U.S. Resilient Market: Last year, commercial revenues outpaced residential, but the category still declined marginally – May 2026

By Darius Helm

In 2025, the U.S. resilient market, comprising LVT, sheet goods, VCT and other forms of resilient flooring, declined 2.4% to an estimated $7.37 billion, with domestic production accounting for just 19% of consumption. 

While imports were down by under 2.5%, domestic production fell 5%. Nevertheless, with new capacity coming online and U.S.-based manufacturers starting to invest in product enhancements, many domestic producers remain well positioned. 

The drop in domestic production reflects two market impacts, one from the state of the U.S. residential market and the other from the tariffs. 

In terms of the market, manufacturers report that the high end continued to be the driver of the category last year, with the lower-end consumer suffering the worst. On the lower end, while the rate of business is down, there’s still billions of dollars worth of product flowing through the market—that’s where the volume is. And ultimately, that left the middle of the market trailing the field. In the residential remodel and builder sectors, manufacturers report that activity is slowest in the middle price points.

Interestingly, domestic production largely goes to the middle of the market. Both the SPCs at the low end of the market, particularly entry-level, and the WPCs and thicker, enhanced SPCs at the higher end largely come from Asia. Bossen and HMTX are the only domestic WPC producers—all the rest make SPC. And while SPC products from domestic manufacturers cover a large swath of the middle of the market, they don’t extend to entry-level constructions or to the higher end—the ultra-wide and ultra-long formats, extra-thick planks, and enhanced surface details. 

To be sure, there is innovation in the U.S. market. CFL and Engineered Floors enhance their domestic SPC using Hymmen’s direct digital printing. And recently, Shaw and Mohawk have been innovating in their U.S. facilities. Others, like AHF, offer high-performance constructions. But for the foreseeable future, the top and bottom of the market will continue to rely on Asian imports.

And then there are the tariff impacts. Last year, as tariffs started to roll out, many U.S. LVT purveyors moved to secure more inventory, filling their warehouses—and further boosting import volumes. A lot of that volume was at price points where U.S. manufacturers could not effectively compete.

PARTNERSHIPS AND PRIVATE LABEL

The explosion of the rigid core category over the last decade transformed not just the manufacturing landscape, but also the ownership paradigm that used to define the industry, where the bulk of the big players in the market made their own products. The rise of hard surface precipitated the transformation, as carpet producers diversified to maintain their growth, but the arrival of rigid LVT accelerated demand, and Asian producers quickly built capacity to serve the market. 

Many U.S. firms, including the leading flooring manufacturers, have extensive supplier partnerships that they navigate through as conditions dictate. Others have very close relationships, going into joint manufacturing ventures, like HMTX with Elegant Home-Tech—the Asian firm that the Stone family has partnered with for years. 

And the model has also shifted for the outflow of product. Most rigid-core facilities don’t make their own manufacturer-branded products. Much of it fuels the private-label programs that distributors are building to differentiate themselves. Almost none of the big players in the resilient market have sufficient capacity from their own production, and some have shifted to a source-only model. Most rely on overseas manufacturing partnerships. 

PRODUCT TRENDS

WPC continues to grow faster than SPC, though from a much smaller base. But it’s moving the needle and helping firms make revenue gains. Manufacturers agree that, looking back, the issue with low-end SPC failures did a service to the larger rigid-core category, breaking the category’s momentum toward commoditization. 

Rod Mcleod, Shaw’s senior product director for resilient, notes that there hasn’t been much of a market for the thinner SPCs due to installation failures and other issues, and the thinnest profiles tend to be confined to the builder market. Specialty retail is where most consumers are trading up to WPC and thicker SPC, Mcleod adds.

SPC is going down, and WPC is going up, contends Harlan Stone, HMTX’s executive chairman, noting that some domestic products are also falling short. Stone is hopeful that the new standards released by the Resilient Floor Covering Institute last year will help guide the industry’s product quality going forward.

THE TOP FIVE

Shaw Industries, whose Coretec brand brought the first rigid-core LVT to market in 2013, has been the largest resilient player in the U.S. market for nearly a decade. Its commercial and residential offering is a mix of sourced products and inhouse domestic production, which includes its Ringgold, Georgia LVT facility, Plant RP. Last year, Shaw’s U.S. resilient sales were up by low single digits to an estimated $2.23 billion.

Shaw invested $90 million in Plant RP last year, commissioning a new flex LVT line, doubling capacity to shorten lead times and improve service and reliability. A lot of that flex product goes to the commercial market through Shaw Contract and Patcraft. Also, to follow through with its product segmentation strategies and brand building, the firm focused on performance-driven differentiations, yielding products like Pet Perfect with PawDefense technology, a new 6.5mm SPC that is up to 50% more scratch resistant than traditional LVT, according to Mcleod. 

On the sourcing side, the firm’s strategy centers on being flexible and nimble. Mcleod notes that Shaw has a huge “basket of strategic suppliers,” including from Vietnam and Thailand for rigid core and South Korea for flex LVT. 

Shaw’s rigid LVT covers all price points from builder grade to the higher end. While it offers some 4.4mm products in Shaw Floors, most of its SPC is 5mm or thicker. And the Coretec brand, which focuses on the middle to higher end of the rigid LVT market, offers WPC as thick as 3/4 inch, with a 30 mil wearlayer.

Last month, Shaw promoted Aaron John to senior vice president of residential sales, following a return to the firm last October after a five-year stint with Starr Office Environments. Prior to that, he was with Shaw for over two decades. 

MSI Surfaces, which got its start as a ceramic and stone importer before entering the resilient market five or six years ago, has massively grown its resilient program, to where it’s now twice as big as its tile offering. And about five years ago, the Shah family, which owns MSI, bought an SPC facility in Cartersville, Georgia. Last year, MSI’s resilient sales ended down a hair but just ahead of the market at an estimated $951 million. Gains in higher price points helped drive revenues.

In addition to making its own SPC, including its Everlife Studio line, the firm also sources SPC, along with its Smithcliffs and Shorecliffs hybrid rigid core. It also offers looselay and gluedown flex LVT, mostly for the commercial market. While its Everlife branded business is bigger, the firm also does a lot of private-label business. MSI has 50 distribution centers across the U.S. and Canada.

Co-CEO Raj Shah notes that last year was “one of the most volatile years in my career,” referencing tariff and trade wars, AI developments, and industry consolidation by Lowe’s and Home Depot. 

“Production was expanded at our LVT manufacturing plant in Cartersville, Georgia,” says Shah, noting that it expanded capacity by about 30%. “We have a full spectrum of manufacturing options—U.S.A., Vietnam, India, South Korea, China, Thailand, Taiwan, Turkey and Cambodia.”

Mohawk Industries had a fairly healthy year in resilient flooring in 2025, with residential business outpacing commercial. It ended the year about even with the market, with U.S. resilient sales estimated at $654 million.

Over the last decade, Mohawk has amassed substantial North American resilient capacity, first with glass-backed sheet goods and flex LVT in Dalton, Georgia, then adding SPC capacity about eight years ago, and in 2022 it started making SPC in Mexicali, Mexico, as well. It also produces its own wearlayers and films in Dalton.

Nevertheless, the bulk of its offering remains sourced, including WPC, which it reintroduced last year in the Karastan and Pergo brands, and its SolidTech R, a PVC-free product introduced last year.

According to vice president of resilient, Adam Ward, SolidTech R, which is almost entirely made of recycled PET and limestone, offers an improved temperature range over PVC products, along with stronger joint integrity and better performance, including scratch resistance, thanks to its melamine-like wearlayer. The product is priced about 10% over standard SPC products. SolidTech R currently goes to the retail and builder markets, as well as to Lowe’s under Pergo’s DuraCraft RE brand.

A couple of months ago, Victor Abelairas, with Mohawk since 2023, was promoted to president of resilient. Abelairas was previously with Honeywell and Intel. 

And just last month, Mohawk announced the acquisition of Hero Flooring, a producer of high-performance commercial resilient products. According to Mohawk Group president Mike Gallman, “Hero is the authorized licensee of flooring product made with Nike Grind rubber, which comes from manufacturing scrap and end-of-life footwear. We look forward to bringing these products to our Mohawk clients.”

It’s been a busy year for Connecticut-based HMTX, with significant changes of leadership, and on the product side, the firm had strong revenues, up over 4% in U.S. flooring sales to an estimated $639 million. The firm goes to market through its Metroflor, Aspecta and Teknoflor brands, but it also relies heavily on private label and home center partnerships, which Harlan Stone characterizes as a significant growth engine in HMTX—and in the industry, he notes.

In terms of leadership changes, in 2024 Debarati Sen was brought on board, ultimately taking over the CEO position as Stone moved to executive chairman, but by the fall of last year, she was gone, with CFO John Henkel stepping in as interim CEO. In April of last year, chief sustainability officer Rochelle Routman also left the firm. And at the end of the year, Russ Rogg, president of HMTX Contract + Trade, also departed. And earlier this year, Jon England, previously with Shaw, was brought in as SVP of Contract and Trade.

Commenting on the changes at the top, Stone says, “It’s an opportunity to look at new directions and look at business with fresh eyes.” He adds that, as executive chairman, he no longer has to concern himself with approving budgets, pricing, day-to-day operations, leaving him free to focus on strategy.

One strategy that’s been particularly successful has been the migration of its production partnerships from manufacturing in China to Thailand, Vietnam, Mexico and the U.S. It’s the same three big Chinese partners, but now their capacity outside of China has exceeded their existing Chinese capacity. Its most prominent partner, Elegant Home-Tech, is the firm’s joint venture partner in both the Pittston, Pennsylvania facility and a facility in Monterrey, Mexico. Both facilities produce WPC. HMTX also has partnerships in South Korea, unrelated to its Chinese partners.

One goal for the year, according to Stone, is to get more diversity from its Pittston plant, and then expand capacity. It’s already the largest domestic WPC producer, Stone notes, with most of the product currently serving the home center market.

After two challenging years and a comprehensive retooling of its Adura Selling System because of Uyghur woes—sales were down 22% in 2023 and another 6% in 2024—Mannington turned the ship around last year, posting 8% growth to an estimated $429 million in U.S. resilient sales from a revised $397 million in 2024. Its residential LVT business grew by about 15% last year, while residential sheet was down by mid-single digits, while commercial vinyl—including LVT and both heterogeneous and homogeneous sheet—was up by high single digits. Mannington is the only U.S. producer of homogeneous sheet, which has a strong position in healthcare.

The privately owned New Jersey firm, celebrating its 110th anniversary this year, makes residential and commercial sheet goods, as well as flex LVT, at its domestic facilities. It sources its rigid LVT, both SPC and WPC—having sold its WPC plant in Calhoun, Georgia to China’s Bossen a couple of years ago—from both domestic and Asian sources. Its WPC business continues to be bigger than its SPC.

Part of what has helped drive Mannington’s business in this challenging economic climate is that the firm stays away from the entry-level market, which has been struggling to find its footing. Sales of WPCs, including from its Adura Apex line, have been robust, along with added value SPC products, like the firm’s hexagonal designs that use real grout.

The firm has recently invested in its LVT facility in Madison, Georgia, adding a few high-speed cut tables. About 98% of the firm’s commercial LVT is made at the facility, and it has recently added a 5mm product to the lineup. Commercial LVT business was up around 10% last year. n