Concrete and Masonry Contractors
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Industry Overview
The US concrete and masonry contracting industry includes about 60,000 establishments (single-location companies and units of multi-location companies) with combined annual revenue of $70 billion. No major companies dominate the industry, which is highly fragmented.
The industry includes three main groups: poured concrete foundation and structure contractors; structural steel and precast concrete contractors; and masonry contractors.
Competitive Landscape
Demand is driven by residential and commercial construction. The profitability of individual companies depends on cost estimation and project management. Large companies have economies of scale in marketing and purchasing. Small companies can compete effectively by specializing. The industry is labor-intensive: annual revenue per employee is less than $150,000.
The federal economic stimulus package approved in 2009, which included billions of dollars for infrastructure projects, should prove to be a boon for concrete and masonry contractors.
Products, Operations & Technology
Major jobs for concrete and masonry contractors include foundations and walls for residential and commercial building projects, as well as for infrastructure such as driveways and parking areas, highways, streets, sidewalks, bridges, tunnels, and sewers.
Concrete is a highly versatile material. Its characteristics depend on the types and proportions of the various materials mixed to create it. Concrete contains portland cement (the binding material); sand; gravel (or other kinds of crushed rock, all called "aggregate"); and water. Some concretes also contain coloring agents, sealants, and other additives to provide special properties. On construction projects, the type of concrete needed is usually specified precisely and may be tested periodically for quality. Contractors usually mix ingredients at a central yard just before delivery to a construction site, where the concrete must be poured within a few hours before it begins to harden, or set.
Concrete contractors primarily pour concrete into prepared forms and molds, which often contain reinforcing steel bars (rebar). Most concrete contractors erect their own forms or molds and place patterns of rebar before pouring. Both form and rebar work are sometimes subcontracted to specialists, especially on complicated projects. Various devices used during the pouring process ensure that air pockets do not form and that the concrete is well compacted. In addition to the familiar mixing trucks with rotating barrels, contractors may use lift buckets and concrete pumps.
Structural steel contractors erect and assemble structural parts made from steel or precast concrete, such as steel beams, structural steel components, and similar products of precast concrete. They also assemble and install other steel construction products, including steel rods, bars, and rebar to reinforce poured-in-place concrete.
Masonry contractors use concrete blocks, bricks, and other pre-formed elements to build walls. Most masonry projects specify a particular type of concrete block, brick, or stone, which the contractor usually buys from wholesalers. Masonry walls may contain reinforcing elements. The mortar that binds the blocks or bricks is typically mixed at the construction site.
To increase margins, some contractors have expanded into fields such as tilt-up construction work, in which walls are poured flat, then tilted into position when hardened, or have added engineering and design capabilities to do design/build projects. To ensure timely execution of work - sometimes on simultaneous projects - companies use project management systems.
