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SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES AND NATURE OF BUSINESS (Policies)
12 Months Ended
Dec. 31, 2011
SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES AND NATURE OF BUSINESS  
Principles of Consolidation
The consolidated financial statements include the accounts of Georgia Gulf Corporation and its wholly-owned subsidiaries. All significant intercompany balances and transactions have been eliminated in consolidation.
Use of Estimates
Management is required to make estimates and assumptions that affect amounts reported in the financial statements and accompanying notes prepared in conformity with accounting principles generally accepted in the United States of America. Actual results could differ from those estimates.
Foreign Currency Translation and Transactions
Our subsidiaries that operate outside the United States use their local currency as the functional currency. The functional currency is translated into U.S. dollars for balance sheet accounts using the month end exchange rates in effect as of the balance sheet date and the average exchange rate for revenues and expenses for each respective period. The translation adjustments are deferred as a separate component of stockholders' equity, within accumulated other comprehensive income (loss), net of tax where applicable. Gains or losses resulting from transactions denominated in foreign currencies are reported in the same financial statement captions as the underlying transactions in the consolidated statements of operations. We recorded a gain of $0.4 million, a gain of $2.7 million, and a loss of $1.1 million, in fiscal years 2011, 2010, and 2009, respectively, within operating income (loss) in the consolidated statements of operations. The year over year fluctuation in transaction related gains or (losses) is due to both the volume of foreign currency denominated transactions and the volatility in the underlying exchange rates.
Cash and Cash Equivalents
Marketable securities that are highly liquid with an original maturity of 90 days or less are considered to be the equivalent of cash for purposes of financial statement presentation.
Accounts Receivable and Allowance for Doubtful Accounts
We grant credit to customers under credit terms that are customary in the industry and based on the creditworthiness of the customer and generally do not require collateral. We also provide allowances for cash discounts and doubtful accounts based on contract terms, historical collection experience, periodic evaluations of the aging of the accounts receivable and specific collectability analysis. Individual accounts are written off once we have determined we have exhausted our collection efforts and the account is not collectable.
Revenue Recognition
We recognize revenue in accordance with generally accepted accounting principles, which requires that four basic criteria be met before revenue can be recognized: (i) persuasive evidence of an arrangement exists; (ii) the price is fixed or determinable; (iii) collectability is reasonably assured; and (iv) product delivery has occurred. We recognize revenue as products are shipped based on free on board ("FOB") terms when title passes to customers, and the customer takes ownership and assumes risk of loss.
Sales Incentives
We offer sales incentives, primarily in the form of volume rebates, slotting fees and advertising allowances to our customers, which are classified as a reduction of net sales and are calculated based on contractual terms of customer contracts. We accrue for these sales incentives based on contract terms and historical experience.
Shipping Costs
All amounts billed to a customer in a sale transaction related to shipping are classified as revenue. Shipping fees billed to customers and included in sales and cost of goods sold were $74.3 million in 2011, $74.4 million in 2010, and $62.0 million in 2009.
Advertising Costs
Advertising costs and promotion expenses generally relate to our vinyl-based building and home improvement products marketed under the Royal Building Products and Exterior Portfolio brand names and are charged to earnings during the period in which they are incurred. Advertising and promotion expenses are included in selling, general and administrative expenses and were $10.8 million, $6.4 million, and $5.7 million, in 2011, 2010, and 2009, respectively.
Inventories
Inventories are valued at the lower of cost or market. Cost is determined using the first-in, first-out method for the majority of inventory and the weighted average cost method for the remainder. Costs include raw materials, direct labor and manufacturing overhead. Market is based on current replacement cost for raw materials and supplies and on net realizable value for finished goods. At December 31, 2011 we had approximately $16.9 million of inventory on consignment.
Property, Plant and Equipment

Property, plant and equipment are stated at cost. Maintenance and repairs are charged to expense as incurred, and major renewals and improvements are capitalized. Interest expense attributable to funds used in financing the construction of major plant and equipment is capitalized. Interest cost capitalized during 2011, 2010, and 2009 was $0.4 million, $0.5 million, and $1.0 million, respectively. Depreciation is computed using the straight-line method over the estimated useful lives of the assets. Depreciation expense totaled approximately $91.4 million, $90.5 million, and $98.5 million, for the years ended December 31, 2011, 2010, and 2009, respectively. The estimated useful lives of our assets are as follows:

Buildings

  27-30 years

Land improvements

  15 years

Machinery and equipment

  2-15 years

Dies and moulds

  3-6 years

Office furniture and equipment

  2-10 years

Computer equipment and software

  3-10 years
Asset Retirement Obligation
We account for asset retirement obligations based on the fair value of a liability for an asset retirement obligation and recognize it in the period in which it is incurred and capitalized as part of the carrying amount of the long-lived asset. When a liability is initially recorded, we capitalize the cost by increasing the carrying value of the related long-lived asset. The liability is accreted to its future value each period, and the capitalized cost is depreciated over the estimated useful life of the related asset. Upon settlement of the liability, a gain or loss is recorded. We had $2.6 million of asset retirement obligations recorded in other non-current liabilities in the consolidated balance sheets as of both December 31, 2011 and 2010.
Other Assets
Other assets primarily consist of advances for long-term raw materials purchase contracts, our investment in joint ventures, assets held for sale and unamortized debt issuance costs. Advances for long-term raw materials purchase contracts are being amortized as additional raw materials costs over the life of the related contracts in proportion to raw materials delivery or related contract terms. Debt issuance costs are amortized to interest expense using the effective interest rate and straight-line methods over the term of the related debt instruments.
Goodwill and Other Intangible Assets
Goodwill is the excess of cost of an acquired entity over the amounts specifically assigned to assets acquired and liabilities assumed in purchase accounting for business combinations. Other identifiable intangible assets are intangible assets such as customer lists, trade names and technology that are identified during acquisitions. The carrying value of our goodwill and indefinite lived intangible assets are tested for impairment annually on October 1 and are tested for impairment between annual impairment tests if an event occurs or circumstances change that would indicate the carrying amounts may be impaired. Indicators include, but are not limited to significant declines in the markets and industries which buy our products, changes in the estimated future cash flows of our reporting units, changes in capital markets and changes in our market capitalization. Impairment testing for indefinite-lived intangible assets other than goodwill consists of comparing the fair value of the asset to the carrying value. Our indefinite-lived assets primarily consist of trade names. The fair values of our trade names are estimated based on the relief from royalty method under the income approach. This approach utilizes a discounted cash flow analysis. Impairment testing for goodwill is a two-step test performed at a reporting unit level. Our reporting units subject to such testing are window and door profiles; mouldings; siding; deck, fence and rail products and compounds (vinyl and additives). An impairment loss may be recognized when the carrying amount of the reporting unit's net assets exceeds the estimated fair value of the reporting unit. Intangible assets with definite lives are amortized on a straight-line basis over their estimated useful lives.
Long-Lived Assets
Our long-lived assets, such as property, plant, and equipment, and intangible assets with definite lives are analyzed for impairment whenever events or changes in circumstances indicate that the carrying amount of an asset may not be recoverable. Recoverability of assets to be held and used is measured by a comparison of the carrying amount of an asset to the estimated undiscounted cash flows over the remaining life of the asset. If the carrying amount of an asset exceeds estimated fair value of the asset, an impairment charge is recognized for the amount by which the carrying amount of the asset exceeds the estimated fair value of the asset based on discounted cash flows. Assets to be disposed of would be recorded at the lower of the carrying amount or fair value less costs to sell and no longer depreciated.
Pension Plans and Other Postretirement Benefit Plans
We have defined contribution pension plans covering substantially all of our employees. In addition, we have two defined benefit pension plans. For the defined benefit pension plans, the benefits are based on years of service and the employee's compensation. Our postretirement benefit plan was terminated and paid out during 2009. Our Canadian defined benefit plan was fully funded in early 2011 to allow benefits to be settled. Our policy on funding the defined benefit plans is to contribute an amount within the range of the minimum required and the maximum tax-deductible contribution. Accounting for employee retirement plans involves estimating the cost of benefits that are to be provided in the future and attempting to match, for each employee, that estimated cost to the period worked. To accomplish this, we make assumptions about discount rates, expected long-term rates of return on plan assets, salary increases and employee turnover and mortality, among others. We reevaluate all assumptions annually with our independent actuaries taking into consideration existing as well as forecasted economic conditions, and our policy and strategy with regard to the plans. As of March 31, 2009, we suspended any further benefits associated with the defined benefit plans. As of December 31, 2011, this benefit remained frozen. Company contributions to our defined contribution plans were suspended in July 2009 and reinstated in July 2010.
Income Taxes
Income taxes are accounted for under the asset and liability method. Deferred tax assets and liabilities are recognized for the future tax consequences attributable to differences between the financial statement carrying amounts of existing assets and liabilities and their respective tax bases. Deferred tax assets and liabilities are measured using enacted tax rates expected to apply to taxable income in the years in which those temporary differences are expected to be recovered or settled. The effect on deferred tax assets and liabilities of a change in tax rates is recognized in income in the period that includes the enactment date. We evaluate the realizability of deferred tax assets by assessing whether it is more likely than not that some or all of the deferred tax assets will not be realized. The ultimate realization of deferred tax assets depends on the generation of future taxable income during the periods in which those temporary differences are deductible. Management considers the scheduled reversal of deferred tax liabilities (including the impact of available carryback and carryforward periods), projected taxable income, and tax-planning strategies available to us in making this assessment. If it is not more likely than not that we will realize a deferred tax asset we record a valuation allowance against such asset. We use a similar evaluation for determining when to release previously recorded valuation allowances. We account for uncertain tax positions when it is more likely than not, based upon the technical merits, that the position will be sustained upon examination.
Self-Insurance Accruals
We are self-insured up to certain limits for costs associated with workers' compensation and employee group medical coverage. Liabilities for insurance claims and reserves include accruals of estimated settlements for known claims, as well as accruals of estimates of incurred, but not reported claims. These accruals are included in other current liabilities in the accompanying consolidated balance sheets. We also use information provided by independent consultants to assist in the determination of estimated accruals. In estimating these costs, we consider historical loss experience and make judgments about the expected levels of costs per claim.
Warranty Costs

We provide warranties for certain building and home improvement products against defects in material, performance and workmanship. We accrue for warranty claims at the time of sale based on historical warranty claims experience. Our warranty liabilities are included in other accrued liabilities in the consolidated balance sheets. Activity in our warranty liabilities for the years ended December 31, 2011, 2010, and 2009 is as follows:

(In thousands)
  2011   2010   2009  

January 1,

  $ 6,560   $ 7,368   $ 7,498  

Estimated fair value of warranty liability assumed in acquisition

    5,629          

Warranty provisions

    4,906     2,114     3,005  

Foreign currency translation

    (119 )   334     896  

Warranty claims paid

    (5,192 )   (3,256 )   (4,031 )
               

December 31,

  $ 11,784   $ 6,560   $ 7,368  
               
Derivative Financial Instruments

Derivatives that are not hedges must be adjusted to fair value through earnings. If the derivative is a hedge, depending on the nature of the hedge, changes in its fair value are either offset against the change in fair value of assets, liabilities, or firm commitments through earnings or recognized in other comprehensive income until the hedged item is recognized in earnings. We engage in activities that expose us to market risks, including the effects of changes in interest rates, foreign currency and changes in commodity prices. Financial exposures are managed as an integral part of our risk management program, which seeks to reduce the potentially adverse effect that the volatility of the interest rate, foreign currency, and commodity markets may have on operating results. We do not engage in speculative transactions nor do we hold or issue financial instruments for trading purposes.

        We formally document all hedging instruments and hedging transactions, as well as our risk management objective and strategy for undertaking hedged transactions. This process includes linking all derivatives that are designated as fair value and cash flow hedges to specific assets or liabilities on the consolidated balance sheet or to forecasted transactions. We also formally assess, both at inception and on an ongoing basis, whether the derivatives that are used in hedging transactions are highly effective in offsetting changes in fair value or cash flows of hedged transactions. When it is determined that a derivative is not highly effective or the derivative expires or is sold, terminated, exercised, or discontinued because it is unlikely that a forecasted transaction will occur, we discontinue the use of hedge accounting for that specific hedge instrument.

Litigation
In the normal course of business, we are involved in legal proceedings. We accrue a liability for such matters when it is probable that a material liability has been incurred and the amount can be reasonably estimated. The accrual for a litigation loss contingency might include, for example, estimates of potential damages, outside legal fees and other directly related costs expected to be incurred.
Environmental Expenditures
Environmental expenditures related to current operations or future revenues are expensed or capitalized consistent with our capitalization policy. Expenditures that relate to an existing condition caused by past operations and that do not contribute to future revenues are expensed in the period incurred. Liabilities are recognized when material environmental assessments or cleanups are probable and the costs can be reasonably estimated.
Accumulated Other Comprehensive loss

Accumulated other comprehensive loss includes foreign currency translation of assets and liabilities of foreign subsidiaries, effects of exchange rate changes on intercompany balances of a long-term nature, unrealized gains and losses on derivative financial instruments designated as cash flow hedges, and adjustments to pension liabilities. Amounts recorded in accumulated other comprehensive loss, net of tax, on the consolidated statements of stockholders' equity as of December 31, 2011 and 2010 are as follows:

(In thousands)
  Accrued
Pension
Benefit
Liability
  Foreign
Currency
Items
  Derivative
Cash Flow
Hedges
  Accumulated
Other
Comprehensive
Loss
 

Balance at December 31, 2009

  $ (23,377 ) $ 18,903   $ 160   $ (4,314 )

Net current period change

    (4,764 )   8,264     264     4,764  

Reclassification adjustment for realized (gains) losses included in net income

    500         (160 )   (660 )
                   

Balance at December 31, 2010

    (27,641 )   27,167     264     (210 )

Net current period change

    (13,618 )   (4,574 )   (453 )   (16,709 )

Reclassification adjustment for realized (gains) losses included in net income

    968         (264 )   (1,232 )
                   

Balance at December 31, 2011

  $ (40,291 ) $ 22,593   $ (453 ) $ (18,151 )
                   

        Other comprehensive (loss) income is derived from adjustments to reflect the unrealized gain (loss) on derivatives, change in pension liability adjustment and change in foreign currency translation adjustment. The components of other comprehensive (loss) income are as follows:

(In thousands)
  Pre-Tax
Amount
  Tax
Expense
(Benefit)
  After-Tax
Amount
 

Year ended December 31, 2009

                   

Unrealized gain on derivatives

  $ 2,926   $ 1,105   $ 1,821  

Change in pension liability adjustment

    (4,888 )   (419 )   (4,469 )

Change in foreign currency translation adjustment

    40,404     22,388     18,016  
               

Other comprehensive (loss) income

  $ 38,442   $ 23,074   $ 15,368  
               

Year ended December 31, 2010

                   

Unrealized gain on derivatives

  $ 168   $ 64   $ 104  

Change in pension liability adjustment

    (5,807 )   (1,543 )   (4,264 )

Change in foreign currency translation adjustment

    17,036     8,772     8,264  
               

Other comprehensive (loss) income

  $ 11,397   $ 7,293   $ 4,104  
               

Year ended December 31, 2011

                   

Unrealized loss on derivatives

  $ (1,146 ) $ (429 ) $ (717 )

Change in pension liability adjustment

    (20,629 )   (7,979 )   (12,650 )

Change in foreign currency translation adjustment

    (8,125 )   (3,551 )   (4,574 )
               

Other comprehensive (loss) income

  $ (29,900 ) $ (11,959 ) $ (17,941 )
               
Stock-Based Compensation

Share-based payments to employees, including grants of employee stock options, restricted stock, restricted stock units and non-employee director deferred shares and restricted stock units are recognized in the financial statements based on their fair values at the grant date. The Company recognizes the cost of all share-based awards on a straight-line basis over the vesting period of the award.

        We eliminate unearned compensation (contra-equity account) related to earlier awards against the appropriate equity accounts, which is additional paid-in capital in our circumstance. Tax benefits relating to excess share-based compensation deductions are presented in the statements of cash flows as a financing activity cash inflow.

Earnings (Loss) Per Share

We calculate earnings per share, using the two-class method. The two-class method requires that share-based awards with non-forfeitable dividends be classified as participating securities. In calculating basic earnings per share, this method requires net income to be reduced by the amount of dividends declared in the period for each participating security and by the contractual amount of dividends or other participation payments that are paid or accumulated for the period. Undistributed earnings for the period are allocated to participating securities based on the contractual participation rights of the security to share in those current earnings assuming all earnings for the period are distributed. Recipients of certain of our restricted stock unit awards have contractual participation rights that are equivalent to those of common stockholders. Therefore, we allocate undistributed earnings to these restricted stock unit participating securities and common stock based on their respective participation percentage.

        The two-class method also requires the denominator to include the weighted average number of shares of restricted stock units participating securities when calculating basic earnings per share. For the years ended December 31, 2011, 2010, and 2009, there were 0.7 million, 1.1 million, and 1.0 million weighted average restricted stock units participating securities, respectively, included in the denominator. Diluted earnings per share also include the additional share equivalents from the assumed conversion of stock based awards including options and certain restricted stock units. Conversion of stock options and certain restricted stock units are calculated using the treasury stock method, subject to anti-dilution provisions.

        In computing diluted earnings per share for the years ended December 31, 2011, 2010, and 2009, common stock equivalents of 0.2 million shares, for all these periods, were not included due to their anti-dilutive effect.

        Computations of basic and diluted earnings per share are presented in the following table:

Basic and Diluted Earnings Per Share—Two-class Method

 
  Year ended December 31,  
(In thousands, except per share data)
  2011   2010   2009  

Basic earnings per share

                   

Undistributed income

  $ 57,757   $ 42,678   $ 131,059  

Deduct: Undistributed earnings—Restricted stock units participating securities

    1,216     1,294     7,869  
               

Common stockholders' interest in undistributed income

  $ 56,541   $ 41,384   $ 123,190  
               

Weighted average common shares—Basic

    34,086     33,825     14,903  

Total basic earnings per common share

  $ 1.66   $ 1.22   $ 8.27  
               

Total basic earnings per restricted stock units participating security

  $ 1.66   $ 1.22   $ 8.27  
               

Diluted earnings per share

                   

Common stockholders' interest in undistributed income

  $ 56,541   $ 41,384   $ 123,190  
               

Weighted average common shares—Basic

    34,086     33,825     14,903  

Stock-based awards

    36         5  
               

Weighted average common shares—Diluted

    34,122     33,825     14,908  
               

Total diluted earnings per share

  $ 1.66   $ 1.22   $ 8.26  
               

Total diluted earnings per restricted stock units participating security

  $ 1.66   $ 1.22   $ 8.26  
               

        On July 28, 2009, we affected a 1-for-25 reverse stock split of our common stock. This reverse stock split has been reflected in share data and earnings per share data contained herein for all periods presented. The par value of the common stock was not affected by the reverse stock split and remains at $0.01 per share. Consequently, on the Company's consolidated balance sheets and consolidated statements of stockholders' equity (deficit), the aggregate par value of the issued common stock was reduced by reclassifying the par value amount of the eliminated shares of common stock to additional paid-in capital. On July 29, 2009, in connection with the debt for equity exchange, we issued approximately 1.3 million common shares and approximately 30.2 million convertible preferred shares to our bond holders that tendered their notes (See Note 9, Long-Term Debt for description of the debt for equity exchange). These common shares are included in the years ended December 31, 2011, 2010, and 2009 earnings per share on a weighted average basis from the date of issuance. On September 17, 2009, the convertible preferred shares were converted to common shares. The preferred shares that converted to common shares were eligible to participate in dividends that we issue and thus were treated as common share equivalents from the period issued until the date they formally converted to common shares in the calculations above.