NCFI Polyurethanes

What NCFI Polyurethanes does

NCFI Polyurethanes is a U.S.-based specialty chemical manufacturer of polyurethane foam systems, operating as a division of Barnhardt Manufacturing Company since 1964. The company produces closed-cell and open-cell spray polyurethane foam (SPF) insulation, SPF roofing systems, geotechnical polyurethane systems for concrete lifting and soil stabilization, and a broad portfolio of custom OEM foam formulations serving aerospace, marine, furniture, décor, and industrial applications. Branded product families include InsulStar, EnduraTech, TerraThane, NatureThane, ThermaThane, CryoThane, ComforThane, IntegraThane, InsulThane, and Strata-Fill, with proprietary technical differentiators such as the original One-Shot production method (1964), first-mover HFC/hydrocarbon blowing agent alternatives (2001), HFO-based low-GWP foams (2020), and bio-based formulations up to 33% renewable content (2010).

The company organizes operations into three product divisions — Construction Products, Geotechnical Products, and OEM Solutions — supported by manufacturing facilities in Mount Airy, NC (since 1966), Ocala, FL (since the 1980s), and Houston, TX (inaugurated 2021), along with seven regional warehouses. NCFI distributes through a network of certified contractors, wholesale distributors, and direct OEM accounts, and serves as an authorized distributor of Graco and PMC spray equipment. Revenue is generated primarily through B2B chemical and equipment sales on a quote-based, project-driven pricing model across multiple verticals and geographies.

The company sells globally (every continent except Antarctica) and emphasizes a partnership-led GTM model anchored by certification programs (GoldStar for SPF insulation, Tier One for roofing, Foam School for geotechnical) and hands-on technical training. Recent strategic activity includes the 2023 divestiture of the Consumer Products Division, the 2021 Houston facility launch, the 2019 creation of a dedicated Geotechnical Division, and the 2020 introduction of HFO-based foam products, all signaling portfolio refocusing on higher-value construction, infrastructure, and OEM applications.

Name

NCFI Polyurethanes

Legal name

NCFI Polyurethanes. A Division of Barnhardt Manufacturing Co.

Website

https://ncfi.com

Company type

Private

Founded year

1964

Operating status

Operating

Headcount range

251–500 employees

Ownership category

akta.pro rank

NAICS

Urethane and Other Foam Product (except Polystyrene) Manufacturing (32615)

SIC

Plastics Foam Products (3086)

akta.pro primary industry

Spray Polyurethane Foam (SPF) Systems Manufacturing (IMANAIAL)

akta.pro secondary industries

Polyurethane (PU) Flexible Foam Manufacturing (IMANAIAC), Polyurethane (PU) Rigid Foam Manufacturing (IMANAIAD), Polyurethanes (MDI/TDI, Polyols, PU Systems) (IMAEADAH), Foam Conversion & Fabrication (Cutting, Laminating, CNC, Packaging Inserts) (IMANAIAJ)

Keywords

• Spray polyurethane foam
• Polyurethane foam systems
• SPF insulation products
• Geotechnical foam solutions
• OEM foam manufacturing

Headquarters

HQ city

Mount Airy

HQ country

United States

HQ region

North America

Offices3 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Operations, Supply Chain, Personnel, Technology or R&D, Marketing or Sales, Infrastructure

Revenue model

1. Polyurethane Foam Product Sales: NCFI manufactures and sells polyurethane foam systems across three divisions: Construction (SPF insulation, roofing), Geotechnical (concrete leveling, soil stabilization), and OEM Solutions (manufacturing applications). Products include branded formulations like InsulStar, EnduraTech, TerraThane, NatureThane, ThermaThane, CryoThane, ComforThane. Revenue is generated through direct sales to certified contractors, distributors, and OEM manufacturers. The company offers equipment from Graco and PMC as authorized distributors.

Pricing tiers

Go-to-market motion3 records

Distribution channels5 records

Marketing channels6 records

Core offering

NCFI Polyurethanes manufactures and sells polyurethane foam systems across three divisions: Construction Products (SPF insulation such as InsulStar and EnduraTech roofing), Geotechnical Products (concrete leveling, soil stabilization, and infrastructure repair systems such as TerraThane and Strata-Fill), and OEM Solutions (custom foam formulations for marine, aerospace, furniture, fire-rated panels, and taxidermy applications). The company also serves as an authorized distributor of Graco and PMC spray equipment and offers contractor certification programs (GoldStar, Tier One, Foam School).

Product overview

NCFI Polyurethanes is a polyurethane foam manufacturer organized into three main divisions: Construction Products, Geotechnical Products, and OEM Solutions. The Construction Products division offers spray polyurethane foam (SPF) insulation products including InsulStar Light, InsulStar, InsulStar 1.7, InsulBloc, AgriThane, and EnduraTech roofing systems. The Geotechnical Products division provides polyurethane systems for concrete leveling, soil stabilization, and infrastructure rehabilitation, including Dual Component Systems, Light Weight Fill Systems (formerly Strata-Fill), Single Component Hydrophobic Systems, and the branded TerraThane system. The OEM Solutions division supplies customized foam formulations for diverse industries including NatureThane (taxidermy), ThermaThane (fire-rated applications), CryoThane (marine/refrigeration), DecoThane (decorative), ComforThane (flexible seating), IntegraThane (integral skin), and InsulThane (spray insulation). NCFI also serves as an authorized distributor of Graco and PMC equipment and offers custom-engineered rigs. The company provides comprehensive training programs including GoldStar certification for SPF applicators, Tier One certification for roofing contractors, and geotechnical training courses, supported by seven warehouses and two manufacturing facilities in Mount Airy, NC and Houston, TX.

Differentiator

Problem solved

Functional benefit

Brands

• InsulStar: SPF insulation formulations branded and launched in 2001, including InsulStar Light, InsulStar 1.7, and related closed-cell and open-cell insulation products.
• EnduraTech
• TerraThane
• NatureThane
• ThermaThane
• CryoThane
• ComforThane
• IntegraThane
• DecoThane
• InsulThane
• GoldStar
• Tier One
• Terrapin

Quantifiable outcome

• InsulStar Light open-cell foam provides significant yield boost compared to previous SEALITE product
• +5 more outcomes

Named customers5 records

Segments5 records

Ideal customer profiles4 records

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature10 records

Partnerships

Seven partnerships are on record, tiered minor, core and flagship.

• Consumer Products Division (Divested)minorOthers · 1 January 2023NCFI completed divestment of its Consumer Products Division in 2023, refocusing resources on construction and geotechnical applications. Division had previously launched Bio-Lux Max foams with up to 33% renewable content.
• Hanford Site (U.S. Department of Energy)coreStrategic or Co-development Partner · 1 January 2011NCFI began environmental remediation efforts in 2011 at the Hanford Site along the Columbia River in Washington State - the most contaminated nuclear site in the U.S. NCFI's polyurethane technology applied to environmental cleanup and stabilization efforts.
• Dalton Foam, Inc.minorStrategic or Co-development Partner · 1 January 1987NCFI acquired Dalton Foam, Inc. in 1987 and subsequently launched the Dalton Foam Division. Acquisition provided rebond urethane carpet cushion product line and enabled recycling of company's own scrap. Division expanded by 24,000 square feet in 1989.
• NASA / Lockheed MartinflagshipStrategic or Co-development Partner · 1 January 1980NCFI was selected by NASA in 1980 to supply foam insulation for the Space Shuttle program, beginning with the first launch in 1981. Collaborated with Lockheed Martin providing foam for the U.S. Space Shuttle's External Tank Program. Received Supplier Quality Excellence Award in 2010 recognizing outstanding contributions to the program.
• Barnhardt Manufacturing CompanyflagshipOthersNCFI Polyurethanes is a division of Barnhardt Manufacturing Company, founded in 1964 by Dr. H.W. Bradley and the Barnhardt family. Barnhardt provides corporate umbrella and organizational infrastructure supporting NCFI's operations.
• GracocoreChannel Partner/ Reseller/ DistributorNCFI is an authorized distributor of Graco equipment including Reactor 3 Series, Gusmer GH-2/GH-4 proportioner systems. Provides plural component foam spray machines, coating rigs, and trailer setups backed by full technical support.
• PMC (Plural Component Systems)coreChannel Partner/ Reseller/ DistributorNCFI is an authorized distributor of PMC equipment including PH-2, PHX-2, and PH/PHX-40 Hydraulic Proportioners. These systems handle polyurethane and polyurea for various insulation, roofing, and protective coating applications.

Scale indicators5 records

Recent moves9 records

Expansion highlights6 records

Broad incumbents

• BASF (Polyurethanes division): BASF is one of the world's largest integrated polyurethane producers, supplying MDI, TDI, polyols, and finished foam systems across construction, automotive, and appliance markets. It is a broad incumbent whose systems-house and raw material footprint overlaps with NCFI's SPF insulation, OEM foam, and geotechnical offerings at much greater scale.
• Covestro: Covestro is a global polyurethane and polycarbonate leader producing MDI/TDI and downstream foam systems. It competes with NCFI in rigid SPF insulation and OEM polyurethane formulations, leveraging backward integration into isocyanates that NCFI does not have.
• Huntsman Corporation: Huntsman's Polyurethanes and Performance Products divisions supply MDI, polyols, and spray foam systems for construction and insulation. It is a direct competitor in SPF chemistry and a broad incumbent serving many of the same construction and OEM customers as NCFI.
• Johns Manville (Berkshire Hathaway): Johns Manville is a major building products manufacturer producing insulation, roofing systems, and engineered foam products. Its SPF insulation and roofing portfolios overlap with NCFI's InsulStar and EnduraTech lines within a much broader insulation portfolio.
• Carlisle Construction Materials: Carlisle is a leading manufacturer of commercial roofing systems, including spray foam and coatings offerings. Its roofing channel and product breadth make it a comparable competitor to NCFI's EnduraTech SPF roofing business, though at much larger scale.

Direct peers

• Demilec (Huntsman): Demilec is a North American spray polyurethane foam systems house (now part of Huntsman) producing closed-cell and open-cell SPF insulation products. It is one of the closest direct peers to NCFI's InsulStar SPF business, serving the same certified contractor channel.
• Icynene-Lapolla: Icynene-Lapolla (acquired by BASF) is a leading spray foam insulation manufacturer offering open-cell and closed-cell SPF systems. It directly competes with NCFI's InsulStar line in residential and commercial insulation through certified applicators.
• Rhino Linings Corporation: Rhino Linings manufactures sprayed polyurethane and polyurea coatings and foams for industrial, construction, and geotechnical applications. Its product range and applicator-based distribution model overlap with NCFI's EnduraTech roofing and geotechnical offerings.
• SWD Urethane: SWD Urethane produces spray polyurethane foam systems, coatings, and geotechnical foams for construction and infrastructure repair. It is a direct competitor in SPF insulation, roofing, and concrete-lifting geotechnical applications.
• Foam Supplies / FSI: Foam Supplies is a polyurethane systems house producing spray foam, rigid foam, and specialty foam systems, including eco-friendly formulations. It competes with NCFI across SPF insulation and OEM polyurethane foam markets.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat6 records

Key risks6 records

Key highlights7 records

Customer concentration

• Xx.com/NCFI

Compliance11 records

Revenue estimate

Valuation estimate

Number of profiles

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about NCFI Polyurethanes