NCFI Polyurethanes is a prominent United States-based manufacturer specializing in high-performance polyurethane foam chemical systems. A division of Barnhardt Manufacturing Company, the company was established in 1964 and has grown to become a leader in both flexible and rigid polyurethane foam technologies, serving a diverse array of global and domestic industries. NCFI's core business is centered on the formulation, manufacturing, and distribution of custom and proprietary polyurethane systems designed to enhance energy efficiency, structural integrity, comfort, and safety across various applications. The company's operations are supported by manufacturing and distribution facilities located throughout the United States, including its headquarters in Mount Airy, North Carolina.
The company's offerings are structured into several key market segments, each featuring specialized product lines and services:
Construction and Insulation Solutions
NCFI is a major supplier in the building envelope market, manufacturing a complete line of spray polyurethane foam (SPF) insulation and roofing systems for residential, commercial, and industrial construction. Their products are formulated as two-component systems that are spray-applied or pour-in-place to create seamless, monolithic insulation and air-sealing barriers.
Products and Applications:
* Spray Foam Insulation: Includes both open-cell and closed-cell SPF systems that comply with regulatory and code requirements. These products are utilized for insulating walls, ceilings, attics, crawl spaces, and air sealing.
* InsulStar® and InsulStar® Light: High-performance insulation systems for residential and commercial applications, known for contributing to energy efficiency by reducing air leakage.
* InsulBloc®: A line of closed-cell foam systems often used in commercial buildings for its structural and high thermal resistance properties.
* Roofing and Coatings: NCFI develops polyurethane foam roofing systems and protective coatings that provide exceptional durability, weather resistance, and thermal insulation for commercial and industrial rooftops.
* Controlled Atmosphere Storage: Polyurethane systems are specifically engineered for applications such as cooler/freezers, controlled atmosphere storage, kilns, and tanks, where precise temperature and environmental control are critical.
* EnduraTech®: An environmentally friendly choice in their insulation offerings, aligning with their commitment to low-GWP (Global Warming Potential) solutions.
Geotechnical Polyurethanes
A distinct and highly specialized division, NCFI's Geotechnical group provides a suite of polyurethane systems for infrastructure and ground stability projects. These products are designed for rapid reaction and expansion, offering non-invasive, cost-effective alternatives to traditional repair methods.
Products and Applications:
* Dual-Component Systems: Formulated for various applications, including concrete lifting (often called "polyjacking" or "slab jacking"), undersealing pavements and concrete structures, and general void filling.
* Light-Weight Fill Systems: Dual-component products engineered for filling large voids and cavities with low exothermic heat generation, suitable for applications like pipe abandonment, trench breakers, pipe pads, and pillows.
* Single-Component Hydrophobic Systems (e.g., Terra-Lok???): A suite of permeation grouts that react with moisture to expand and form a solid, water-tight, and highly dense cellular structure. They are primarily used for soil stabilization, void filling, joint sealing, and stopping water intrusion in seawalls, underground infrastructure, and sinkhole remediation.
OEM (Original Equipment Manufacturer) Solutions
The OEM Solutions Group collaborates with manufacturers across various sectors, creating custom and standardized flexible and rigid foam components for inclusion in end-user products.
Products and Applications:
* Flexible Foams: Used extensively for comfort and cushioning applications:
* Furniture and Seating: High-performance foams for upholstered furniture and seating systems.
* Transportation Seating: Specialty foams for automotive, rail, and other transportation seating.
* Bedding and Carpet Underlay: Foams for mattresses, pillows, and carpet cushioning.
* Specialty Molding: Customized rigid and flexible foam formulations for specialty molding applications, taxidermy, and various custom parts.
* Aerospace Applications: Provides engineered rigid and flexible foam systems for the aerospace industry, addressing critical needs such as thermal and acoustic insulation for passenger cabin walls and ceilings, vibration control (e.g., flight deck pads), and comfort components like seat cushions.
* Packaging and Cold Chain: Protective foam for safe shipping and insulation for panels, doors, and cooler/freezer units.
Marine Flotation
NCFI is a leading supplier of pour-in-place and spray-applied polyurethane foam systems specifically designed for marine flotation and buoyancy applications, including boat and dock construction.
Technical and Support Services
In addition to its chemical manufacturing, NCFI Polyurethanes provides a comprehensive support ecosystem for its customers and applicators. This includes:
* Design Specification and Technical Advice: Providing expertise to architects, engineers, and contractors on product selection and application protocols.
* Application Equipment: Selling and servicing application equipment, including rigs, plural component foam spray machines, and coating rigs, as authorized distributors for industry-leading brands like Graco and PMC.
* Training and Startup Service: Offering hands-on training and on-site startup assistance to ensure the correct and efficient application of their foam systems in the field.
* Research and Development: Maintaining an in-house R&D team dedicated to refining existing formulas and developing new, advanced polyurethane technologies, with a strong focus on environmentally sound, low-GWP solutions.
NCFI's commitment to innovation and quality assurance, backed by decades of experience, positions it as a key provider of versatile polyurethane solutions that address complex challenges in construction, geotechnical repair, custom manufacturing, and beyond.
