ThermaFoam
ThermaFoam is a Dallas-based EPS insulation manufacturer and Carlisle Companies subsidiary producing roof, wall, below-grade, geofoam, and OEM specialty products for commercial, residential, infrastructure, and DIY markets across the U.S., now operating under the Insulfoam brand.
- Company typePrivate
- Founded1959
- HeadquartersPuyallup, United States
- Headcount501–1,000
- GTM typeB2B
- OfferingHardware or Manufacturing
What ThermaFoam does
ThermaFoam is a Dallas, Texas-based manufacturer and fabricator of expanded polystyrene (EPS) insulation products, founded in 1978 and operating as a subsidiary of Carlisle Companies (NYSE: CSL) under the legal entity Carlisle EPS Holding, LLC. The company produces a horizontal portfolio of EPS insulation solutions organized around five application areas: roof insulation (flute fill, faced & laminated EPS, tapered EPS, unfaced EPS), wall insulation (cavity, tongue groove, exterior grade & EIFS, faced & laminated, unfaced), below-grade insulation (drainage board, faced & laminated, unfaced), geofoam structural fill for infrastructure projects, and OEM & specialty products including DIY, cores & packaging, and building components. Products comply with ASTM C578 and ASTM D6817 standards, qualifying them for code-specified commercial, residential, and infrastructure use. Manufacturing is anchored at a single facility in Hillsboro, Texas.
The company's revenue model is hardware sales of physical insulation products, distributed through a B2B field sales motion via commercial sales representatives accessed through a representative locator system. Pricing is quote-based and not publicly disclosed. Customer segments span commercial construction (primary), residential construction, DIY/homeowners, infrastructure (e.g., highway reconstruction projects), and OEM/specialty manufacturers. Marketing is conducted through content marketing (technical articles, project profiles), organic social media (Facebook, YouTube, LinkedIn, Flickr), email newsletters, and a technical resource library covering climate zones, codes, assemblies, and product data sheets.
As of May 29, 2026, ThermaFoam officially rebranded to Insulfoam, a Carlisle company and one of the nation's leading EPS insulation manufacturers. The transition consolidates product lines under a unified national brand, expands manufacturing and distribution capabilities across the U.S., and updates code documentation and product markings at the Hillsboro facility. The legal entity remains Carlisle EPS Holding, LLC, and the business continues to operate as part of Carlisle's building envelope segment, where approximately 70% of demand is classified as nondiscretionary reroofing.
ThermaFoam firmographics
Firmographics- Name
- ThermaFoam
- Legal name
- Carlisle EPS Holding, LLC
- Website
- https://thermafoam.com
- Company type
- Private
- Founded year
- 1959
- Operating status
- Operating
- Headcount range
- 501–1,000 employees
- Short description
- ThermaFoam is a Dallas-based EPS insulation manufacturer and Carlisle Companies subsidiary producing roof, wall, below-grade, geofoam, and OEM specialty products for commercial, residential, infrastructure, and DIY markets across the U.S., now operating under the Insulfoam brand.
- Ownership category
- akta.pro rank
ThermaFoam industry classification
Industry- Product category
- Building Insulation Manufacturing
- NAICS
- Polystyrene Foam Product Manufacturing (32614), Polystyrene Foam Product Manufacturing (326140)
- SIC
- Plastics Foam Products (3086), Plastics Products, Nec (3089)
- akta.pro primary industry
- Expanded Polystyrene (EPS) Foam Manufacturing (IMANAIAA)
- akta.pro secondary industries
- Foam Plastic Insulation (EPS/XPS/PIR/PUR) (IMADAGAD), Foam Protective Packaging (EPS/EPE/EPP, PU, Molded Foam) (IMALAFAA)
Keywords
Where ThermaFoam is headquartered
LocationHeadquarters
- HQ city
- Puyallup
- HQ country
- United States
- HQ region
- North America
Offices1 record
Markets served
ThermaFoam business model
Business model- GTM type
- B2B
- Offering type
- Hardware or Manufacturing
- Cost components
- Supply Chain, Operations, Personnel, Marketing or Sales, Infrastructure
Revenue model
- EPS Insulation Products: Sale of expanded polystyrene insulation products for commercial, residential, infrastructure, and OEM applications. Products include roof insulation (flute fill, faced & laminated EPS, tapered EPS, unfaced EPS), wall insulation (cavity, tongue groove, exterior grade & EIFS), below-grade insulation (drainage board), geofoam (structural fill), and OEM specialty products.
Go-to-market motion1 record
Distribution channels2 records
Marketing channels5 records
ThermaFoam product offering
Product offeringCore offering
ThermaFoam (now operating as Insulfoam) is a Dallas, Texas-based manufacturer of expanded polystyrene (EPS) insulation products for the building envelope. The company produces EPS boards for roof, wall, below-grade, geofoam structural fill, and OEM/specialty applications, all conforming to ASTM C578 and ASTM D6817 standards. Products are sold to commercial builders, residential builders, infrastructure contractors, and OEM customers through commercial sales representatives.
Product overview
ThermaFoam (now Insulfoam) is a single unified product portfolio of high-performance expanded polystyrene (EPS) insulation solutions. The product lines cover four primary application areas: Roof (including Flute Fill, Faced & Laminated EPS, Tapered EPS, and Unfaced EPS), Wall (including Cavity, Tongue Groove, Exterior Grade & EIFS, Faced & Laminated EPS, and Unfaced EPS), Below-Grade (including Drainage Board, Faced & Laminated EPS, and Unfaced EPS), and Geofoam (Structural Fill for infrastructure). Additionally, OEM & Specialty products include DIY, Cores & Packaging, and Building Components. As of May 29, 2026, ThermaFoam has transitioned to the Insulfoam brand, maintaining the same product types under expanded manufacturing and distribution capabilities.
Differentiator
Problem solved
Functional benefit
Quantifiable outcome
- Nondiscretionary reroofing demand represents approximately 70% of building envelope business
Companies that use ThermaFoam
Customer profileSegments5 records
Ideal customer profiles1 record
ThermaFoam technology and API
TechnologyTechnology focussed No
API detail
- Has API
- No
- API docs
- API detail
Core technology
AI maturity
App detail
Feature1 record
ThermaFoam partnerships and signals
Strategic signalScale indicators2 records
Recent moves4 records
Expansion highlights4 records
ThermaFoam competitors and assessment
Company assessmentDirect peers
- ACH Foam Technologies: ACH Foam is a major U.S. manufacturer of expanded polystyrene (EPS) products for protective packaging, building insulation, and geofoam. It directly competes with ThermaFoam/Insulfoam across the same EPS product categories, application segments, and customer base.
- Rmax (Rmax Operating LLC): Rmax manufactures polyiso and other rigid foam insulation panels for commercial and residential building envelopes. It overlaps with ThermaFoam/Insulfoam in continuous insulation, roofing recover, and EIFS-style wall applications, addressing the same architects and contractors.
- Plymouth Foam: Plymouth Foam is a U.S.-based EPS molder producing insulation, packaging, and OEM specialty foam products. It competes head-to-head with ThermaFoam/Insulfoam across packaging cores, geofoam, and custom molded EPS components.
- Insulfoam (pre-acquisition baseline): Insulfoam is the Carlisle-owned EPS insulation brand that ThermaFoam was merged into on May 29, 2026. As the consolidated brand, it shares identical product lines (roof, wall, below-grade, geofoam, OEM), certifications (ASTM C578/D6817), and the Carlisle supply chain.
- Foam Products Corporation: Foam Products Corporation is a custom EPS and foam fabricator serving packaging, building, and OEM markets. It is comparable to ThermaFoam/Insulfoam's OEM & Specialty, DIY, and cores & packaging product lines.
Broad incumbents
- Atlas Roofing Corporation: Atlas Roofing is a large building-envelope manufacturer offering polyiso and other rigid foam insulation products that compete with EPS in commercial roofing and wall assemblies. It serves the same B2B construction customer base but with a broader portfolio spanning multiple chemistries.
- Kingspan Group: Kingspan is a global building envelope manufacturer offering rigid foam insulation panels (including PIR and quadCore products) that compete with EPS in commercial roofing and wall assemblies. It targets the same architectural-specification channel with broader geographic reach.
- Owens Corning: Owens Corning is a major U.S. building products manufacturer offering foam insulation boards (FOAMULAR extruded polystyrene) and roofing systems that compete directly with ThermaFoam/Insulfoam in commercial building envelope applications.
- Dow Chemical (XPS/STYROFOAM): Dow is a large chemical manufacturer whose STYROFOAM brand of extruded polystyrene (XPS) rigid insulation is the principal substitute for EPS in building envelope applications. It competes with ThermaFoam/Insulfoam for the same commercial and residential specification slots.
Emerging players
- Beaver Plastics: Beaver Plastics manufactures geofoam and rigid EPS insulation products for infrastructure and building applications. It overlaps with ThermaFoam/Insulfoam most directly in geofoam structural fill and below-grade insulation.
Market position
Strengths4 records
Weaknesses4 records
Competitive moat4 records
Key risks6 records
Key highlights6 records
Customer concentration
ThermaFoam social profiles
Digital presenceThermaFoam compliance and trust
Trust signalCompliance2 records
ThermaFoam financial estimates
Financial estimateRevenue estimate
Valuation estimate
ThermaFoam leadership team
Management profileNumber of profiles
ThermaFoam funding detail
Funding detailFunding overview
Funding rounds
Investors
Funding detail is available on the Subscription and Enterprise plan.Contact sales →
ThermaFoam M&A and investment
M&A and investmentM&A
Investments
M&A and investment is available on the Subscription and Enterprise plan.Contact sales →
Frequently asked questions about ThermaFoam
What does ThermaFoam do?
ThermaFoam (now operating as Insulfoam) is a Dallas, Texas-based manufacturer of expanded polystyrene (EPS) insulation products for the building envelope. The company produces EPS boards for roof, wall, below-grade, geofoam structural fill, and OEM/specialty applications, all conforming to ASTM C578 and ASTM D6817 standards. Products are sold to commercial builders, residential builders, infrastructure contractors, and OEM customers through commercial sales representatives.
Is ThermaFoam a public or private company?
ThermaFoam is a private company. It is classified as corporate owned and is currently operating.
When was ThermaFoam founded?
ThermaFoam was founded in 1959. It employs 501 to 1,000 people.
Where is ThermaFoam based?
ThermaFoam is headquartered in Puyallup, United States, in the North America region.
How does ThermaFoam make money?
One revenue line is on record: EPS Insulation Products.
Who are ThermaFoam's main competitors?
Direct peers on record are ACH Foam Technologies, Rmax (Rmax Operating LLC), Plymouth Foam, Insulfoam (pre-acquisition baseline) and Foam Products Corporation. Broad incumbents are Atlas Roofing Corporation, Kingspan Group, Owens Corning and Dow Chemical (XPS/STYROFOAM). Beaver Plastics is listed as an emerging player.
Does ThermaFoam have an API?
No public API is recorded for ThermaFoam.
What industry is ThermaFoam in?
ThermaFoam's product category is Building Insulation Manufacturing. Its primary akta.pro industry code is IMANAIAA, Expanded Polystyrene (EPS) Foam Manufacturing, with a secondary code of IMADAGAD, Foam Plastic Insulation (EPS/XPS/PIR/PUR). Its NAICS code is 32614 and its SIC code is 3086.