Plasti-Fab

What Plasti-Fab does

Plasti-Fab is a North American manufacturer of Expanded Polystyrene (EPS) rigid foam insulation, building systems, and geotechnical products, founded in 1968 and headquartered in Calgary, Alberta. The company operates nine manufacturing facilities across Canada (British Columbia, Alberta, Saskatchewan, Manitoba, and two in Ontario) and the United States (Ohio and Minnesota), employing roughly 325 people, and is the only vertically integrated EPS producer in North America, controlling resin production through its former parent PFB Corporation and converting that resin into finished rigid foam, geofoam, structural insulated panels (Insulspan), and insulating concrete forms (Advantage ICF). Its core technology platform centres on proprietary EPS chemistry augmented by Neopor graphite-enhanced polystyrene (GPS) variants that deliver higher R-values per inch than competing materials.

The commercial model is hardware sales of branded insulation and geotechnical products (PlastiSpan, DuroSpan/DuroFoam, EnerSpan, Energreen, GeoSpec, GeoVoid, GeoSpan, Radon Guard, FanFold) distributed through building supply dealers across Canada and the United States, supplemented by direct technical sales representatives and custom shape-moulding services for OEM packaging and specialty applications. End markets are segmented into Residential Construction (renovation, foundations, ceilings, radon mitigation), Commercial Construction (roofing, EIFS, cold storage, code-listed assemblies), Civil and Infrastructure (geofoam lightweight fill, slope stabilisation, compressible fills), and Custom/OEM Solutions (product protection, buoyancy, specialty packaging). Pricing is project-quoted through the dealer and direct-sales channels with no public disclosure of list prices.

Since October 2024 Plasti-Fab has operated as a wholly-owned subsidiary of Carlisle Companies Incorporated (NYSE: CSL) following Carlisle's acquisition of PFB Corporation and the Insulspan brand, giving the business access to a larger building-products commercial platform while retaining its regional manufacturing footprint, vertical integration, GREENGUARD and CCMC code listings, and brand portfolio.

Name

Plasti-Fab

Legal name

Plasti-Fab Ltd.

Website

https://plastifab.com

Company type

Private

Founded year

1968

Operating status

Operating

Headcount range

251–500 employees

Short description

Plasti-Fab manufactures Expanded Polystyrene (EPS) rigid foam insulation, building systems, and geotechnical products for residential, commercial, and infrastructure applications across North America, operating nine production facilities and serving customers via dealers and direct sales.

Ownership category

akta.pro rank

Product category

Building Insulation Materials

NAICS

Polystyrene Foam Product Manufacturing (32614)

SIC

Plastics Foam Products (3086)

akta.pro primary industry

Expanded Polystyrene (EPS) Foam Manufacturing (IMANAIAA)

akta.pro secondary industries

Styrenics (PS, EPS, ABS, SAN) (IMAEANAC), Foam Protective Packaging (EPS/EPE/EPP, PU, Molded Foam) (IMALAFAA), Foam Conversion & Fabrication (Cutting, Laminating, CNC, Packaging Inserts) (IMANAIAJ)

Keywords

• EPS insulation products
• Geofoam lightweight fill
• ICF building systems
• Structural insulated panels
• Construction insulation materials

Headquarters

HQ city

Calgary

HQ country

Canada

HQ region

North America

Offices9 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

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

Revenue model

1. EPS Insulation Products: Sale of expanded polystyrene insulation products including PlastiSpan, DuroSpan, and GPS insulation for residential, commercial, and industrial construction applications. Products are sold through building supply dealers and directly to contractors.

Go-to-market motion1 record

Distribution channels3 records

Marketing channels7 records

Core offering

Plasti-Fab manufactures and supplies Expanded Polystyrene (EPS) rigid foam insulation products, building systems (ICF and SIPs), and geotechnical fill materials for residential, commercial, civil infrastructure, and custom packaging applications across North America. Operating nine manufacturing facilities across Canada and the United States, the company is the only fully vertically integrated EPS producer in North America, controlling production from raw polystyrene resin through to finished insulation, geofoam, and architectural shape-moulded products.

Product overview

Plasti-Fab is the only vertically integrated EPS (expanded polystyrene) company in North America, manufacturing and supplying a comprehensive portfolio of insulation and geotechnical products since 1968. The company operates from nine manufacturing facilities across Canada and the United States. The core product line centers on PlastiSpan® insulation (available in types 1, 2, 20, 25, 30, 40, 60, HD, EFS, RN, and HD Hydronic variants) and DuroSpan®/DuroFoam® insulation products. Advanced offerings include DuroSpan® GPS (graphite-enhanced polystyrene) insulation providing R5, R7.5, and R10 per inch performance. The company also offers EnerSpan® and Energreen® insulation product lines. Complementing insulation are two building systems: the Advantage ICF System® (insulating concrete forms) and the Insulspan® SIP System (structural insulated panels). Geotechnical solutions include GeoSpec® lightweight fill, GeoVoid® and GeoSpan® compressible fill products for soil stabilization. Specialty products include FanFold® panels and Radon Guard® for radon mitigation. Custom solutions encompass shape moulded packaging, specialty cut foam, protective corners, mailers, box liners, medical packaging, and coolers. All products are GREENGUARD certified and manufactured with low-VOC resin using vertically integrated processes from proprietary resin manufacturing to finished products.

Differentiator

Problem solved

Functional benefit

Brands

• PlastiSpan: EPS insulation products for construction applications including roofs, walls, floors, and foundations
• DuroSpan
• DuroFoam
• GeoSpec
• GeoVoid
• GeoSpan
• Advantage ICF System
• Insulspan SIP System
• Radon Guard
• EnerSpan
• Energreen
• DuroSpan GPS

Products and services

• PlastiSpan EPS Insulation
• DuroSpan / DuroFoam Insulation
• DuroSpan GPS Insulation
• EnerSpan Insulation
• Energreen Insulation
• Roofing Insulation
• Advantage ICF System
• Insulspan SIP System
• GeoSpec Lightweight Geofoam Fill
• GeoVoid Compressible Fill
• GeoSpan Compressible Fill
• FanFold Underlayment
• Radon Guard
• Custom Shape-Moulded Solutions

Quantifiable outcome

• 100 tonnes of emissions prevented annually through low-VOC resin use
• +3 more outcomes

Named customers8 records

Segments4 records

Ideal customer profiles4 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature4 records

Partnerships

One partnership is on record.

• PFB CorporationflagshipStrategic or Co-development PartnerParent company that manufactures proprietary resin used by Plasti-Fab. PFB was the original owner of Plasti-Fab and Insulspan brands before acquisition by Carlisle. The vertical integration from PFB's resin manufacturing through Plasti-Fab's EPS production is core to the company's competitive advantage.

Scale indicators4 records

Recent moves6 records

Expansion highlights6 records

Direct peers

• Insulfoam: Direct EPS insulation peer that was folded into Carlisle's building products portfolio alongside Plasti-Fab via the PFB Corp acquisition. Operates EPS plants across the United States producing rigid foam insulation, geofoam, and roof insulation — overlapping with Plasti-Fab's product mix.
• ACH Foam Technologies: Major North American EPS manufacturer producing rigid foam insulation, geofoam, protective packaging, and custom molded foam. Direct overlap with Plasti-Fab in both insulation and packaging/custom EPS product lines.
• Benchmark Foam Inc. U.S.-based EPS insulation, geofoam, and roofing insulation manufacturer with overlap to Plasti-Fab's core insulation and civil/infrastructure product lines, particularly in Midwest geographies.
• FMI-EPS: EPS rigid foam insulation and geofoam manufacturer serving residential, commercial, and infrastructure markets across the United States. Direct product overlap with Plasti-Fab's PlastiSpan/DuroSpan and GeoSpec lines.

Broad incumbents

• Atlas Roofing Corporation: Established U.S. manufacturer of polyiso and XPS roof and wall insulation. Competes with Plasti-Fab EPS in commercial roofing and building envelope applications, particularly single-ply and built-up roofing assemblies.
• Kingspan Group: Global building envelope manufacturer with significant insulation, insulated panel (Kingspan Insulated Panels), and structural insulated panel offerings. Competes with Plasti-Fab's SIP/ICF systems and high-performance rigid insulation.
• Owens Corning: Diversified building products major whose Foamular XPS line competes directly with Plasti-Fab's EPS insulation in residential and commercial building envelope applications. Broader scale and Fiberglas insulation create broad category overlap.
• DuPont (Styrofoam Brand XPS): Original Styrofoam-brand extruded polystyrene insulation manufacturer and the historical incumbent Plasti-Fab explicitly positions against on R-value stability, GWP, and cost. Direct category competitor in rigid foam insulation.

Others

• BASF (Neopor / Styrodur): Supplies Neopor GPS graphite-enhanced polystyrene raw material that Plasti-Fab uses in its DuroSpan GPS line; also markets Styrodur XPS. Strategic input supplier and adjacent competitor in rigid foam chemistry.

Emerging players

• ROCKWOOL: Mineral wool insulation manufacturer with strong momentum in commercial and high-performance building applications. Increasingly substitutes for rigid foam insulation in fire- and acoustic-sensitive assemblies, creating indirect competitive pressure on EPS.

Market position

Strengths5 records

Weaknesses4 records

Competitive moat6 records

Key risks6 records

Key highlights6 records

Customer concentration

• YouTubeyoutube.com/channel/UCyGP3_iPQwtL8H9QG8DMIbQ
• Facebookfacebook.com/PlastiFabEPS
• LinkedInlinkedin.com/company/263513
• Instagraminstagram.com/plastifab_eps

Compliance8 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles2 records

Subsidiaries1 record

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 Plasti-Fab