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Spring 2019
What’s
popular in
the kitchen
and bath
ALSO:
n An interior designer’s
perspective
n The history of the
association
n The long life of Al-Co
T O 19
0
IU DEON 2
G YC
L
PO
INSIDE THIS
ISSUE…
PRESIDENT’S LETTER
4 Kitchen and bath
trends Strength in
joining forces
A designer’s
perspective
18 Profile on Al-Co
Products
22 Special preview of
POLYCON 19
I’VE BEEN STRUCK FROM EARLY ON by how proud our members are
12 The history
of ICPA
to be part of this organization. We have a rich and deep past rooted in
our mutual desire to lean on each other in learning to make the best
products we can. Most recently, as we succeeded in pulling away to
DEPARTMENTS become our own association, we have used that rich heritage to give
us direction. We are returning to our roots: concentrating on a few
2 President’s letter
24 ICPA news to know key areas such as technical issues, develop- of those very first meetings with technical
26 Index of advertisers ing strong networks and exchanging informa- demonstrations, tabletop discussions, talks
tion on marketing, employee retention, plant from regulatory experts and social events to
ON THE COVER: This operations and technology. Those who were give us time to network. What we’re chat-
award-winning kitchen
illustrates several of the with this association when it started almost ting about might be different from the early
trends currently catching fire
50 years ago, looked at the some of the same days: all businesses today are struggling with
including white and grey as
countertop and kitchen color issues. staying relevant and vital in the fast-paced
choices, higher backsplashes
and overall clean lines As part of the gener- world of today. But it gives
everywhere. This kitchen, as ation that follows those me faith to know that, from
well as those shown in our
founders, I recognize the the very beginning, we have
feature that begins on page
4, won National Kitchen and
WE MUST FIND
need for the organization recognized and used one ba-
Bath Association awards. The WAYS TO USE
cover kitchen was designed to gather together the THE CURRENT sic tenet, which is that we’re
by Beverly Leigh Binns. tribal knowledge and past REVOLUTION, much stronger as a unit
work that has been created “THE INTERNET OF working together than we
PRODUCED BY by our founders. If we can THINGS,” TO OUR can be as individuals. John
GSP Publishing harness this information, ADVANTAGE. Kohler, whose company
Genilee Swope Parente, we will not need to rein- Al-Co is profiled on page 18
Executive Editor vent the wheel by dealing and who has been with ICPA
gsparente@verizon.net
with the problems of yesterday. Instead, we from its very early days, says that’s why Al-Co
PUBLISHED BY must find ways to use the current revolution, has made it a point to go to every meeting.
“The Internet of Things,” to our advantage, as See what some of our other long-time
well look at new tools for selling our products members have to say in the history piece
4949 Old Brownsboro Rd. to the sustainability crowd. The CCT course starting on page 12. Then go to page 22 and
Ste. 232
Louisville, KY 40222 helps with the former, it is our duty to forge see why I’m excited about POLYCON Kansas
ahead and find ways to focus on the latter. 2019. If you’re at the meeting, be sure to pass
Phone: 470-219-8139
www.TheICPA.com What we’re learning to do with this new along your ideas on how we can move for-
ICPA is to take the backbone we developed as ward; especially those of you who have been
For advertising rates,
please contact an association over our long history and use it with us from the beginning. n
Jennifer Towner at to tackle the new issues. That’s why POLYCON Luke Haas
Jennifer@theicpa.com or
470-219-8139 is so exciting to me. It follows the structure ICPA President
The Look that Makes
the Difference.
enhances almost any surface with spec-
tacular granite colors and textures. With nearly unlimited
application potential, Poly Stone™ is an excellent choice
for use in bathroom vanities, shower surrounds, solid sur-
face kitchen counter tops, wall panels and furnishings –
which makes it particularly suitable for bathroom facilities.
More information at www.acsinternational.com and 1-800-669-9214.
PREDICTING TRENDS IN ANY INDUS- used, a trend backed up by Houzz ar-
TRY that makes products for the home ticles that forecast remodeling trends
can be a guessing game—what’s popu- for 2019. Houzz says tile is rising from
lar is based on regional tastes, personal the countertop to the ceiling, often be-
preferences and today—the significant hind features such as floating shelves
influence of HGTV and other home and flanking range hoods. Elledecor.
shows, online design sites and blogs
read by people seeking design ideas. Looking com adds that big backsplashes are
also being used in smaller areas of the
at 2019
It’s a game everyone in the surfaces home such as powder rooms.
or kitchen and bath product-making Larger background areas could be
industry plays gladly, however, because significant for companies that create
kitchen
it affects the bottom line. them because, according to the 2019
To help us “play,” we turn to interior U.S. Houzz Kitchen Trends Study, nine
designers, design consultants and on- out of ten renovating homeowners
and bath
line web sites that make their living (87%) are installing a backsplash.
telling people “what’s hot and what’s That survey found that the most
not.” Each year, these experts give their popular materials for these features
guesses about what might be popular
in the coming months.
Sometimes one source or expert
trends are ceramic or porcelain tile (55%), fol-
lowed by natural stone (23%).
directly contradicts another. More often, BY GENILEE SWOPE PARENTE Color me pink maybe?
they agree. Several sources said that one of the
Here’s a few tidbits on what’s been forecast for 2019 and big trends in kitchen and baths today are colors that pop.
beyond: For several design firms, that translates into accenting the
kitchen using bright colors such as pink, burnt orange and
Give me more height neon green. In some cases, it means using those colors for
Several sources say one of the hot trends in kitchens these wall accents or counter appliances, but pops are also show-
days is bigger backsplashes and accent walls. Home & Gar- ing up as cabinetry, in fixtures and in other areas of the
den magazine said more full-height backsplashes will be kitchen or bath. Living Etc. magazine said such colors are
Designers
are bringing
mother nature indoors
by situating outdoor
patios/decks off the room
and using rolling screens
and other tools for
separation. Designed by
Sandra Gjesdahl
ALL PROJECTS PHOTOGRAPHED ARE 2018 AWARD-WINNING
PROJECTS FROM THE NATIONAL KITCHEN AND BATH ASSOCIATION.
4 SPRING 2019 | CAST POLYMER CONNECTION
Large,
curbless
showers are in
style. Designed
by Shea
Pumarejo
CAST POLYMER CONNECTION | SPRING 2019 5
part of the retro movement inspired by designs of earlier Meanwhile Décor Mag agrees the most frequently re-
years such as the 1930s and 1950s. The magazine referred quested countertop material designers are asked for is
to what’s popular as “candy pop colors.” Meanwhile, Pan- quartz and less and less people want concrete because it
tone’s color of the year is Living Coral, which the company is both hard to maintain and “tends to date kitchen décor.”
describes as “an animated, life-affirming shade of orange The trend to engineered materials carries to the floor.
with golden undertones.” Last year’s shade was ultra violet, Engineered wood, vinyl and laminate has become nearly
a deep purple hue. twice as popular (40%) as natural hardwood (24%), according
the Houzz.
Keep some dark and moody
While pops of color are touted all over the web, another White wins for surfaces
trend designers say is occurring throughout homes is darker Also winning in the area of countertops is white, according
walls and colors that are deeper and richer to create moods to Houzz’ kitchen trends survey. Nearly one in three up-
and contrast with light colors. Houzz forecasting articles graded counters (31%) are done in various shades of white,
predicted colors such as navy and forest green joining black which now include creams and off whites. That compares to
as favorite paint colors, a reaction to the whites and brights just two years ago, when white held only 22% of the market.
that have dominated the design world the last few years. White is also popular for backsplashes with 35% choosing
Houzz also identified a new trend in kitchen islands: the use that material compared to 20% multi-colored and 14% gray.
of colors such as emerald and deep teal. Meanwhile, white remains by far the top choice for re-
modeling kitchen cabinetry, according to Houzz’ 2019
Quartz rules kitchen survey. It constituted 43% among choices compared
For the first time since Houzz began tracking data four to wood at 25% and gray at 11%.
years ago, engineered quartz is more popular than natural
stone, according to the Houzz kitchen trends study. That Mixing it up
study shows that 48% of people renovating their home favor While white and dark colors are both part of the design buzz
quartz, making it more popular than natural stone at 43%. today, one of the trends most frequently discussed for kitch-
Meanwhile, granite has declined considerably: 40% of ens the last few years is contrasting materials and colors
renovating homeowners upgrading their counters chose this such as dark cabinets mixed with warm woods and white
material two years ago, compared with 30% who are choos- cabinetry with dark counters and accents. Many designers
ing it now. refer to the “tuxedo” look (black against white) as particu-
larly popular this year.
Tiles in new shapes
Houzz says that in kitchens, subway tiles and offset brick
patterns used as backsplashes are starting to see some de-
sign fatigue. Carl Mattison Design and other interior design-
ers have recently said the larger-format tiles in herringbone,
chevron or stacked patterns, which offer some variety as
well as less grout lines, are a fresh look now sought by home-
owners.
Meanwhile, in the bathroom, unusual tiles such as Moroc-
can blue tiles are being used as the centerpiece of design ef-
forts, sometimes starting on the floor. Then the rest of what’s
there in the room, including surfaces, is designed to fit the
Backsplashes colors (e.g. warm gray, light blue-gray, charcoal, powder blue
are reaching to match Moroccan designs).
towards the ceilings
while upper cabinets are
giving way to windows or
features such as cooking
Accessibility for boomers
hoods. Designed by One of the key conclusions in the 2018 U.S. Houzz Bathroom
Kurt Hakansson
Trends Study is that boomers changing their bathrooms are
6 SPRING 2019 | CAST POLYMER CONNECTION
considering what they can do to make their lives easier as
they age. More than a third of those surveyed said this was
an immediate concern and nearly a quarter (22%) said they
are planning ahead for future needs. Among those with
renovations already underway, almost half said they have
changed the bathroom layout. Other upgrades include in-
stalling accessibility features such as seats, low curbs, grab
bars and non-slide floors in upgraded showers and bathtubs. An
increasingly
For the 2019 kitchen study, the numbers were even higher popular feature
with over a third (37%) of boomers reporting they were con- for luxury bathrooms
are destination tubs.
sidering aging needs during kitchen renovations. In that Designed by Raul
room, they are putting in better lighting, more accessible Saldivar
cooktops, touch free faucets and other tools.
Meanwhile, a study of people ages 51 to 69 done for Hart-
ford insurance found that boomers are looking at a number
of tools to make their lives simpler in old age such as coun-
tertops at different heights (42% of respondents) and walk-in
showers with little or no threshold (47%).
To tub or not to tub
Experts seem to disagree whether bathtubs are in or out want canvases influenced by Mother Nature, which means
these days. Houzz’s 2018 bathroom trends forecast found they want features such as waterfall edges on kitchen cabi-
that 80% of homeowners were planning an upgrade of their netry, colors that are earth tones and accents such as stone
bathtubs with soaking tubs the most popular option (69%), work. Meanwhile, Houzz experts say that one trend today
while many design sites tout the use of “destination” tubs is to have the kitchen open to the outdoors, especially in
today as centerpieces of design. Home & Garden says room warmer climates. Houzz predicted more decks and patios
for those tubs and the extra space needed to house them is immediately available to the kitchen through collapsible
coming from hall and bedroom closets. doors and window walls.
At the same time, one third of those quizzed for the
Houzz bathroom study said they’ll remove the tub com- Down on the farm
pletely, while several online bloggers say boomers do not For several years now, contemporary design has been giving
want tubs and in fact, fear that the thinner edges of some of way to the farmhouse look in kitchens. According to Houzz’
the newer spa-like tubs create safety problems. 2019 kitchen trends survey, transitional remains at the top
(21%, down from 26% last year), while contemporary has
What happened to my cabinets? dropped to 15% (down from 21% just two years ago) and
Many sources reported in 2018 that for 2019 and beyond, a farmhouse has risen to 14% (from 11% two years ago).
trend in kitchen design is to get rid of upper level cabine-
try, as well as glass shelving. Gates Interior Design said the Stay tuned for more
reason for this choice is the popularity of minimalism, and One of the most-cited sources for predicting trends in kitch-
several designers mentioned that instead of upper cabinets, ens and baths is the Kitchen and Bath Industry Show. This
designers are putting in windows for extra light. Meanwhile, year’s show was late in February (too late for publishing in
the functionality that used to be above the countertop is this issue) but Cast Polymer Connection will follow up this
now found via the closet: more and bigger pantries are being summer with reports on what else is happening with con-
requested for storage. Designers are also getting cleverer in sumer tastes and designer responses. Executive Editor Ge-
creating concealed storage areas such as deep drawers on nilee Swope Parente asks members who attended the show
perimeters and base cabinets. to please contact her and tell her what trends you saw
(gsparente@verizon.net). n
Give me Mother Nature
GENILEE SWOPE PARENTE is executive editor of Cast Polymer
House Beautiful says more and more home owners today
Connection. Send your ideas and suggestions to gsparente@verizon.net.
CAST POLYMER CONNECTION | SPRING 2019 7
A designer’s
thoughts on cast
polymer products
8 SPRING 2019 | CAST POLYMER CONNECTION
EDITOR’S NOTE: Cast Polymer Connection asked a well-known The last decade has seen the appearance of polymers
interior designer to give her perspective on how she views the improve dramatically. Today, this material looks authentic
current market for cast polymer products. Here’s what she said: with real dimension and thickness, and it comes in a myr-
iad of textures and colors. In many cases, polymers provide
BY ANNE THE USE OF POLYMERS IS WIDESPREAD options not available in nature—such as pure white tiles and
SNEED throughout the construction and design in- countertops, a color not found in natural stone.
dustry in both the residential and commercial The cast polymer industry has expanded into another
industries, and that growth is poised to increase because niche by manufacturing products more consistent with or-
of product benefits as well as a widening range of offerings ganic quality materials, creating the nexus where the array
made from polymers. As we continue to see the of polymer-made products meets the demand of con-
appetite for these products swell, even sumers who desire natural elements and
more new products and applica- materials, but are looking for more du-
tions will emerge. rable products as well as more color
From a designer’s per- THE LAST DECADE HAS options.
spective, the critical factors SEEN THE APPEARANCE
in considering whether to OF POLYMERS IMPROVE Polymers vs. natural stone
choose these products are an DRAMATICALLY. No one would argue that natural
understanding of how a resi- materials are beautiful and organic,
dential client lives or wants to which is why they continue to be a trendy
live or how a commercial client’s building option. However, the world is now see-
customers and employees will interact with the prod- ing the negatives surrounding their use. In many cases
uct. today, they are not the best option because they don’t per-
The secondary consideration is the character of the form as well as non-natural choices, and they need much
house or building and what surface materials or bath/ more care than their polymer counterparts.
kitchen features fit naturally into that character. Nature has created beauty through materials such as
Many people will be surprised if you tell them to look slate, granite and travertine, which are often used for floor
around their homes, offices and other buildings to count tiles, sinks and surrounds, fireplaces, countertops and vari-
all the items made from compounds that include polymers. ous other aesthetic design elements. But before a builder or
They don’t realize they are used in plastics, adhesives, designer opts for using natural stone elements, they have
paints, fiberglass, foam cushions, and even some fabrics many factors to consider in making choices. The lifestyle of
and Teflon-coated cookware as well as floor tiles, counter- the homeowner or how much traffic a commercial building
tops, shower stalls and tubs. The list of items made using will see should be at the forefront of any decision-making
polymers is nearly endless, yet the list continues to grow. process.
Here’s a list of some of the today’s natural elements and
Changes in perception possible issues to keep in mind that illustrate my point:
Although people don’t know how extensively polymers
touch their lives, many homeowners, designers, specifiers n Slate can sustain water damage; it comes in limited
and others have recognized that, as far as bathroom and colors and is cold to the touch.
kitchen surfaces, many improvements have been made over n Limestone has limited options in color and can stain
the last several years. The main change is that the aesthetics easily.
and appearance of polymer surfaces have greatly broadened n Granite is very expensive, may be challenging to install
in selection. Polymers created for home use, for example, and needs to be resealed on a regular basis.
especially those made to look like stone and used for tile and n Travertine is very porous, needs resealing frequently,
countertops, have gone from a bad rap because they didn’t and comes in colors and pattern variations that can
look authentic to disbelief about how real they look. be difficult to match.
n Flagstone has so many product variations, it can
require different levels of care, and some types are
OPPOSITE (TOP, right and left): Bright white does not appear in nature so
designers are relying on polymers; (BOTTOM, from left): A popular look today subject to erosion.
is called “tuxedo,” which means black and white contrasts. Designers today
n Concrete can stain, crack and chip after the material
are learning how to mix natural materials such as wood with durable and
functional surfaces. (Photos: Anne Sneed Architectural Interiors) settles.
CAST POLYMER CONNECTION | SPRING 2019 9
In the case of concrete, many builders and hard landscap- Unique design elements
ers have started adding polymers to reduce cracking and Today’s cast polymer products reflect a cadre of decorative
chipping. Concrete polymer castings, which are often used color and material options that, for those of us choosing the
as yard and garden pavers, offer great design options today design, mean flexibility to customize a product for the space.
and play an integral role in bridging the desire for natural In polymer use, the amount of pigment can be turned up
elements with man-made products. One of the key benefits or down to provide just the right appearance to meet each
of these are that they provide endless design possibilities yet owner’s individual tastes and match the color palette for the
offer the strength of engineered materials. They also offer rest of a room. Polymers today offer options that are a far cry
flexibility and long-term durability, making this material a from yesteryear when the opacity could never mask the mid-
natural choice for projects that need resistance to corrosion dle layers of compressed materials, which lead to unsightly
and weather. cut lines and the need to mask the layers with “patches.”
Also significant today is that, with Cast polymer today also offers options
many people concerned about us- that can reflect the times. During the fi-
ing up our natural resources, THE AMOUNT nancial downturn, for example, many
natural stone has lost a bit of OF PIGMENT CAN BE TURNED people reverted to smaller homes,
favor. Choosing polymer op- UP OR DOWN TO PROVIDE opting for more peace of mind with
tions offers the possibility of
JUST THE RIGHT APPEARANCE smaller mortgages. This trend con-
TO MEET EACH OWNER’S
recycling at the end of the ini- tinues well into the financial recovery,
INDIVIDUAL TASTES
tial use. with millennials and seniors alike cov-
eting smaller homes for different reasons—
Consistency and millennials simply want to enter the home-buying
combinations market at a price point they can afford while not compro-
Since today’s polymer surface materials look more like mising quality of life; seniors may want to simplify their
natural materials but are easier to maintain and incred- life and get back to basics, choosing spaces that offer size
ibly durable, they appeal to today’s buyer of building prod- and functionality over massive square footage. Both groups
ucts looking for a material with consistent performance need more affordable price points, but they are unwilling to
over the life of the product. This makes them appeal not sacrifice style. Integrating natural elements with engineered
just to homeowners, but to those specifying for hotels, retail, products allows them access to both those requirements.
schools and other heavily used areas. As far as homeowners, The key for both home and commercial design is that
nearly limitless colors and pattern variations exist, so buyers each project needs the right design decision makers who
can choose products that meet their personality, taste and have the experience to incorporate research and forecast-
lifestyle demands. ing trends so they can present designs that won’t fall out
Natural stone is imperfect, so those looking for consis- of favor. They need to present options designed for today’s
tency may choose surfaces made from polymers to get a taste that can endure into the future. These designers must
certain look while withstanding the test of time. understand that their designs are not just about their own
All of this will only improve the situation for those who artistic skills, but rather about sharing a client’s vision by
deal with cast polymer as it can offer more options and uses bringing more ideas to the proverbial porcelain neolith table,
in the home as well as commercial buildings. including ideas for how best to use cast polymer products.
Cast polymer products have always been popular for the Whether a project is a new build or a remodel, an opulent,
highly trafficked areas of a home or building, such as kitch- multi-level structure or a simple small home, each effort
ens and restrooms/bathrooms. But so, too, are natural prod- should combine practicality and durability with aesthetics
ucts in favor because of their beauty. Today, many designers and functionally. Because cast polymers meet all these crite-
or specifiers find that using a combination of both natural el- ria, the world will see ever-increasing choices for new unique
ements and polymers in surface materials provides the best products enter the market. n
of both worlds. Integrating natural materials such as woods
ANNE SNEED heads a multi-dimensional interior design firm, Anne Sneed
or stones with polymer-based surfaces creates a seamless
Architectural Interiors (www.annesneed.com) based in California with
design that appeals to the eye and performs well over time clients across the United States. Her firm designs for both residential and
while offering a nearly endless choice of colors, textures, commercial clients, specializing in creating inspiring spaces with realistic
real estate investment parameters. She is a multi-award winner for Best of
finishes and patterns. Houzz design and has written for numerous architectural publications.
10 SPRING 2019 | CAST POLYMER CONNECTIONICPA: The journey to
today’s organization
WITH ALL THAT’S HAPPENED Kitchen and Bath of Lubbock, TX, said it best in one of the
BY GENILEE
SWOPE PARENTE OVER THE LAST FIVE YEARS as columns he wrote as president of ICPA in 2014 (He passed
ICPA became its own separate or- away in 2016). He was talking about why people need an
ganization, it’s easy to lose track of the fact that this association and why members, during the tough years of
most recent development is only a mile marker on what the last decade, needed to remember the early days of
has been a very long journey. ICPA members talk fre- the organization.
quently about the need to bring in new generations of “We joined [back then] because we needed to network
decision-makers and managers, but one of the realities ... never has that reason been stronger [than during harsh
the younger professionals need to recognize is just how economic times].”
solid the base of the organization is. There are second “We joined to learn new ways of doing business ... a
and third generations in the cast polymer industry only vehicle for keeping up with the trends, opportunities, new
because that first generation provided a very strong basis materials, new place to find clients.”
upon which to grow. “Finally, we joined to form a family, which old timers
Industry icon Royce Newsom, head of Venetian Marble like myself still rely upon heavily. I want to be able to pick
TECHNICAL
STANDARDS
FORMATION OF
REGIONALS
12 SPRING 2019 | CAST POLYMER CONNECTIONup the phone and get an answer to one of my problems by their product, which was initially developed for the military
talking to one of my friends,” he concluded. during World War II,” he says. One of the experimenters was
As some of the founding companies of ICPA approach a his own father Lou Gruber, who worked for a kitchen cab-
half decade of existence, CPC decided to take a look back inet company in Southern California. His father’s earliest
at how it all began and what other major milestones there experiment failed—he thought the material might make a
have been. good glue for doors, but he quickly discovered it hardens too
much and too fast to work. Still, Lou Gruber and others on
The early days the west coast began creating a surface product by mixing
Accounts of how and why this association was born differ resin with limestone, which formed a material that looked
according to region and the recollection of the person look- like marble.
ing back, but a few facts are undisputed. One of them is that “Those first attempts did not have finished gel coats, just
making cultured marble was a pretty new business, only the resin and the limestone with a little bit of pigment added
a few decades old, when the idea to form the association to it,” Garasi explains.
began. Still, “It became popular with the building industry, which
Lou Garasi, who with his father Lou Gruber and brother was looking for a product to replace the small pieces of tile
George Gruber, started Gruber Systems many used in the bathroom along the vanity,” Garasi says. Eventu-
years ago, says the industry stretches ally, people extended the new surface material onto the cab-
back to the late 1950s, when a number inet tops and created vanity top units into which sinks could
of people on the west coast were experimenting be dropped, making installation of this essential bathroom
with what could be done with polyester resin. feature a much easier process for the construction industry.
“Manufacturers of resin were looking for applica- Garasi says his father began showing such vanity tops to
tions that would give them a market for a builder in Southern California in about 1958.
Meanwhile, the same sort of experimentation was going
on in other places across the U.S. and manufacturers of the
early versions of cultured marble began popping up and
making a profit. However, they faced the problems of dealing
THE GREAT with a process that was still experimental and sometimes
RECESSION resulted in cracking or yellowing.
Suppliers to the industry, including Gruber Systems
(which went on to become a premier maker of molds for
manufacturers) can be given much of the credit for starting
the process of bringing those manufacturers together to
discuss their problems. Several people interviewed for this
NAME article gave credit to Pat Young, a representative for Gruber,
CHANGES for her efforts in the late 1960s to get people together, but
other supplier representatives also were encouraging man-
ufacturers to tackle product challenges by talking to each
other. Talk also began about the need to develop standards
that would ensure quality.
Richard Higgins, founder of HK Research Corporation, was
one of those suppliers and has remained in the business 59
years. He tells this story: “I was a polyester formulator back
in the early days, and I remember one call I got in 1964. The
caller said he was making sinks out of boat resin and sand.
I was in the laboratory at the time and shared what he said
with those around me, and I remember a lot of laughter
about his idiocy,” he recalls.
Jack Simmons, senior management consultant, ACS Inter-
national, points out that those early attempts suffered from
inferior resins and fillers. “The resins were not designed for
CAST POLYMER CONNECTION | SPRING 2019 13cast polymer nor were the fillers. The fillers were too coarse CMI is born
and not particle packed. The resins were modifications of the The official start date for a national association was October
standard resins being made at the time,” he explains. 1973, when a group of people met at L&M Cultured Marble,
The industry has come a very long way since then, but Chicago, and formed the Cultured Marble Institute. But peo-
one of the reasons is that people like those early experi- ple also were getting together as small groups in their areas
menters pushed suppliers for better resins and gel coats of the country and several of those groups later became
while suppliers pushed manufacturers towards regional subsets of the national.
working together to raise the quality of the prod- Although growing
uct. regulatory concerns,
Someone had to do some pushing because, in problems such as ther-
the early years of the industry, the thought of one mal shock and yellow-
manufacturer going into another manufacturer’s ing, and the desire to
facility to see how they conducted business was find ways to insert qual-
unheard of; the makers of the products feared ity into the backbone of
competition. the industry were the
“Over time, however, main reasons for early
suppliers were able meetings, Garasi recalls
to pull manufactur- another major event that
ers together and ex- pushed companies into
plain that as a group, action in the early 70s:
we would create ben- the middle eastern oil em-
efits in purchasing raw bargo.
materials and a voice “Our industry was under
in meeting with OSHA extreme stress because of
[Occupational Health that embargo and the re-
and Safety Administra- sulting rise in prices. Polyes-
tion] and other regulators,” ter resin, which is a basic component of our
says John Kohler, who ran industry, went from 17 cents to over a dol-
Al-Co Products, Inc., Latty,
OH for almost four decades The association has always extended a line of
communications to its members through newsletters
(see page 18). As a group, “We and magazines. The newsletters on this page illustrate
issues of importance in the 1980s. The magazines on
could share information with
page 15 were part of the 1990s and 2000s.
each other so we could all Below: Meeting coverage of Marblecon ‘81
manufacture a better product.” from an old magazine.
14 SPRING 2019 | CAST POLYMER CONNECTIONlar per pound in a little over a month,” of the South (one of the oldest regionals). The
he recalls. “We wanted to see what we success of that meeting lead to more meetings
could do in terms of putting our voices and the formation of the Mid Atlantic Cultured
together and affecting policies that Marble Association (the northeast predecessor).
could protect our industry” against such George Conly, who retired from Tri City Mar-
stress, he says. ble, Allentown, PA in 2006 and was an active
Victor Mannino, president of L&M, was part of the Northeast for many years, recalls
elected the first president of CMI in 1974 the first meetings of his organization.
followed by other early pioneers including “My company got a call from someone
Robert Taylor, Taylor Industries Inc. (1975- from New Orleans, inviting us to Philly [Phil-
76), and William Lippert, Lippert Molded adelphia]. He explained the concept of put-
Marble (1976-1977). The annual meeting ting together an organization for better
became a standard occurrence, along with buying power and more knowl-
a technical meeting, a tour of the hosting edge because there weren’t many
company’s facilities and much discussion people back then that had a good
about better ways to make the prod- grasp on the chemistry of what we
uct. were doing,” he says.
“The technical committee was “If you had a problem, you usu-
a very important part of the orga- ally went to your supplier who of-
nization” from the beginning, says ten said, ‘that’s interesting—It’s the
Richard Marshall, owner of R.J. Mar- first time I’ve heard of that. However,
shall Company, which he and his once we got together with other peo-
wife Joanie founded in 1978. “The ple in the business, we realized we
committee had about 20 members in were all having the same kinds of
the early days, and we had about the problems,” he says.
same number coming to meetings to
the observe the technical presenta- The name change
tions and discussions. Jim Maass [Re- The 1980s and 1990s were a boon time for the cul-
ichhold] and I presented at so many of tured marble industry. Marshall says there were
those meetings, we knew each other’s 1,500 cultured marble manufacturers in the U.S.
speeches,” he says. and Canada at the end of the 1980s, and each annual meet-
After a few years of Chicago meetings, two major events ing of the national association drew 300-400 people.
happened: the national association hired its first manage- Each of the regionals also held their own meetings (some
ment firm (Bostrom Association Management Company, getting together for multi-region events), published their
Chicago) to oversee growth, and regionals started to blos- own newsletter or magazine, and had their own governing
som and become officially chartered as part of the national boards.
effort. In the 1978 membership/product directory there are As far as the national association, as the industry grew,
no regionals listed, but by 1980 there were eight. At one so did the expense of running it through the Chicago man-
time, there were ten regions including a European faction. agement firm. In the early 1990s, many associations were
The annual meeting, during those decades was called CMI coming to the Washington, DC area to be closer to the gov-
Marblecon. ernment. The decision was made to move the association
Each regional formed in a different way, but they were from Chicago to the DC area and a new management firm
often called together by suppliers—informal meetings that was hired—Association Management Group, Arlington, VA
grew into an organization and eventually became part of the (close to downtown DC).
national organization, often after having been influenced by One of the most often discussed issues during this time
one of the other regionals. The predecessor to the organiza- was the need to change the name.
tion that became the Northeast Cast Polymer Association, “CMI was too limiting a name because we were all diver-
for example, was formed after a letter went out inviting area sifying,” says Jim Steigmeyer, who retired from Roma Marble
manufacturers to get together to talk about their problems Inc., Ludlow, MA in 2014 and was president of CMI (1990-91),
and meet representatives of the Cultured Marble Association when the association was interviewing new management
CAST POLYMER CONNECTION | SPRING 2019 15companies. Many members during the early 1990s were mak- and 2) the larger association (which was
ing and fabricating solid surfaces and other products, by now ACMA) began to focus its efforts on
and the association needed to reflect the engi- the regulatory/legislative arena and other
neered nature of what they did, he says. big-ticket issues that were not priorities for
CMI became the International Cast Polymer ICPA’s smaller members.
Association in 1993 and the regionals followed By 2013-14, discussions began about how
suite with their names. Marblecon became POLY- to become an independent association.
CON, though the format of the meetings stayed the “In early 2014, I traveled to Lubbock, TX
same: heavy emphasis on technical information, to meet with Royce [Newsom] at his request,”
tours of plants, demonstrations and educational Werstler explains. “He loaded me into his pickup
sessions. truck and drove me to a lake on the outskirts of
By the year 2001, the association was again the town. Had I not known Royce as I did, I might
looking for change because of deep administra- have thought he was driving me to a clandestine
tive cost increases, and ICPA was introduced to location to outfit me with cement boots,” he jokes.
the Composites Fabricators Association—CFA (which later As it was, Royce thought Werstler, having headed the
became American Composites Manufactures Association— transition to an alliance under CFA/ACMA in 2002, should
ACMA). return to the presidency to lead the charge to become a
“After significant discussion and due diligence, ICPA en- standalone organization.
gaged the folks at CFA to act as the ICPA management group. That happened in 2014 when a small committee of mem-
We were in need of a group that could facilitate ICPA’s growing bers traveled to ACMA to announce the desire to be a self-man-
needs such as shared staff, tradeshow planning and magazine aged association. In 2015, ICPA again became its own nonprofit
sourcing,” says Todd Werstler, who as president of ICPA in 501 (C)6 and hired Jennifer Towner as executive director.
2002 oversaw that phase of the association’s transformation. The association had come full circle, driven by the same
The association then became the International Cast Polymer values that got it started in the first place: the need to net-
Alliance. work, to acquire technical and practical information and to
The relationship worked well until several major events have a stronger voice. n
happened starting in about 2007: 1) the building market col-
GENILEE SWOPE PARENTE is executive editor of Cast Polymer
lapsed, forcing many companies to close their doors (mem-
Connection. She wrote this article to begin the process of gathering
bership fell from 300 to less than 70 in a few short years) archival information and historical information for the association.
Parente and ICPA Executive Director Jennifer Towner encourage those
Above: POLYCON used to be Marblecon. who have such information to contact ICPA headquarters and share what
Below: Snapshots of POLYCON ‘03 booths from an old magazine. they know.
16 SPRING 2019 | CAST POLYMER CONNECTIONPROFILE
Al-Co Products, Inc.:
A solid past; a bright future
AL-CO PRODUCTS, INC., LATTY, OH, AND ICPA SHARE A
COMMON BOND: they’ve both been around about half a
century. But while the association was just a concept in the
mid-1960s—the beginnings of discussions between compa-
nies in the same business who thought they might benefit
by joining forces—Al-Co was solidifying its existence by be-
coming a corporation. That happened in 1968.
What the organizations have in common is that 1) they
owe their heritage to the original product cast polymer man-
ufacturers made, cultured marble, and 2) they’ve weathered
many storms over the years. Both the corporation and the
association have watched as the product and what can be The staff at Al-Co include (from left): Tim Berg, sales manager; Dennis Arend,
done with it have evolved, broadened and greatly improved supervisor; Matthew Bradley; Angie Mobley, office manager; Alyssa Mobley;
Juan Rodriquez; Eric Reeb; Bret Busch, plant manager; John Kohler; Marc
in quality over the years. Shuherk.
“The cast polymer industry back in the days when we
were just getting started was a group of companies making retained both the name and its status as an Indiana corpo-
something fairly new in the world that still had its share ration, which it still holds today.
of technical glitches. The individual companies felt like we By the time the company was moved to Ohio, John Kohler
each had our ‘secrets’ in casting marble,” says John Kohler, had been hired for his background in manufacturing and
who is semi-retired from the company but ran it for most of quality control, and the company quickly began to move for-
those 50 years. ward, offering table tops and slab material with cutouts for
“Those of us that have been around since those beginning drop or undermount bowls. In 1970, with the assistance of
years laugh now about what we were to learn, which was that Gruber’s molds for integral bowls, backsplashes and float-
by joining together, sharing best practices and working with ing bowls, the business expanded to offer customers one-
our greatest supporters—our suppliers—we could create a piece vanity tops, a product that remains the backbone of
beautiful product that offers a wide range of design options the company. By the mid-1980s, the company had expanded
and has a solid reputation for endurance and flexibility.” to include a second shift of employees to accommodate the
growing business, and in 1991, the company built a second
A rich history building. In the mid-1990s, the company realized it needed an
There are not that many cast polymer companies with a autocasting machine, a move it made in 2000. A third building
history that goes as far back as Al-Co’s.
A popular offering at Al-Co is the A’Vant line of granite and quartz bathroom
Even before it was incorporated in 1968, an operation countertops.
existed under the name Al-Co (named for the county where
it was established: Allen County, IN) that was making cast
polymer bathroom surfaces. It was owned by an individual,
Richard Robertson. Robertson sold his business in Harlan,
IN to Havilland Drainage Products, a clay-tile manufacturer
whose board had been on the lookout for another type of
business venture. They found potential for profit in Al-Co.
Two years later, the manufacturing operation was moved to
Latty, OH to be closer to Havilland’s other manufacturing fa-
cilities and to take advantage of an empty facility the parent
company owned. Although Al-Co left the state of Indiana, it
18 SPRING 2019 | CAST POLYMER CONNECTIONwas added in 2007 to accommodate the new machinery
This award-winning grandfather clock illustrates how cast polymer
and the business it brought. can be used outside the kitchen/bath.
Kohler remained at the helm for many years and
was instrumental in the company becoming one of day is to treat your people right. We do that by work-
the early members of ICPA’s predecessor association: ing with them when they need time off, listening to
Al-Co joined the Cultured Marble Institute in 1978. them when they have ideas or suggestions, and doing
Kohler remains active in the business, though he little things like bringing in the occasional lunch or
went into semi-retirement in 2003 when the current snacks. We are always looking for ways to make their
head Bret Busch, CCT-CP, manager of the company, jobs easier, which makes them more efficient and hap-
took over. Busch brought the company through the pier.” The benefits of this approach go beyond keeping
dark days of the Great Recession and into the current individuals happy, he points out.
rejuvenated industry. Like Kohler, he remains a cheer- “Over the years, many of our workers have been
leader for the industry and its association. hired because they were referred by another employee,”
“We have been through so many changes in this he explains.
industry over the years, as has our association. The
one constant in both has been the dedication and The customer base
commitment of the companies, and in the case of Longevity also extends to the company’s customer base.
ICPA, our elected representatives, to making the in- “We still have some customers today that started
dustry better,” Busch says. with us over 50 years ago,” Busch says.
Al-Co does most of its business with cabinet shops
Al-Co’s Backbone and smaller lumber/plumbing yards. It uses a dealer-
The rich history of Al-Co extends to its employees. Kohler based model that relies on excellent customer service, the
was with the company 48 years before going into semi-re- ability to customize and its own reputation as its strongest
tirement, and Busch has been with the company since 1987, selling tools. Al-Co’s highest selling items remain vanity tops,
when he was hired as a laborer. Busch worked his way up though the business has expanded to include shower pans,
to supervisor in two years, then took over as manager of backsplashes, shower panels, windowsills and whatever else
operations in 2003. He became a shareholder in 2010 and is customers want.
currently a co-majority shareholder. “I believe the first thing that attracts someone to a prod-
The rest of the staff also have longevity with the com- uct is how it looks or catches the eye,” Busch says. “The next
pany. thing they ask is ‘how much?’” he adds.
“We’ve been very fortunate that the core of our workforce In the big box stores today, people see only a limited se-
has been us for more than 30 years,” Busch says. Office man- lection of colors, bowl styles and standard sizes.
ager Carol Jeffery, for example, retired several years ago with “If you want something different you have to special order
25 years under her belt. Sales Manager Fred Schubert retired and that’s where we come in. About 95% of what we do is
last year with 35 years, and one of the production crew customization,” he says.
members Kevin Albright is retiring this year with 47 years. Therein lies the company’s greatest draw, he says.
Those long careers illustrate one of Al-Co’s greatest “Our ability to make and offer custom products not read-
strengths, but also one of the most pressing issues both for ily available in general retail stores and our good lead times
Al-Co and the industry in general. are our most significant strengths,” Busch says.
“We all want to retire someday, so we know in the next That reality makes the relationships Al-Co has with its
half decade, we’ll be losing the most experienced of our em- dealers the cornerstone of the company, he adds.
ployees,” Busch says. Al-Co is tackling that issue along with To ensure those relationships flourish, “We stand behind
many others by working on a company strategy Busch says what we sell. We treat our dealers like we want to be treated
will hopefully “take us into the next 50 years.” by giving them a good product at a fair price, then when
One of the tools it has always used is to try to keep current there is a problem, we listen and correct it quickly,” he says.
employees on board. Busch says that requires paying a fair As a result, even companies that leave briefly to try some
wage, learning to be flexible on work schedules and looking for other company out, often return to Al-Co, and one source of
ways to show appreciation. new business has been employees who leave one dealer or
“As important as seeing that staff is compensated to- store to go to another, then seek out the company they know
CAST POLYMER CONNECTION | SPRING 2019 19The other challenge for a small company is getting the
word out that the business exists. Most recently, Al-Co has
gotten into radio advertising as a means to relay to people
what’s available and that Al-Co is there to provide it.
The competition
Like many cast polymer companies, Al-Co used to consider
companies that offered laminate and solid surface, as well
as other cultured stone manufacturers, as its main compe-
tition. That’s changed in the last decade or so, Busch said.
“Now we hear from our dealers that our competition is
Al-Co’s facilities cover 16,000 square feet. natural granite or quartz,” Busch says.
That doesn’t cause much concern in today’s marketplace,
does the job right, he says. however, because of the wide varieties of colors and finishes
Like all cast polymer companies, the business took a that new materials offer as well as the newer methods of
nosedive during the Great Recession though that dive was manufacturing for the cast polymer industry. Because of
not as deep for the well-established, smaller firm as what those two factors, cast polymer companies offer something
happened with some larger companies. The staff at its peak dealing with natural stone or retailers with limited products
was 15 people; it’s currently operating with 11. During the can’t offer: the ability to fashion a product according to the
troubled times, “We were forced to lay off some personnel, parameters of what’s desired and the realities of dimension
and there were pay freezes, which we absolutely hated of and cost.
course. But we were fortunate in that the remaining employ- “To win out over what else is out there, we stay competi-
ees stuck with us during that time,” Busch says. tively priced, but at the same time, we can give customers a
The firm did learn a lesson that some other cast polymer look that is different than what they see on the floor of a big
manufacturers learned during the crash, which was that it box store,” Busch adds.
was time to look at diversification. Al-Co developed a limited Al-Co also tries to stay on top of today’s trends to enable
program selling directly to consumers, and it has started it to compete.
selling into the commercial construction field. “We rely heavily on our dealers to tell us what’s hap-
pening because they are the ones that work directly with
Al-Co’s current toolbox customers and will be telling them how good our product
To appeal to all these groups, the company relies on social is,” he says.
media, its own website and a showroom, which has grown From his perspective, he sees the most current trend as
as the company grew. an increase in undermount sinks and vessel bowls with
“When we first started in the business, we had the one loose or no backsplashes, a trend he said is driven largely by
building, which held everything: production, warehouse, of- what people are seeing on HGTV and housing design pro-
fice. We had one, 19-inch by 17-inch vanity top we showed in grams. He also sees a lessening of bathtubs in the bathroom.
that facility that basically served us for 22 years,” Busch says. “While we still have the molds, we haven’t made a bath-
However, Al-Co knew the product would sell itself if peo- tub in several years. Just watch one of the home shows or flip
ple had the opportunity to touch and feel. through a magazine and you’ll see a beautiful shower. You
“Once we built our second building (1991), we finally had don’t generally hear: ‘look at my beautiful bathtub,’” he says.
an area big enough for showing more product, and by the
time our third building was built and we could move produc- A continued commitment
tion, we finally had a separate showroom,” Busch says. Today, One way all companies can keep up with what’s happening
the company has 16,000 total square feet of space, including is by being active in the industry’s trade association, ICPA,
a dedicated showroom where customers of dealers can see and Busch says Al-Co intends to do just that.
the many options and where designers and other influencers “To see what has been done in our organization since our
can experience cast polymer firsthand. ‘rebirth’ as ICPA is very exciting to witness,” he says. “It’s also
“One of the greatest challenges of dealing with this prod- an excellent reminder that the association is only as strong
uct is to show designers and interior decorators that we are as its members. As our industry rebounds and grows, we will
not the old, outdated product of years past,” Busch explains. be stronger in what we do if we do it together,” he says. n
20 SPRING 2019 | CAST POLYMER CONNECTIONThe
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@AOCresinsHigh attendance, new events
will be part of POLYCON
Kansas City
A RECORD NUMBER OF MANUFACTURERS HAVE SIGNED improve their products and the way their plants are run.
UP TO ATTEND POLYCON KANSAS CITY 2019 APRIL 10-12 The demos and a kick-off lunch will be held at the Polynt
at the Sheraton Overland Park Hotel at the Convention Cen- Application Center in North Kansas City, which is about 20
ter, Overland Park, KS. As of press time, over 150 people were minutes from the Kansas City International Airport. The
registered—45 manufacturer companies—and many exhib- lunch starts at noon and demonstrations take place until
itors had committed to showing their wares and explaining about 5 p.m. Among topics planned for the afternoon are
their services during the event’s exhibition. gel coat application, how to build one-off production molds,
The growth is not surprising given the fact this is the creating the Tyvarian process, spray coating of vanity tops
fifth annual event since reincorporating as the ICPA; Each and much more.
year’s conference has built upon the excitement of previ- Attendees are then on their own for dinner, but a welcom-
ous events. Some major changes were made to the ing reception is planned for later that night back at
structure of the conference this year to take the Sheraton (8 to 10 p.m. cocktails and dessert)
advantage of what’s been popular and where so that attendees can get started on one of
this year’s conference is located. the main reasons people attend POLYCON:
For example, this year’s POLYCON networking with peers and making new
starts off the way many past events have friends.
ended: with the ever-popular manufac-
turing demonstrations and seminars. Hands-on demonstrations on technique are planned for
Wednesday. This year’s demos and seminars will take
These talks are designed to give attendees
place at the spacious, well-appointed Polynt Application
tips on specific techniques they can use to Center (left).
22 SPRING 2019 | CAST POLYMER CONNECTIONA day of learning A highlight of the week is the dinner where ICPA members who have given time
and resources to the industry and association are honored for their achievements
Thursday, April 11 will be the general session with association and contributions.
updates and new programs, the keynote address, presenta-
tions by platinum and gold sponsors, a day of educational
sessions, roundtable discussions and visiting with exhibitors. Exhibits, awards, a special tour
Keynote speaker this year is Lisa Ryan, an award-win- The exhibit floor is open the entire day Thursday and breaks
ning presenter whose enthusiasm is infectious and whose during the day have been designed to allow sufficient time
knowledge is based on years of dealing with the challenges for attendees to talk to those who offer products and ser-
that industrial companies face. Ryan’s interactive and enter- vices that help plants run smoother and the bottom line look
taining sessions are designed to help attendees with one of better. There are several new suppliers exhibiting this year.
the top issues facing manufacturers today: how to keep the That night is the special POLYCON Events Dinner and As-
skilled workers vital to operations engaged in what they do. sociation Awards Ceremony designed to be both entertaining
Also going on that morning is a three-hour training session and inspiring. Among the awards handed out are:
for those striving to become a Certified Composites Techni-
cian for Cast Polymer (CCT-CP). ICPA has been working with n The Royce Newsom Pinnacle Award. This honor is given
the American Composites Manufactures Association (ACMA) to a long-time member who has contributed much of
to revise and update the former certification program. his or her career to raising the standards of the cast
Giving special presentations during the morning are this polymer industry.
year’s platinum sponsors, companies that host some of n The President’s Award. A person who has sacrificed
the major POLYCON events. They include Composites One much time, effort and resources in the last year is
(welcome cocktail reception); R.J. Marshall/Marshall Gruber honored by ICPA President Luke Haas.
Companies (general session luncheon) and Interplastic Cor- n Best of the Best Awards for the Best Innovative Design
poration (reception before the awards dinner). and the Most Innovative Manufacturing Technique.
That afternoon, attendees break into roundtable sessions These two awards are based on votes from attendees
that are repeated throughout the afternoon to allow op- who are given a chance to touch and read about entries
portunities to tackle multiple issues in one day. Ryan will for the contest during the POLYCON event.
conduct several of those sessions to continue talking about
employee engagement, but also planned are legislative and On Friday, April 12, ICPA manufacturer members will have
regulatory discussions with John Schweitzer, ACMA, and a unique opportunity to visit a large operation in full pro-
Kelly DeBusk, Compliance Composites LLC; Lean Manufac- duction: The Onyx Collection, which is in Belvue, Kansas.
turing with ICPA President Luke Haas (Elite Marble Company, The company makes shower bases and pans, conversions for
LLC), plant tips from Dirk DeVuyst (International Marble tub to shower, lavatories, tub surrounds, fireplace hearths,
Institute) and Patrick Sak (U.S. Marble), a special presen- slabs, seats, trim and other accessories in almost any size or
tation on Occupational Safety and Health Administration shape that are sold all over the U.S. Buses will travel to the
developments, including the Safe+Sound program (see page giant manufacturing plant from the hotel and back as well
24) and more. Visit the POLYCON website, POLYCONevent. as from the plant to the airport. Tour participants have to be
com for all the up-to-date information in the programming ICPA members, and must sign up separately for the tour and
and to register to attend. travel by one of the planned charter bus trips. n
CAST POLYMER CONNECTION | SPRING 2019 23You can also read
