US Spray Polyurethane Foam Market Research Report: By Product (Open-Cell, Closed-Cell) and By End-User (Commercial, Residential, Industrial) - Forecast to 2035

US Spray Polyurethane Foam Market Overview

As per MRFR analysis, the US Spray Polyurethane Foam Market Size was estimated at 195 (USD Million) in 2023. The US Spray Polyurethane Foam Market Industry is expected to grow from 208.9(USD Million) in 2024 to 971.8 (USD Million) by 2035. The US Spray Polyurethane Foam Market CAGR (growth rate) is expected to be around 14.999% during the forecast period (2025 - 2035).

Key US Spray Polyurethane Foam Market Trends Highlighted

The US Spray Polyurethane Foam Market has been observing several significant trends that influence its development. A key market driver is the increasing demand for energy-efficient construction materials, as homeowners and builders actively seek solutions that provide better insulation, thus leading to lower energy costs. This push aligns with national initiatives promoting sustainability and reducing carbon footprints, resonating with the U.S. government's goals for improving energy efficiency in residential and commercial buildings.

Recent trends show a growing preference for eco-friendly and low-VOC (volatile organic compounds) formulations, reflecting a shift towards environmentally responsible products. These developments are further supported by regulatory changes that encourage the use of sustainable materials in construction. Additionally, the rising awareness about indoor air quality and the importance of building health has led to an uptick in demand for spray foam insulation as a solution that enhances air sealing and energy performance.

Opportunities in the US market include advancements in spray foam technology that improve application processes and overall product performance. Manufacturers can tap into this by innovating solutions that address specific local needs, such as those in regions with extreme weather conditions. Furthermore, with the ongoing expansion of the construction and renovation markets, particularly in the residential sector, there is substantial room for growth.

Continued education and training of applicators on the benefits and use of spray foam can increase market penetration. As builders and consumers prioritize performance and environmental impacts, the US Spray Polyurethane Foam Market is likely to see a significant shift towards high-performance, sustainable solutions.

Source: Primary Research, Secondary Research, MRFR Database and Analyst Review

US Spray Polyurethane Foam Market Drivers

Increasing Demand for Energy-Efficient Solutions

The US Spray Polyurethane Foam Market Industry is experiencing substantial growth due to the rising demand for energy-efficient building materials. According to the U.S. Department of Energy, buildings account for approximately 40% of the total energy consumption in the United States, prompting consumers and builders to seek effective insulation solutions. Spray polyurethane foam is known for its superior thermal insulation properties, significantly reducing heating and cooling costs.

The Energy Information Administration reports a projected increase in energy prices, which motivates homeowners and businesses to invest in insulating products that can lead to long-term savings on energy bills. Various organizations, such as the American Society of Heating, Refrigerating and Air-Conditioning Engineers, are also advocating for energy-efficient building practices, boosting the demand for spray polyurethane foam in residential and commercial construction.

Growth in Construction Activities

The resurgence of the construction sector in the United States is a primary driver for the US Spray Polyurethane Foam Market Industry. The U.S. Census Bureau indicated that construction spending reached nearly $1.5 trillion in 2022, marking a 10% increase from the previous year. This uptick in construction activities is accompanied by a growing trend towards sustainable materials and innovative building practices. Spray polyurethane foam's versatility allows it to be used in various applications, including roofs, walls, and floors, making it a preferred choice among construction professionals.

The National Association of Home Builders has highlighted the importance of using superior insulation materials in new home constructions, thus supporting market growth.

Stringent Regulations on Building Codes and Energy Efficiency

In the United States, governmental regulations aimed at promoting energy efficiency and sustainability are significantly influencing the US Spray Polyurethane Foam Market Industry. The International Code Council establishes energy codes that advocate for improved insulation in buildings. These regulations mandate higher standards for thermal performance, leading contractors and builders to adopt spray polyurethane foam due to its efficient insulating properties.

Additionally, various states have implemented their own codes reflecting these requirements. For example, California has enforced stringent energy efficiency standards through Title 24 of the California Code of Regulations, which has led to a marked increase in the adoption of spray polyurethane foam products in both residential and commercial buildings.

Rising Awareness of Health and Environmental Benefits

As awareness increases regarding the environmental impact of construction materials, the US Spray Polyurethane Foam Market Industry is benefitting from a shift in consumer preferences towards eco-friendly alternatives. Initially, concerns regarding the environmental impact of certain chemicals in foam products slowed adoption; however, advancements in formulas and the introduction of low-global warming potential (GWP) alternatives have mitigated these issues.

The Environmental Protection Agency (EPA) supports initiatives that endorse the use of environmentally friendly building materials, which aligns with the growing consumer preference for products that minimize their carbon footprint. Consequently, this trend is expected to propel the growth of the spray polyurethane foam market in the United States as consumers increasingly prioritize both health safety and environmental sustainability.

US Spray Polyurethane Foam Market Segment Insights

Spray Polyurethane Foam Market Product Insights

The US Spray Polyurethane Foam Market is characterized by diverse product offerings that cater to different insulation and sealing needs within multiple industries. The market is primarily segmented into Open-Cell and Closed-Cell Spray Polyurethane Foam, each serving unique purposes and applications. Open-Cell Foam is recognized for its lightweight structure and flexibility, providing excellent sound absorption and thermal insulation, which makes it suitable for interior applications such as walls and ceilings in both residential and commercial buildings.

Its ability to expand upon application also enables it to fill irregular spaces and gaps, thus enhancing its appeal among contractors and builders who emphasize energy efficiency and reducing air leaks. On the other hand, Closed-Cell Foam is lauded for its rigidity, high compressive strength, and moisture barrier properties, which makes it ideal for outdoor applications and environments that may be exposed to extreme conditions, including roofs and foundation walls.

The impervious nature of Closed-Cell Foam to moisture and air infiltration contributes to its significant demand among industrial sectors where durability and long-term performance are critical. Both product types are witnessing considerable growth driven by rising awareness of energy-efficient building practices and stringent building codes that encourage the use of advanced insulation materials. The shift towards sustainable construction practices and renovation of older buildings adds further impetus, as both Open-Cell and Closed-Cell foams provide effective solutions in addressing these demands.

The US government's initiatives to promote energy conservation and reduce carbon emissions further bolster the market, creating considerable opportunities for innovation within these segments. Additionally, profiles of the target market users indicate a growing inclination towards eco-friendly materials, prompting manufacturers to develop products that meet these preferences while maintaining performance standards. As these segments continue to evolve, they present promising avenues for growth in the US Spray Polyurethane Foam Market, catering to the increasing demand for diverse applications in various sectors.

Source: Primary Research, Secondary Research, MRFR Database and Analyst Review

Spray Polyurethane Foam Market End-User Insights

The End-User segment of the US Spray Polyurethane Foam Market reflects diverse applications across several key areas, namely Commercial, Residential, and Industrial sectors. The demand for spray polyurethane foam in the residential sector has been fostered by the growing emphasis on energy efficiency and insulation properties, making it a preferred choice for homeowners seeking to reduce energy costs and improve comfort. Meanwhile, the commercial sector has shown significant growth due to increased construction activities and a surge in demand for building materials that provide enhanced thermal performance and moisture protection.

This is further fueled by regulatory measures aimed at increasing energy efficiency in commercial buildings. The Industrial sector also plays a vital role, particularly in applications requiring robust insulating solutions, such as in manufacturing facilities and warehouses. The importance of this segment is underscored by the increasing focus on sustainable construction practices and the need for materials that can withstand harsh conditions.

As the market evolves, each of these areas emphasizes innovative solutions and advanced product formulations to meet the changing demands of end-users, thereby driving overall market growth and contribution to US Spray Polyurethane Foam Market revenue.

US Spray Polyurethane Foam Market Key Players and Competitive Insights

The competitive landscape of the US Spray Polyurethane Foam Market is characterized by a diverse array of companies, all vying for market share within a rapidly expanding sector. This market has witnessed significant growth due to increased consumer awareness regarding energy efficiency and the environmental benefits associated with spray polyurethane foam (SPF) insulation. The competitive insights reveal a dynamic environment where various firms leverage advanced technologies and superior product offerings to differentiate themselves.

Innovation plays a critical role, as manufacturers work to develop formulations that not only meet stringent regulatory requirements but also satisfy consumer demand for sustainable building materials. Moreover, the market dynamics are influenced by fluctuating raw material costs and shifting regulations, which present both challenges and opportunities for growth among industry players.

NCFI Polyurethanes stands out within the US Spray Polyurethane Foam Market due to its strong commitment to research and development, allowing for the continuous enhancement of its product line. This company has built a solid reputation for its high-performance SPF solutions, focusing on applications ranging from residential insulation to commercial roofing. NCFI Polyurethanes has established a robust distribution network, ensuring that its products reach a wide customer base effectively.

One of the strengths of NCFI lies in its ability to provide customized solutions tailored to the specific needs of various industries, which enhances customer satisfaction and loyalty. The company’s emphasis on sustainability and eco-friendly formulations further bolsters its position in the market as consumers increasingly seek environmentally responsible options.

General Plastics Manufacturing Company

General Plastics Manufacturing Company is another prominent player in the US Spray Polyurethane Foam Market, known for its innovative approach to product development. The company specializes in producing high-quality foam products, offering a range of solutions designed for insulation and other applications in the building industry. General Plastics Manufacturing Company has a notable presence in the market, characterized by its extensive experience and established customer relationships.

Key products include rigid foam insulation with superior thermal performance, which positions the company favorably among contractors and builders looking for reliable materials. The company is also focused on expanding its market reach through strategic partnerships and collaborations that enhance its technology and service capabilities.

Furthermore, General Plastics has undertaken several mergers and acquisitions to boost its product range, fostering growth opportunities in the US market while reinforcing its competitive edge through innovation and superior service offerings.

Key Companies in the US Spray Polyurethane Foam Market Include

• NCFI Polyurethanes


• General Plastics Manufacturing Company


• CertainTeed


• BASF


• InstaFoam Products


• IcyneneLapolla


• ThermoBond


• Huntsman


• Demilec


• Spray Foam Systems


• Dupont


• Carpenter Co.


• Dow


• Sika

US Spray Polyurethane Foam Market Industry Developments

The US Spray Polyurethane Foam Market has seen significant developments recently, particularly in growth trends and innovations. Major players such as BASF and Dow have been enhancing their product lines with sustainability features to meet increasing regulatory demands. In September 2023, NCFI Polyurethanes launched a new eco-friendly foam designed for better insulation and lower environmental impact, reflecting the market's shift toward greener products.

Furthermore, in July 2023, Demilec and InstaFoam Products announced a strategic partnership aimed at improving manufacturing efficiency and expanding market reach. These collaborations underscore an ongoing trend toward mergers and acquisitions in the industry. Over the last two years, the market has witnessed a robust growth rate, with estimated valuations projected to increase significantly, fueled by rising demand for energy-efficient building solutions.

Companies like Huntsman and IcyneneLapolla have also made strides in Research and Development to innovate formulations that enhance performance and application versatility. As federal and state regulations evolve, the sector remains dynamic, with companies positioning themselves to capitalize on emerging opportunities within the construction and insulation markets.

US Spray Polyurethane Foam Market Segmentation Insights

Spray Polyurethane Foam Market Product Outlook

• Open-Cell


• Closed-Cell

Spray Polyurethane Foam Market End-User Outlook

• Commercial


• Residential


• Industrial

Report Scope:

Report Attribute/Metric Source:	Details
MARKET SIZE 2018	195.0(USD Million)
MARKET SIZE 2024	208.9(USD Million)
MARKET SIZE 2035	971.8(USD Million)
COMPOUND ANNUAL GROWTH RATE (CAGR)	14.999% (2025 - 2035)
REPORT COVERAGE	Revenue Forecast, Competitive Landscape, Growth Factors, and Trends
BASE YEAR	2024
MARKET FORECAST PERIOD	2025 - 2035
HISTORICAL DATA	2019 - 2024
MARKET FORECAST UNITS	USD Million
KEY COMPANIES PROFILED	NCFI Polyurethanes, General Plastics Manufacturing Company, CertainTeed, BASF, InstaFoam Products, IcyneneLapolla, ThermoBond, Huntsman, Demilec, Spray Foam Systems, Dupont, Carpenter Co., Dow, Sika
SEGMENTS COVERED	Product, End-User
KEY MARKET OPPORTUNITIES	Green building initiatives, Energy efficiency regulations, Rising construction activity, Demand for insulation solutions, Home renovation trends
KEY MARKET DYNAMICS	increasing energy efficiency demand, rising construction activities, growing insulation needs, environmental regulations tightening, technological advancements in formulation
COUNTRIES COVERED	US