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NCI Building Systems

NCI Building Systems, Inc. was a leading North American manufacturer and marketer of metal products for the nonresidential , specializing in engineered building systems, metal components, insulated metal panels, and metal coil coating services. Founded in 1984 in , and reincorporated in in 1991, the company grew through strategic acquisitions, including Metal Building Components, Inc. in 1998, Robertson-Ceco Corporation in 2006, Metl-Span in 2012, and CENTRIA in 2015, which expanded its product offerings and market reach. The company's operations were divided into four main segments: Engineered Building Systems, which designed and manufactured custom metal buildings for and use; Metal Components, producing panels, , and accessories for walls and roofs; Insulated Metal Panels, offering energy-efficient building envelopes; and Metal Coil Coating, providing prepainted steel and aluminum coils for further fabrication. With 36 facilities across the , , and , NCI served a diverse customer base including approximately 3,200 builders, over 1,000 insulated metal panel dealers, and 5,500 architects, focusing on low-rise nonresidential markets such as /, architectural, agricultural, and institutional structures. In November 2018, NCI Building Systems merged with Ply Gem Parent, LLC, a major producer of residential exterior building products, to form , creating one of the largest exterior building products companies in with over 20,000 employees and 80 locations. The merger combined NCI's commercial expertise with Ply Gem's residential focus, enhancing capabilities in new construction and repair/remodel markets, while NCI's legacy brands and operations continued under the new entity. In July 2022, was acquired by affiliates of and taken private. Prior to the merger, NCI was publicly traded on the under the ticker NCS.

History

Founding and Early Years

NCI Building Systems was founded in 1984 as National Components Inc. by Johnie Schulte, Jr. in , . Schulte, who had begun his career in the metal building industry in the mid-1950s working on the machine shop floor at Metallic Building Company, drew on decades of hands-on experience in punching, shearing, and fabricating metal components to establish the company. From its inception, the company concentrated on basic metal building components, such as roof and wall panels, secondary structural framing, and joists and decks, alongside initial operations in metal , which involved cleaning, treating, and painting continuous for the nonresidential sector. These products targeted the low-rise (five stories or less) nonresidential market, serving applications in commercial, industrial, and agricultural buildings. Early operations were centered in , with the establishment of key facilities in the to support regional demand and efficient distribution. The company experienced steady organic revenue growth through the late 1980s and early 1990s, driven by expanding production capacity and in the burgeoning low-rise nonresidential sector. To facilitate further expansion and prepare for public listing, NCI reincorporated in in 1991, which supported its the following year and laid the groundwork for subsequent acquisitions that amplified its foundational strengths.

Expansion and Acquisitions

In the late , NCI Building Systems pursued aggressive growth through strategic acquisitions to broaden its product offerings and market reach. A pivotal move was the 1998 acquisition of Metal Building Components, Inc. (MBCI) from for $550 million in cash and 700,000 shares of NCI , which nearly doubled the company's base to approximately $936.6 million by fiscal 1999 and established it as the largest domestic manufacturer of metal building components. This deal expanded NCI's product lines to include a wider array of metal roofing, wall panels, and structural components, integrating MBCI's 39 facilities across 19 U.S. states and into NCI's operations. Building on this foundation from its early manufacturing focus, NCI continued acquisitions in the to enhance capabilities in metal coil coating and components. In 2000, the company acquired the remaining share of its DOUBLECOTE metal coil-coating from Consolidated Systems for $26 million, gaining full control of this key supplier of pre-painted steel and aluminum coils used in its products. That same year, NCI purchased Midland Metals, a Midwest producer of metal building components, for an undisclosed amount, which strengthened its regional presence and component manufacturing. Further bolstering the components segment, 2003 saw the acquisition of Texas-based Able Manufacturing and Wholesale Company for $3.3 million, adding specialized door systems, while 2004 brought Heritage Building Systems and Steelbuilding.com in for $30 million plus stock, expanding engineered metal building options. In 2005, NCI acquired rights from STEELOX Systems, LLC, integrating advanced panel technologies into its portfolio. The decade's largest deal was the 2006 purchase of Robertson-Ceco Corporation (RCC) for $370 million, incorporating brands like Star Building Systems, Ceco, and Robertson, which added seven manufacturing plants and enhanced engineered building systems with innovative framing and enclosure solutions. These acquisitions drove the evolution of NCI's business segments, formalizing a three-segment —metal coil , metal components, and engineered building systems—by the mid-2000s through seamless integration of acquired technologies. For instance, DOUBLECOTE's expertise directly supported the components and building systems segments by providing high-quality pre-finished materials, while RCC's assets diversified engineered systems with custom metal for commercial applications. This integration improved and , contributing to revenue growth from $1.1 billion in fiscal 2000 to over $2.5 billion by fiscal 2007. NCI's public listing on the under the ticker NCS in August 1998, following its in 1992, facilitated these expansions by providing access to capital markets for funding deals like MBCI and RCC. Financial milestones underscored this growth, including a exceeding $1 billion post-1998 listing and improved EBITDA margins from integrated operations, which rose to around 10% by the late amid nonresidential demand. Geographic expansion accompanied these efforts, with new manufacturing plants and acquired facilities extending NCI's footprint across the U.S. In 1996, a new plant opened in California to serve the West Coast, complemented by the Mesco Metal Buildings acquisition in Dallas, Texas. The 1997 purchase of facilities in Houston, Texas, and Jemison, Alabama, from Carlisle Engineered Metals further solidified the South, while a 51% joint venture in Mexico initiated international manufacturing for framing systems. By 2002, a new metal roof and wall panels plant in Big Rapids, Michigan, targeted the Midwest, and 2003 saw a frames plant in Lexington, Tennessee. The RCC acquisition in 2006 added plants in key regions, bringing NCI's total to over 40 facilities nationwide by the mid-2010s, enabling localized production and reduced logistics costs.

Merger with Ply Gem and Legacy

In July 2018, NCI Building Systems, Inc. announced an all-stock merger with Ply Gem Parent, LLC, a major producer of exterior building products, to form a combined entity focused on non-residential and residential markets. The transaction, valued at approximately $2.5 billion, positioned NCI s to own about 53% of the new company, with the deal expected to generate around $4.5 billion in annual revenue. The merger was completed on November 16, 2018, following approval and regulatory clearances, officially establishing Cornerstone Building Brands as the successor entity. Following the merger, Cornerstone Building Brands underwent a on April 11, 2019, unifying NCI's and Ply Gem's operations under a single corporate identity to streamline product offerings in metal building systems, siding, and windows. This included the formal name change to Cornerstone Building Brands, Inc., effective May 23, 2019, and the integration of NCI's metal components and engineered building divisions into Cornerstone's broader portfolio, enhancing supply chain efficiencies and market reach. As part of post-merger expansion, Cornerstone acquired Environmental Materials, LLC (doing business as Environmental StoneWorks) on February 20, 2019, for about $179 million, bolstering NCI's legacy in sustainable building products through manufactured stone veneers that complement metal systems. NCI's merger-era contributions extended its influence in the industry by advancing metal building efficiency, particularly through innovations in insulated metal panels (IMPs) that improved energy performance and reduced construction costs in non-residential applications. These developments, rooted in NCI's pre-merger expertise, helped drive broader adoption of metal systems for their durability and in and industrial structures. As of 2025, NCI's brands and technologies, including Star Building Systems and MBCI metal roofing solutions, continue to operate under , supporting ongoing innovations like Hypersteel cold-formed that enhance structural efficiency. In July 2025, Cornerstone appointed industry veteran Gunner Smith as its new CEO to drive profitable growth. The company further expanded in September 2025 by acquiring Metal Sales Manufacturing Corporation, enhancing its metal roofing and wall systems offerings. Cornerstone remains North America's largest manufacturer of exterior building products, with NCI's legacy integral to its approximately $5.6 billion in annual revenue as of 2024 and focus on sustainable construction.

Business Operations

Metal Coil Coating Segment

The Metal Coil Coating segment of NCI Building Systems involved the preparation of flat-rolled and other metals through a continuous process that cleans, chemically treats, slits, embosses, and applies protective paints or finishes to coils, enhancing their , , and aesthetic qualities for use in applications. This process begins with uncoiling raw metal, followed by surface cleaning to remove oils and contaminants, pretreatment with coatings to promote and inhibit , and then the application of high-performance paints via reverse-roll coating, which are cured in ovens to form a uniform, durable layer. The coated coils are then recoiled or cut into sheets for shipment, serving both internal NCI operations and external customers in industries like and automotive. NCI's coil coating operations were conducted at multiple facilities across the , including specialized plants for light-gauge and heavy-gauge metals to optimize efficiency. Prior to divestiture, the segment included five light-gauge facilities and two heavy-gauge sites, enabling annual processing capacities of approximately 900,000 metric tons while maintaining high utilization rates through base-loaded internal demand from NCI's other segments. These locations were strategically positioned near mills and fabrication sites to minimize transportation costs and support just-in-time delivery. Legacy operations were divested in June 2022 to Steel Limited for $500 million, with securing long-term supply agreements. Technological advancements in NCI's coil coating included the development and use of advanced pretreatment systems, such as or chrome-free conversions, which significantly improved by forming protective barriers on the metal surface before application. Pre-merger innovations focused on high-durability formulations, including fluoropolymer-based coatings that offered superior and color retention, extending the lifespan of coated metals in harsh environments without compromising formability. These enhancements, refined through internal R&D and partnerships with suppliers, allowed for customized finishes that met stringent building codes for non-residential structures. The segment contributed approximately 10.4% to NCI's external sales in fiscal 2018 ($207.8 million external on $2.0 billion total), functioning as a foundational that supported efficiencies across the company by providing a reliable internal supply of coated materials. In fiscal 2016, for example, it generated $247.7 million in total sales ($106.6 million external), with operating margins benefiting from despite fluctuations in prices and product mix. This smaller-scale segment was essential for stabilizing supply and reducing external dependencies. Supply chain integration was a core strength, with NCI sourcing raw steel coils primarily from major U.S. mills like and , which provided the flat-rolled base material essential for . The segment's operations were tightly linked to upstream suppliers through long-term contracts to against price volatility, ensuring consistent quality and volume for . Coated coils from this segment directly fed into NCI's Metal Components operations for further fabrication.

Metal Components Segment

The Metal Components segment of NCI Building Systems focused on manufacturing and distributing metal products essential for nonresidential , including and wall systems, insulated metal panels (IMPs), structural framing components like purlins and girts, metal partitions, roll-up , trims, flashings, and related accessories. These products were designed for durability, aesthetic versatility, and functional performance in , , institutional, and agricultural applications, supporting both new builds and retrofit projects. The segment's offerings emphasized to meet diverse architectural and structural needs, positioning NCI as a key supplier in the low-rise nonresidential market. Production relied on advanced roll-forming and assembly techniques at 14 specialized facilities across the , including three dedicated to door manufacturing. Pre-finished steel coils were fed into roll-formers and fabrication to shape panels, , and accessories with precision, enabling efficient, high-volume output while accommodating custom specifications. This hub-and-spoke model optimized and reduced lead times, with a strong emphasis on through cost-control initiatives and processes tailored for nonresidential building demands. Legacy operations continue under Cornerstone Building Brands, enhanced by the 2024 acquisition of Metal Sales Manufacturing Corp., which expanded capabilities in metal roofing and systems. As NCI's largest revenue-generating segment pre-acquisitions like IMPs, Metal Components accounted for approximately 43% of in fiscal 2014 and 30.6% ($612.6 million in external sales) in fiscal , reflecting steady growth from $495.0 million in 2016. This scale underscored its market leadership, with NCI recognized as the largest producer and distributor of metal components for building construction, driven by a focus on quality, service, and competitive pricing in a fragmented . Key innovations included energy-efficient IMP designs offering superior thermal insulation and reduced energy consumption, as well as specialized products like Soundwall™ for acoustic control and Nu-Roof™ cool roofing systems to promote in commercial structures. Pre-merger distribution leveraged a nationwide of manufacturing plants and eight Metal Depots retail outlets, with sales directed to contractors, end users, and distributors through direct channels. This approach facilitated broad accessibility and supported the segment's role in delivering tailored solutions for efficient, customizable nonresidential projects.

Insulated Metal Panels Segment

The Insulated Metal Panels (IMP) segment of NCI Building Systems manufactured energy-efficient insulated metal panels for walls, roofs, and facades in nonresidential , providing , structural support, and aesthetic finishes. Acquired through the 2012 purchase of Metl-Span and expanded via the 2015 CENTRIA acquisition, this segment offered products like concealed-fastener and exposed-fastener panels, doors, and framing systems compliant with standards from the Metal Building Manufacturers Association (MBMA) and energy codes. Operations utilized 10 facilities across for panel fabrication, integrating foam cores ( or ) between metal skins via continuous or processes to achieve high R-values for . Customization included architectural finishes and integration with building systems for applications in , , and settings. Legacy IMP operations continue under Building Brands, serving over 1,000 dealers and contributing to sustainable building envelopes. In fiscal 2018, the IMP segment generated $504.4 million in total sales (21.2% of consolidated, $424.8 million external), driven by demand for energy-efficient solutions and growth in retrofit markets. Innovations included high-performance panels with coatings and advanced for LEED-certified projects.

Engineered Building Systems Segment

The Engineered Building Systems segment of NCI Building Systems focused on the , engineering, and fabrication of pre-engineered metal buildings tailored for industrial and applications, providing comprehensive solutions for nonresidential needs. This segment manufactured main frames, Long Bay® Systems—a patented wide-span framing option enabling bay spacings of 40 to 60 feet for open interiors—and offered value-added engineering and drafting services to support custom project requirements. These systems were engineered to comply with industry standards such as those from the Metal Building Manufacturers Association (MBMA), ensuring structural integrity and adaptability for uses like facilities and warehouses. Legacy operations persist under brands like Ceco and , with ongoing advancements in software and . Integration of components formed the core of this segment's operations, assembling sourced elements—such as those from the Metal Components segment—into building systems that included structural framing, roofing, and cladding for efficient on-site installation. Customization was achieved through advanced software tools, including those from Metal Building Software Inc., which facilitated precise modeling, load analysis, and optimization to meet specific site conditions, seismic requirements, and aesthetic preferences. Buildings were designed for quick modifications before, during, or after erection, allowing economic expansions or reconfigurations without major disruptions. As a key segment within NCI's portfolio, the Engineered Building Systems group emphasized high-value services for larger-scale projects, contributing approximately $244 million in sales during the fourth quarter of fiscal 2018 ($755.4 million external for the full year), compared to higher volumes in other areas post-merger. Representative pre-merger projects included the Plastics manufacturing facility, where Ceco Building Systems (an NCI brand) engineered a custom with integrated cladding for powersports , optimizing and durability. Another example was Hangar 19 at , featuring a tailored wide-span design for storage that combined structural elements with weather-resistant cladding for demands.

Products and Markets

Core Product Offerings

NCI Building Systems offered a range of metal-based products designed for nonresidential , emphasizing durability, , and aesthetic versatility. These offerings, which continued under Cornerstone Building Brands following the 2018 merger, included standing seam roofs under the MBCI brand. These roofs featured concealed fastener systems that allowed for thermal movement without piercing the panel surface and were typically constructed from 24-gauge galvanized steel with options for premium coatings such as ® 200 or 300 series for enhanced corrosion resistance and color retention. Available in snap-lock or mechanically seamed variants like Double-Lok® or LokSeam®, they provided a lifespan of up to 60 years, outperforming traditional shingles in longevity and weather resistance by reducing maintenance needs and through superior integration. Wall panels from NCI, also via MBCI, encompassed both exposed and concealed fastener types in single-skin and insulated configurations, available in gauges from 22 to 29 for varying structural demands. These panels offered finish options including Galvalume Plus® or metallic coatings in over 40 colors, enabling horizontal or vertical installation for modern architectural designs. Compared to conventional brick or wood siding, NCI's wall panels provided faster installation and higher impact resistance, while meeting standards like ASTM E283 for air infiltration. Insulated variants integrated foam cores for added thermal performance, evolving from basic metal skins in the 1990s to high-performance options post-2012 Metl-Span acquisition. Insulated metal panels (IMPs) represented a core evolution in NCI's lineup, acquired through Metl-Span in 2012 to bolster energy-efficient solutions. These panels featured or foam cores sandwiched between facings (typically 26- to 22-gauge exterior and 26-gauge interior), achieving R-values up to 42 for walls and 56 for roofs in products like CFR® or LS-36™, far surpassing traditional insulated forms in and weight reduction. Finish options included smooth, stucco-embossed, or profiles with Kynar 500® coatings for UV protection, and sustainable variants like EcoScreen® single-skin panels promoted recyclability—steel components are 100% recyclable—aligning with credits for material resource efficiency. IMPs offered comparative advantages over walls, including lower installed costs and quicker assembly, while certifications such as UL 263 for resistance and FM 4471 for wind loads ensured compliance in commercial and industrial applications. Metal doors, including roll-up and walk-through models, complemented NCI's systems with robust for secure access in metal buildings. Walk doors, available in sizes like 3' x 7' (3070), featured optional and powder-coated finishes in standard colors like white, while roll-up doors met IBC standards. These doors evolved from basic components to integrated, energy-efficient designs post-mergers, providing better sealing than traditional hollow metal doors. Framing systems, comprising primary (columns, rafters) and secondary (girts, purlins) steel members, used high-strength ASTM A992 in sections optimized via for . Gauges ranged from 12-16 for structural to 24 for secondary, with Galvalume coatings for , and they met AISI S100 for , offering lighter weight and faster erection than concrete alternatives.

Target Market Segments

NCI Building Systems primarily targeted the low-rise nonresidential , which encompassed buildings of five stories or fewer and represented approximately 87% of the $295 billion U.S. nonresidential as of 2018. The company's core segments included and applications, such as warehouses, factories, and centers; architectural uses for aesthetically driven structures like office buildings and retail spaces; and agricultural facilities, including barns and storage units. Additional segments encompassed energy-related projects, such as power generation facilities, and broader retail environments requiring durable metal components. Demand in these markets was propelled by steady in nonresidential activity prior to NCI's merger with , with positive economic conditions, availability of financing, and rising needs serving as key drivers. The low-rise segment's scale provided NCI with significant opportunities, as it accounted for the majority of new builds and repair/retrofit projects across these industries, though the company held a focused rather than dominant in metal building products. These market segments and product lines continued under Building Brands after the merger. Geographically, NCI concentrated its operations in , operating 36 manufacturing and distribution facilities across the , , and , with a particular emphasis on U.S. states like , , and , where construction demand was robust due to and industrial . This regional focus aligned with higher activity in southern and southwestern markets, supporting efficient supply chains for regional customers. The primary customer base consisted of approximately 3,200 affiliated builders, over 1,000 insulated metal panel dealer partners, and around 5,500 architects and specifiers, alongside general contractors, developers, and end-users engaged in low-rise projects. No single customer exceeded 2% of NCI's sales, reflecting a diversified base. Influencing trends included increasing regulations and standards, which boosted demand for NCI's metal products incorporating 30% to 60% recycled content and insulated systems compliant with stricter building codes.

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