims and legal • require us to dedicate a substantial portion of expenses associated with those claims. our cash flows from operations to payments If the Proposed Plan is not confirmed, the amount on our indebtedness, thereby reducing the of Debtors’ asbestos personal injury liabilities will not availability of our cash flows to fund working be resolved and will likely be subject to substantial capital, capital expenditures and other general dispute and uncertainty. In that event, if the amount of operating requirements; such liabilities is not resolved through negotiation or through federal asbestos legislation, such liabilities • limit our flexibility in planning for, or reacting likely will be determined by the Court through an to, changes in our business and industry, estimation proceeding in the Chapter 11 Cases. The which may place us at a disadvantage ACC and the Futures Representative have stated in a compared to our competitors with stronger court filing that they estimate that the net present value liquidity positions, thereby hurting our results of the Debtors’ liability for present and future asbestos of operations and ability to meet our debt personal injury liabilities is approximately $5.5 billion service obligations with respect to our and that the Debtors are insolvent. The Debtors have outstanding indebtedness; and stated that they believe they are solvent if their asbestos liabilities are fairly and appropriately valued. If the • limit, along with the financial and other Proposed Plan is not confirmed, the amount of Debtors’ restrictive covenants in our outstanding asbestos personal injury liabilities could ultimately be indebtedness, our ability to borrow additional determined to be significantly different from the funds. currently accrued reserve. This difference could be material to the Corporation’s financial position, cash Our businesses are cyclical in nature, and prolonged flows and results of operations in the period recorded. periods of weak demand or excess supply may have a See Part II, Item 7, Management’s Discussion and material adverse effect on our business, financial Analysis of Results of Operations and Financial condition and operating results. Condition, and Part II, Item 8, Financial Statements and Supplementary Data - Notes to Consolidated Financial Our businesses are cyclical in nature and sensitive to Statements, Note 2, Voluntary Reorganization Under changes in general economic conditions, including, in Chapter 11, and Note 18, Litigation, for additional particular, conditions in the housing and information on the bankruptcy proceeding and litigation construction-based markets. Prices for our products and matters. services are affected by overall supply and demand in the market for our products and for our competitors’ products. In particular, market prices of building 10
  23. 23. performance, and develop our manufacturing and products historically have been volatile and cyclical, distribution capabilities. and we, like other producers, may have limited ability We also compete through our use of information to control the timing and amount of pricing changes for technology and expect to continue to improve our our products. Prolonged periods of weak demand or systems. We need to provide customers with timely, excess supply in any of our businesses could negatively accurate, easy-to-access information about product affect our revenues and margins and harm our liquidity, availability, orders and delivery status using state-of- financial condition and operating results. the-art systems in order to maintain our market share. The markets that we serve, including, in particular, While we may use manual processes for short-term the housing and construction-based markets, are failures and disaster recovery capability, a prolonged significantly affected by the movement of interest rates. disruption of systems or other failure to meet Significantly higher interest rates could have a material customers’ expectations for the capabilities and adverse effect on our business and results of operations. reliability of these systems could adversely affect our Our business is also affected by a variety of other results of operations, particularly during any prolonged factors beyond our control, including, but not limited period of disruption. to, employment levels, foreign currency exchange rates, We intend to continue making investments in office vacancy rates, unforeseen inflationary pressures research and development to develop new and and consumer confidence. Since our operations occur in improved products and more-efficient production a variety of geographic markets, our businesses are methods. We believe we need to continue to develop subject to the economic conditions in each such new products and improve our existing products and geographic market. General economic downturns or production efficiency in order to maintain our market localized downturns in the regions where we have leadership position. A failure to continue making such operations could have a material adverse effect on our investments could restrain our revenue growth and business, financial condition and operating results. harm our operating results and market share. In The seasonal nature of our businesses may adversely addition, even if we are able to invest sufficient affect our quarterly financial results. resources in research and development, these investments may not generate net sales that exceed our A majority of our business is seasonal with peak sales expenses, generate any net sales at all or result in any typically occurring from spring through the middle of commercially acceptable products. autumn. Quarterly results have varied significantly in the past and are likely to vary significantly from quarter If costs of key raw materials or employee benefits to quarter in the future. Such variations could have a increase, or the availability of key raw materials negative impact on our financial performance and the decreases, our cost of products sold will increase, and trading prices of our common stock or our other our operating results may be materially and adversely securities. affected. We face competition in each of our businesses. If we The cost and availability of raw materials and energy cannot successfully compete in the marketplace, our are critical to our operations. For example, we use business, financial condition and operating results substantial quantities of gypsum, wastepaper, mineral may be materially and adversely affected. fiber, steel, perlite, starch and high pressure laminates. The cost of these items has been volatile, and We face competition in each of our operating segments. availability has sometimes been limited. We source Principal methods of competition include quality of some of these materials from a limited number of products, service, location, pricing, compatibility of suppliers, which increases the risk of unavailability. systems, range of products and product design features. Furthermore, we may not be able to pass increased raw Aggressive actions by our competitors could lead to materials prices on to our customers if the market or lower pricing by us in order to compete. To achieve existing agreements with our clients do not allow us to and/or maintain leadership positions in key product raise the prices of our finished products. If price categories, we must continue to develop brand adjustments significantly trail the increase in raw recognition and loyalty, enhance product quality and materials prices or if we cannot effectively hedge 11

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