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    Spray Polyurethane Foam Market

    ID: MRFR/CnM/5879-HCR
    140 Pages
    Anshula Mandaokar
    October 2025

    Spray Polyurethane Foam Market Research Report Information By Product (Open-Cell, Closed-Cell), By End-User (Commercial, Residential, Industrial), And By Region (North America, Europe, Asia-Pacific, And Rest Of The World) – Market Forecast Till 2035

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    Spray Polyurethane Foam Market Infographic
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    Spray Polyurethane Foam Market Summary

    As per MRFR analysis, the Spray Polyurethane Foam Market Size was estimated at 1.669 USD Billion in 2024. The Spray Polyurethane Foam industry is projected to grow from 1.786 USD Billion in 2025 to 3.513 USD Billion by 2035, exhibiting a compound annual growth rate (CAGR) of 7.0 during the forecast period 2025 - 2035.

    Key Market Trends & Highlights

    The Spray Polyurethane Foam Market is experiencing robust growth driven by sustainability and technological advancements.

    • North America remains the largest market for spray polyurethane foam, driven by increasing construction activities.
    • Asia-Pacific is emerging as the fastest-growing region, reflecting a surge in demand for energy-efficient building solutions.
    • Closed-cell foam dominates the market, while open-cell foam is witnessing rapid growth due to its versatility in applications.
    • Key market drivers include the rising demand for energy efficiency and the growing awareness of health and safety standards.

    Market Size & Forecast

    2024 Market Size 1.669 (USD Billion)
    2035 Market Size 3.513 (USD Billion)
    CAGR (2025 - 2035) 7.0%

    Major Players

    BASF SE (DE), Huntsman Corporation (US), Dow Inc. (US), Covestro AG (DE), Saint-Gobain (FR), Nippon Polyurethane Industry Co., Ltd. (JP), Sika AG (CH), Gaco Western (US), Icynene-Lapolla (US)

    Spray Polyurethane Foam Market Trends

    The Spray Polyurethane Foam Market is currently experiencing a notable transformation, driven by increasing demand for energy-efficient insulation solutions across various sectors. This material is recognized for its superior thermal performance, which contributes to reduced energy consumption in residential and commercial buildings. Additionally, the growing awareness regarding environmental sustainability is prompting manufacturers to innovate and develop eco-friendly formulations. As a result, the market is witnessing a shift towards products that not only meet performance standards but also align with green building practices. Furthermore, advancements in application techniques and equipment are enhancing the efficiency and effectiveness of spray polyurethane foam installations, making it a preferred choice among contractors and builders. In the context of evolving regulations and standards, the Spray Polyurethane Foam Market is likely to see increased scrutiny regarding safety and environmental impact. This could lead to the emergence of stricter compliance requirements, compelling manufacturers to adapt their offerings accordingly. Moreover, the expansion of the construction industry in emerging economies presents a significant opportunity for market growth. As urbanization continues to rise, the demand for insulation materials, including spray polyurethane foam, is expected to increase. Overall, the Spray Polyurethane Foam Market appears poised for growth, driven by technological advancements, regulatory changes, and a heightened focus on sustainability.

    Sustainability Initiatives

    The Spray Polyurethane Foam Market is increasingly influenced by sustainability initiatives. Manufacturers are focusing on developing eco-friendly products that minimize environmental impact. This trend aligns with global efforts to reduce carbon footprints and promote green building practices.

    Technological Advancements

    Technological advancements in application methods are reshaping the Spray Polyurethane Foam Market. Innovations in equipment and techniques enhance the efficiency of installations, making the material more appealing to contractors and builders.

    Regulatory Compliance

    Regulatory compliance is becoming a critical factor in the Spray Polyurethane Foam Market. Stricter safety and environmental regulations are prompting manufacturers to adapt their products, ensuring they meet evolving standards.

    The increasing emphasis on energy efficiency and sustainable building practices is driving a notable shift towards the adoption of spray polyurethane foam in construction applications.

    U.S. Department of Energy

    Spray Polyurethane Foam Market Drivers

    Growth in Construction Activities

    The resurgence of construction activities across various sectors seems to be a pivotal factor influencing the Spray Polyurethane Foam Market. With urbanization and infrastructure development on the rise, there is a notable increase in demand for innovative building materials. Spray polyurethane foam is favored for its versatility and ease of application, making it suitable for a range of construction projects. Recent statistics indicate that the construction sector is experiencing robust growth, which is expected to drive the demand for insulation materials, including spray foam. This growth trajectory suggests a promising outlook for the spray foam market as it aligns with the evolving needs of modern construction.

    Rising Demand for Energy Efficiency

    The increasing emphasis on energy efficiency in construction and renovation projects appears to be a primary driver for the Spray Polyurethane Foam Market. As energy costs continue to rise, builders and homeowners are seeking materials that provide superior insulation properties. Spray polyurethane foam offers high R-value per inch, which translates to better thermal performance. According to recent data, the insulation market is projected to grow significantly, with spray foam expected to capture a larger share due to its effectiveness in reducing energy consumption. This trend is likely to encourage more widespread adoption of spray foam solutions in both residential and commercial applications, thereby propelling the market forward.

    Growing Demand for Sustainable Building Solutions

    The increasing demand for sustainable building solutions is likely to significantly impact the Spray Polyurethane Foam Market. As environmental concerns gain prominence, builders and architects are actively seeking materials that contribute to sustainability goals. Spray polyurethane foam is recognized for its energy efficiency and potential to reduce carbon footprints in buildings. Recent market analyses indicate that the green building materials sector is expanding, with spray foam being a preferred choice due to its eco-friendly properties. This growing inclination towards sustainability is expected to drive innovation and investment in the spray foam market, aligning with global efforts to promote environmentally responsible construction practices.

    Increased Awareness of Health and Safety Standards

    The heightened awareness regarding health and safety standards in building materials is likely to bolster the Spray Polyurethane Foam Market. As consumers and builders become more informed about the potential health impacts of construction materials, there is a growing preference for products that meet stringent safety regulations. Spray polyurethane foam, when applied correctly, can contribute to healthier indoor environments by minimizing air leaks and improving air quality. Furthermore, regulatory bodies are increasingly mandating compliance with safety standards, which may drive the adoption of spray foam solutions that adhere to these guidelines. This trend indicates a shift towards safer building practices, potentially enhancing the market's growth.

    Technological Innovations in Application Techniques

    Technological advancements in application techniques for spray polyurethane foam are emerging as a significant driver for the Spray Polyurethane Foam Market. Innovations such as improved spray equipment and application methods are enhancing the efficiency and effectiveness of foam installation. These advancements not only reduce labor costs but also minimize waste, making the process more sustainable. As technology continues to evolve, it is likely that the market will see an increase in the adoption of spray foam solutions, particularly in complex projects where precision is crucial. This trend suggests that ongoing research and development in application technologies will play a vital role in shaping the future of the spray foam market.

    Market Segment Insights

    By Product: Closed-Cell (Largest) vs. Open-Cell (Fastest-Growing)

    In the Spray Polyurethane Foam Market, the product segment showcases a distinct distribution of market share between closed-cell and open-cell foams. Closed-cell foam predominates due to its superior insulating properties and moisture resistance, making it a preferred choice for various applications including roofing and insulation. Open-cell foam, while currently a smaller segment, is gaining traction for its cost-effectiveness and versatility, particularly in residential construction and soundproofing.

    Spray Polyurethane Foam: Closed-Cell (Dominant) vs. Open-Cell (Emerging)

    Closed-cell spray polyurethane foam is recognized for its strength, durability, and excellent thermal insulation properties, contributing to its dominance in the market. It is particularly effective in sealing spaces, providing energy savings, and is widely used in commercial and industrial applications. In contrast, open-cell spray foam, known for its lighter weight and ease of application, is emerging rapidly, especially in residential markets where affordability and sound dampening are key considerations. Despite its lesser market share, the increasing demand for environmentally friendly and energy-efficient building materials is poised to drive the growth of open-cell options in the coming years.

    By End-user: Commercial (Largest) vs. Residential (Fastest-Growing)

    In the Spray Polyurethane Foam Market, the end-user segment exhibits varied distribution among commercial, residential, industrial, and others. The commercial sector holds a significant portion of the market owing to the high demand for insulation and roofing solutions in commercial buildings. In contrast, the residential segment has been gaining momentum and is currently the fastest-growing segment, driven by a surge in new housing projects and renovation activities that prioritize energy efficiency. The growing awareness of the benefits associated with spray polyurethane foam, such as enhanced insulation performance and versatility, is contributing to the upward trend in the residential market. Meanwhile, the industrial segment remains steady, catering to specific applications that require specialized insulation solutions. The preference for sustainable and energy-efficient building solutions continues to bolster growth in the entire end-user category, reflecting a positive outlook for the Spray Polyurethane Foam Market across different sectors.

    Commercial (Dominant) vs. Residential (Emerging)

    The commercial segment of the Spray Polyurethane Foam Market is currently the dominant player, characterized by extensive usage in high-rise buildings, warehouses, and industrial facilities. This segment benefits from bulk installations and long-term contracts, making it a preferred choice for contractors and builders. On the other hand, the residential sector presents itself as an emerging segment, fueled by an increasing focus on energy efficiency and sustainable living. Homeowners are increasingly turning to spray polyurethane foam for insulation due to its ability to provide superior thermal performance and air sealing capabilities. This shift towards energy-efficient homes is expected to significantly drive growth in the residential segment as consumers increasingly prioritize comfort and energy savings.

    Get more detailed insights about Spray Polyurethane Foam Market

    Regional Insights

    By region, the study provides market insights into North America, Europe, Asia-Pacific, and the Rest of the World. North America market accounted for the largest share of the Spray Polyurethane Foam Market and is expected to register a healthy CAGR during the review period. This market growth can be attributed to the increasing construction spending in the region. Growing energy consumption by residential buildings has resulted in a surge in demand for energy-efficient construction materials and thus, spray polyurethane foam in the region.

    Figure 3: SPRAY POLYURETHANE FOAM MARKET SHARE BY REGION 2023 (%)    SPRAY POLYURETHANE FOAM MARKET SHARE BY REGION Source: Secondary Research, Primary Research, Market Research Future Database, and Analyst Review

    Asia-Pacific is another prominent market on account of increasing residential and commercial construction coupled with growing urbanization and changing living standards. Additionally, increased investment by the government in developing nations such as India, China, and ASEAN for infrastructure development has resulted in an increase in construction activities, which is expected to propel the market growth during the review period.

    The European market is expected to drive market growth on account of the expanding construction industry in Western and Northern Europe with increased spending on construction, renovation, and maintenance to meet the growing requirement for modern architecture and smart buildings.

    Key Players and Competitive Insights

    Major market players are spending a lot of money on R&D to increase their product lines, which will help the Spray Polyurethane Foam market grow even more. Market participants are also taking a range of strategic initiatives to grow their worldwide footprint, with key market developments such as new product launches, contractual agreements, mergers and acquisitions, increased investments, and collaboration with other organizations. Competitors in the Spray Polyurethane Foam industry must offer cost-effective items to expand and survive in an increasingly competitive and rising market environment.

    The major market players are investing a lot of money in R&D to expand their product lines, which will spur further market growth for Spray Polyurethane Foam. With significant market development like new product releases, contractual agreements, mergers and acquisitions, increased investments, and collaboration with other organizations, market participants are also undertaking various strategic activities to expand their global presence. To grow and thrive in a market climate that is becoming more competitive and growing, competitors in the Spray Polyurethane Foam industry must offer affordable products.

    Manufacturing locally to cut operating costs is one of the main business tactics manufacturers use in the global Spray Polyurethane Foam industry to benefit customers and expand the market sector. The Spray Polyurethane Foam market has recently given medicine some of the most important advantages. Major Spray Polyurethane Foam market players, including Huntsman International LLC (US), Accella Polyurethane Systems (US), BASF SE (Germany), Certainteed (US), and others, are attempting to increase market demand by funding R&D initiatives.

    Huntsman Corporation is a manufacturer of differentiated organic chemical products. It operates in four segments: Polyurethanes, Performance Products, Advanced Materials, and Textile Effects. The company offers polyurethane chemicals, performance products such as amines and maleic anhydride, advanced materials including epoxy, acrylic, and polyurethane-based polymer products, as well as textile chemicals, dyes, and inks.

    Also, BASF is a company that provides petrochemicals, intermediates, performance materials, monomers, dispersions and pigments, performance chemicals, catalysts, coatings, and care chemicals. It conducts its operations through six business segments: Chemicals, Materials, Industrial Solutions, Surface Technologies, Nutrition and Care, and Agricultural Solutions.

    Key Companies in the Spray Polyurethane Foam Market market include

    Industry Developments

    • Q2 2024: Huntsman Launches Next-Generation Spray Polyurethane Foam Insulation System Huntsman Corporation announced the commercial launch of its new closed-cell spray polyurethane foam insulation system, designed to meet stricter environmental and energy efficiency standards in North America.
    • Q2 2024: BASF Opens New Spray Polyurethane Foam Application Center in Texas BASF inaugurated a new application center in Houston, Texas, dedicated to the development and testing of spray polyurethane foam products for the construction and automotive sectors.
    • Q3 2024: Carlisle Companies Acquires Spray Foam Equipment Manufacturer Accella Performance Materials Carlisle Companies completed the acquisition of Accella Performance Materials, a leading manufacturer of spray foam equipment and systems, to expand its building envelope solutions portfolio.
    • Q3 2024: Covestro Announces Strategic Partnership with US Roofing Contractor for SPF Solutions Covestro entered into a multi-year partnership with a major US roofing contractor to supply spray polyurethane foam systems for commercial roofing projects across the Midwest and Southeast.
    • Q4 2024: Lapolla Industries Wins Major Contract for Spray Foam Insulation in Florida School District Lapolla Industries secured a contract to provide spray polyurethane foam insulation for a large-scale school renovation project in Florida, aiming to improve energy efficiency and hurricane resilience.
    • Q4 2024: Demilec Launches Low-GWP Spray Polyurethane Foam Product Line Demilec, a subsidiary of Huntsman, introduced a new line of spray polyurethane foam products with ultra-low global warming potential (GWP) blowing agents, targeting compliance with upcoming US environmental regulations.
    • Q1 2025: Johns Manville Appoints New Vice President for Spray Foam Business Johns Manville announced the appointment of a new Vice President to lead its spray polyurethane foam division, signaling a renewed focus on innovation and market expansion.
    • Q1 2025: Icynene-Lapolla Expands Manufacturing Capacity with New Facility in Georgia Icynene-Lapolla opened a new manufacturing facility in Georgia to increase production of spray polyurethane foam products and meet growing demand in the southeastern United States.
    • Q2 2025: Owens Corning Acquires Minority Stake in Spray Foam Startup AeroBarrier Owens Corning invested in AeroBarrier, a startup specializing in spray-applied air sealing technology, to enhance its building materials portfolio and accelerate innovation in the spray foam sector.
    • Q2 2025: Soprema Group Launches Bio-Based Spray Polyurethane Foam in Europe Soprema Group introduced a new bio-based spray polyurethane foam product in the European market, aiming to reduce carbon footprint and appeal to environmentally conscious builders.
    • Q3 2025: Gaco Western Secures Supply Agreement with Major Homebuilder for SPF Insulation Gaco Western signed a multi-year supply agreement with a top US homebuilder to provide spray polyurethane foam insulation for new residential developments nationwide.
    • Q3 2025: Huntsman Receives EPA Approval for Next-Gen Low-Emission Spray Foam System Huntsman Corporation received US EPA approval for its next-generation low-emission spray polyurethane foam system, enabling broader adoption in green building projects.

    Future Outlook

    Spray Polyurethane Foam Market Future Outlook

    The Spray Polyurethane Foam Market is projected to grow at a 7.0% CAGR from 2024 to 2035, driven by increasing demand for energy-efficient insulation and sustainable building practices.

    New opportunities lie in:

    • Expansion into emerging markets with tailored insulation solutions.
    • Development of eco-friendly formulations to meet regulatory standards.
    • Integration of smart technology in application processes for efficiency.

    By 2035, the market is expected to solidify its position as a leader in insulation solutions.

    Market Segmentation

    Spray Polyurethane Foam Market Product Outlook

    • Open-Cell
    • Closed-Cell

    Spray Polyurethane Foam Market End-user Outlook

    • Commercial
    • Residential
    • Industrial
    • Others

    Report Scope

    MARKET SIZE 20241.669(USD Billion)
    MARKET SIZE 20251.786(USD Billion)
    MARKET SIZE 20353.513(USD Billion)
    COMPOUND ANNUAL GROWTH RATE (CAGR)7.0% (2024 - 2035)
    REPORT COVERAGERevenue Forecast, Competitive Landscape, Growth Factors, and Trends
    BASE YEAR2024
    Market Forecast Period2025 - 2035
    Historical Data2019 - 2024
    Market Forecast UnitsUSD Billion
    Key Companies ProfiledMarket analysis in progress
    Segments CoveredMarket segmentation analysis in progress
    Key Market OpportunitiesGrowing demand for energy-efficient insulation solutions drives innovation in the Spray Polyurethane Foam Market.
    Key Market DynamicsRising demand for energy-efficient insulation solutions drives innovation and competition in the Spray Polyurethane Foam Market.
    Countries CoveredNorth America, Europe, APAC, South America, MEA

    Market Highlights

    Author
    Anshula Mandaokar
    Team Lead - Research

    Anshula Mandaokar holds an academic degree in Chemical Engineering and has been contributing to the field for more than 5 years. She has expertise in Market Research and Business Consulting and serves as a Team Lead for a reputed Market Research firm under the Chemicals and Materials domain spectrum. She has worked on multiple projects, generating explicit results in a quick turnaround time. Her understanding of data interpretation justifies her role as a leader.

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    FAQs

    How much is the Spray Polyurethane Foam market?

    The Spray Polyurethane Foam Market size was valued at USD 1.10 Billion in 2022.

    What is the growth rate of the Spray Polyurethane Foam market?

    The global market is projected to grow at a CAGR of 7% during the forecast period, 2025-2035.

    Which region held the largest market share in the Spray Polyurethane Foam market?

    North America had the largest share of the Spray Polyurethane Foam Market.

    Who are the key players in the Spray Polyurethane Foam market?

    The key players in the market are Huntsman International LLC (US), Accella Polyurethane Systems (US), BASF SE (Germany), Certainteed (US), Icynene (Canada), DowDuPont (US), NCFI Polyurethanes (US), Invista (US), Isothane Ltd (UK), Johns Manville (US), Soprema (France), Specialty Products Inc (US), and Rhino Linings Corporation (US).

    Which Product led the Spray Polyurethane Foam market?

    The Closed-Cell categories dominated the market in 2023.

    Which End-user led the Spray Polyurethane Foam market?

    The Commercial had the largest share in the global market for Spray Polyurethane Foam.

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