Polyurethane Spray Foam Market
Polyurethane Spray Foam Market Forecasts to 2032 – Global Analysis By Type (Open-Cell Spray Foam and Closed-Cell Spray Foam), Density, Distribution Channel, Application, End User and By Geography
According to Stratistics MRC, the Global Polyurethane Spray Foam Market is accounted for $5.34billion in 2025 and is expected to reach $8.35 billion by 2032 growing at a CAGR of 6.6% during the forecast period. Polyurethane spray foam is an adaptable insulation solution made by combining polyol and isocyanate, which react to expand and create a seamless, airtight coating. It offers superior thermal insulation, sound dampening, and protection against moisture. Widely utilized in homes, offices, and industrial facilities, it enhances energy efficiency, minimizes air infiltration, and boosts comfort. The foam conforms to various surfaces and irregular spaces, making it ideal for application in walls, roofs, attics, and other cavities.
Market Dynamics:
Driver:
Growing demand for energy-efficient buildings
The global push for sustainable construction is fueling the uptake of polyurethane spray foam (SPF) as a high-performance insulation solution. With stricter building codes and energy mandates, SPF is increasingly preferred for its superior thermal resistance and air-sealing capabilities. Developers are integrating SPF into smart building systems to enhance energy monitoring and reduce HVAC loads. Innovations in low-emission blowing agents and hybrid foam technologies are improving environmental compliance. The material’s ability to reduce operational energy costs is making it a strategic choice for both new builds and retrofits. As climate-conscious design becomes mainstream, SPF is emerging as a key enabler of net-zero buildings.
Restraint:
High cost compared to alternatives
The need for specialized equipment and trained professionals adds to installation costs, limiting accessibility in cost-sensitive markets. Regulatory compliance with fire safety and VOC standards further increases formulation complexity and expense. Volatility in petrochemical-based raw materials also contributes to pricing challenges. While SPF offers long-term energy savings, the upfront investment can deter adoption in low-budget projects. This cost disparity is particularly evident in developing regions where affordability drives material selection.
Opportunity:
Shift towards bio-based and sustainable formulations
Polyurethane Spray Foams seeing a transition toward bio-based SPF products made from renewable sources such as soy, castor oil, and recycled content. These sustainable alternatives are gaining traction among eco-conscious builders and regulatory bodies promoting low-carbon construction. Advances in water-blown and HFO-based systems are enabling high-performance insulation with reduced environmental impact. Manufacturers are investing in R&D to improve durability, fire resistance, and thermal efficiency of green SPF variants. Certifications like LEED and GREENGUARD are accelerating adoption in commercial and institutional projects. This evolution is opening new growth channels in regions prioritizing circular economy and carbon neutrality.
Threat:
Complexity of installation and need for skilled labour
Applying SPF requires precise temperature control, safety protocols, and technical expertise, making it a labor-intensive process. Inadequate installation can compromise insulation performance and pose health risks due to off-gassing. A shortage of certified applicators is limiting market expansion, especially in underserved and fast-growing areas. Training programs and accreditation efforts are underway but remain unevenly distributed. Liability concerns and high insurance premiums for SPF contractors add further operational hurdles.
Covid-19 Impact:
The pandemic disrupted construction schedules and supply chains, temporarily slowing SPF demand across sectors. Lockdowns and labor shortages delayed insulation projects, while raw material constraints led to price fluctuations. However, increased home renovation activity during remote work periods boosted interest in energy-efficient upgrades. Government recovery programs and green stimulus initiatives in regions like North America and Europe supported SPF adoption. Manufacturers responded by digitizing training and sales channels to maintain engagement with contractors. Post-Covid strategies now emphasize supply chain resilience, automation, and sustainable material sourcing.
The closed-cell spray foam segment is expected to be the largest during the forecast period
The closed-cell spray foam segment is expected to account for the largest market share during the forecast period, due to its high R-value, moisture resistance, and structural reinforcement capabilities. It is widely used in applications requiring vapor barriers and thermal insulation across residential, commercial, and industrial settings. Innovations in fire-retardant additives and low-GWP blowing agents are enhancing its regulatory compliance and safety profile. The material’s rigidity and compressive strength make it suitable for roofing, wall cavities, and below-grade insulation. Its ability to improve building envelope integrity is driving adoption in flood-prone and high-humidity regions.
The residential construction segment is expected to have the highest CAGR during the forecast period
Over the forecast period, the residential construction segment is predicted to witness the highest growth rate, driven by growing awareness of energy efficiency and indoor air quality. Homeowners are increasingly choosing SPF to reduce utility bills and enhance thermal comfort. Government incentives and green building certifications are encouraging retrofits and new installations. Emerging trends include integration with smart HVAC systems and modular housing applications. SPF’s quick application and space-saving properties make it ideal for urban housing developments. As cities expand and sustainability becomes a priority, residential SPF usage is set to accelerate.
Region with largest share:
During the forecast period, the Asia Pacific region is expected to hold the largest market share, supported by rapid urbanization and infrastructure investment. Countries like China, India, and Japan are implementing energy-efficient building codes and promoting local production of insulation materials. Strategic partnerships between global players and regional manufacturers are enhancing technology transfer and market penetration. The region is also witnessing increased adoption of robotic spraying equipment and AI-enabled quality control systems. Government subsidies and import substitution policies are boosting demand for SPF in both commercial and residential sectors. As climate resilience becomes central to policy, SPF is gaining traction across diverse construction formats.
Region with highest CAGR:
Over the forecast period, the North America region is anticipated to exhibit the highest CAGR, driven by strong regulatory frameworks and technological innovation. The U.S. and Canada are leading in the development of low-emission SPF systems and advanced application tools. Energy mandates like California’s Title 24 and federal tax credits are accelerating adoption in both new builds and retrofits. Contractors are leveraging digital platforms for project planning, compliance tracking, and remote training. R&D efforts are focused on recyclable and bio-based formulations to meet sustainability goals.
Key players in the market
Some of the key players in Polyurethane Spray Foam Market include BASF SE, The Dow Chemical Company, Zotefoams plc, Huntsman Corporation, Rogers Corporation, Covestro AG, Recticel NV/SA, Johns Manville, Future Foam Inc., Carlisle Companies Inc., Foamcraft Inc., CertainTeed Corporation, Lapolla Industries Inc., Icynene-Lapolla, and Demilec Inc.
Key Developments:
In October 2025, Dow and MEGlobal have finalized an agreement for Dow to supply an additional equivalent to 100 KTA of ethylene from its Gulf Coast operations. The ethylene will serve as a key feedstock for MEGlobal’s ethylene glycol (EG) manufacturing facility co-located at Dow’s and MEGlobal’s Oyster Creek site.
In August 2025, Covestro has signed an agreement with Vencorex Holding SAS, to acquire two legal entities with stand-alone production sites for HDI derivates in Rayong, Thailand and Freeport, USA. The legal entities and sites were formerly part of the French aliphatics specialist Vencorex. With this acquisition, Covestro strategically expands and improves its aliphatics production portfolio in the US and in the Asia-Pacific region.
Types Covered:
• Open-Cell Spray Foam
• Closed-Cell Spray Foam
Densities Covered:
• Low-Density Spray Foam
• Medium-Density Spray Foam
• High-Density Spray Foam
Distribution Channels Covered:
• Direct Sales
• Distributors/Wholesalers
• Online Retail
Applications Covered:
• Insulation
• Roofing
• Wall Coatings
• Flooring
• Sealants and Adhesives
• Other Applications
End Users Covered:
• Residential Construction
• Commercial Construction
• Industrial Buildings
• Transportation
• Marine
• Other End Users
Regions Covered:
• North America
o US
o Canada
o Mexico
• Europe
o Germany
o UK
o Italy
o France
o Spain
o Rest of Europe
• Asia Pacific
o Japan
o China
o India
o Australia
o New Zealand
o South Korea
o Rest of Asia Pacific
• South America
o Argentina
o Brazil
o Chile
o Rest of South America
• Middle East & Africa
o Saudi Arabia
o UAE
o Qatar
o South Africa
o Rest of Middle East & Africa
What our report offers:
- Market share assessments for the regional and country-level segments
- Strategic recommendations for the new entrants
- Covers Market data for the years 2024, 2025, 2026, 2028, and 2032
- Market Trends (Drivers, Constraints, Opportunities, Threats, Challenges, Investment Opportunities, and recommendations)
- Strategic recommendations in key business segments based on the market estimations
- Competitive landscaping mapping the key common trends
- Company profiling with detailed strategies, financials, and recent developments
- Supply chain trends mapping the latest technological advancements
Free Customization Offerings:
All the customers of this report will be entitled to receive one of the following free customization options:
• Company Profiling
o Comprehensive profiling of additional market players (up to 3)
o SWOT Analysis of key players (up to 3)
• Regional Segmentation
o Market estimations, Forecasts and CAGR of any prominent country as per the client's interest (Note: Depends on feasibility check)
• Competitive Benchmarking
Benchmarking of key players based on product portfolio, geographical presence, and strategic alliances
Table of Contents
1 Executive Summary
2 Preface
2.1 Abstract
2.2 Stake Holders
2.3 Research Scope
2.4 Research Methodology
2.4.1 Data Mining
2.4.2 Data Analysis
2.4.3 Data Validation
2.4.4 Research Approach
2.5 Research Sources
2.5.1 Primary Research Sources
2.5.2 Secondary Research Sources
2.5.3 Assumptions
3 Market Trend Analysis
3.1 Introduction
3.2 Drivers
3.3 Restraints
3.4 Opportunities
3.5 Threats
3.6 Application Analysis
3.7 End User Analysis
3.8 Emerging Markets
3.9 Impact of Covid-19
4 Porters Five Force Analysis
4.1 Bargaining power of suppliers
4.2 Bargaining power of buyers
4.3 Threat of substitutes
4.4 Threat of new entrants
4.5 Competitive rivalry
5 Global Polyurethane Spray Foam Market, By Type
5.1 Introduction
5.2 Open-Cell Spray Foam
5.3 Closed-Cell Spray Foam
6 Global Polyurethane Spray Foam Market, By Density
6.1 Introduction
6.2 Low-Density Spray Foam
6.3 Medium-Density Spray Foam
6.4 High-Density Spray Foam
7 Global Polyurethane Spray Foam Market, By Distribution Channel
7.1 Introduction
7.2 Direct Sales
7.3 Distributors/Wholesalers
7.4 Online Retail
8 Global Polyurethane Spray Foam Market, By Application
8.1 Introduction
8.2 Insulation
8.3 Roofing
8.4 Wall Coatings
8.5 Flooring
8.6 Sealants and Adhesives
8.7 Other Applications
9 Global Polyurethane Spray Foam Market, By End User
9.1 Introduction
9.2 Residential Construction
9.3 Commercial Construction
9.4 Industrial Buildings
9.5 Transportation
9.6 Marine
9.7 Other End Users
10 Global Polyurethane Spray Foam Market, By Geography
10.1 Introduction
10.2 North America
10.2.1 US
10.2.2 Canada
10.2.3 Mexico
10.3 Europe
10.3.1 Germany
10.3.2 UK
10.3.3 Italy
10.3.4 France
10.3.5 Spain
10.3.6 Rest of Europe
10.4 Asia Pacific
10.4.1 Japan
10.4.2 China
10.4.3 India
10.4.4 Australia
10.4.5 New Zealand
10.4.6 South Korea
10.4.7 Rest of Asia Pacific
10.5 South America
10.5.1 Argentina
10.5.2 Brazil
10.5.3 Chile
10.5.4 Rest of South America
10.6 Middle East & Africa
10.6.1 Saudi Arabia
10.6.2 UAE
10.6.3 Qatar
10.6.4 South Africa
10.6.5 Rest of Middle East & Africa
11 Key Developments
11.1 Agreements, Partnerships, Collaborations and Joint Ventures
11.2 Acquisitions & Mergers
11.3 New Product Launch
11.4 Expansions
11.5 Other Key Strategies
12 Company Profiling
12.1 BASF SE
12.2 The Dow Chemical Company
12.3 Zotefoams plc
12.4 Huntsman Corporation
12.5 Rogers Corporation
12.6 Covestro AG
12.7 Recticel NV/SA
12.8 Johns Manville
12.9 Future Foam Inc.
12.10 Carlisle Companies Inc.
12.11 Foamcraft Inc.
12.12 CertainTeed Corporation
12.13 Lapolla Industries Inc.
12.14 Icynene-Lapolla
12.15 Demilec Inc.
List of Tables
1 Global Polyurethane Spray Foam Market Outlook, By Region (2024-2032) ($MN)
2 Global Polyurethane Spray Foam Market Outlook, By Type (2024-2032) ($MN)
3 Global Polyurethane Spray Foam Market Outlook, By Open-Cell Spray Foam (2024-2032) ($MN)
4 Global Polyurethane Spray Foam Market Outlook, By Closed-Cell Spray Foam (2024-2032) ($MN)
5 Global Polyurethane Spray Foam Market Outlook, By Density (2024-2032) ($MN)
6 Global Polyurethane Spray Foam Market Outlook, By Low-Density Spray Foam (2024-2032) ($MN)
7 Global Polyurethane Spray Foam Market Outlook, By Medium-Density Spray Foam (2024-2032) ($MN)
8 Global Polyurethane Spray Foam Market Outlook, By High-Density Spray Foam (2024-2032) ($MN)
9 Global Polyurethane Spray Foam Market Outlook, By Distribution Channel (2024-2032) ($MN)
10 Global Polyurethane Spray Foam Market Outlook, By Direct Sales (2024-2032) ($MN)
11 Global Polyurethane Spray Foam Market Outlook, By Distributors/Wholesalers (2024-2032) ($MN)
12 Global Polyurethane Spray Foam Market Outlook, By Online Retail (2024-2032) ($MN)
13 Global Polyurethane Spray Foam Market Outlook, By Application (2024-2032) ($MN)
14 Global Polyurethane Spray Foam Market Outlook, By Insulation (2024-2032) ($MN)
15 Global Polyurethane Spray Foam Market Outlook, By Roofing (2024-2032) ($MN)
16 Global Polyurethane Spray Foam Market Outlook, By Wall Coatings (2024-2032) ($MN)
17 Global Polyurethane Spray Foam Market Outlook, By Flooring (2024-2032) ($MN)
18 Global Polyurethane Spray Foam Market Outlook, By Sealants and Adhesives (2024-2032) ($MN)
19 Global Polyurethane Spray Foam Market Outlook, By Other Applications (2024-2032) ($MN)
20 Global Polyurethane Spray Foam Market Outlook, By End User (2024-2032) ($MN)
21 Global Polyurethane Spray Foam Market Outlook, By Residential Construction (2024-2032) ($MN)
22 Global Polyurethane Spray Foam Market Outlook, By Commercial Construction (2024-2032) ($MN)
23 Global Polyurethane Spray Foam Market Outlook, By Industrial Buildings (2024-2032) ($MN)
24 Global Polyurethane Spray Foam Market Outlook, By Transportation (2024-2032) ($MN)
25 Global Polyurethane Spray Foam Market Outlook, By Marine (2024-2032) ($MN)
26 Global Polyurethane Spray Foam Market Outlook, By Other End Users (2024-2032) ($MN)
Note: Tables for North America, Europe, APAC, South America, and Middle East & Africa Regions are also represented in the same manner as above.
List of Figures
RESEARCH METHODOLOGY
We at ‘Stratistics’ opt for an extensive research approach which involves data mining, data validation, and data analysis. The various research sources include in-house repository, secondary research, competitor’s sources, social media research, client internal data, and primary research.
Our team of analysts prefers the most reliable and authenticated data sources in order to perform the comprehensive literature search. With access to most of the authenticated data bases our team highly considers the best mix of information through various sources to obtain extensive and accurate analysis.
Each report takes an average time of a month and a team of 4 industry analysts. The time may vary depending on the scope and data availability of the desired market report. The various parameters used in the market assessment are standardized in order to enhance the data accuracy.
Data Mining
The data is collected from several authenticated, reliable, paid and unpaid sources and is filtered depending on the scope & objective of the research. Our reports repository acts as an added advantage in this procedure. Data gathering from the raw material suppliers, distributors and the manufacturers is performed on a regular basis, this helps in the comprehensive understanding of the products value chain. Apart from the above mentioned sources the data is also collected from the industry consultants to ensure the objective of the study is in the right direction.
Market trends such as technological advancements, regulatory affairs, market dynamics (Drivers, Restraints, Opportunities and Challenges) are obtained from scientific journals, market related national & international associations and organizations.
Data Analysis
From the data that is collected depending on the scope & objective of the research the data is subjected for the analysis. The critical steps that we follow for the data analysis include:
- Product Lifecycle Analysis
- Competitor analysis
- Risk analysis
- Porters Analysis
- PESTEL Analysis
- SWOT Analysis
The data engineering is performed by the core industry experts considering both the Marketing Mix Modeling and the Demand Forecasting. The marketing mix modeling makes use of multiple-regression techniques to predict the optimal mix of marketing variables. Regression factor is based on a number of variables and how they relate to an outcome such as sales or profits.
Data Validation
The data validation is performed by the exhaustive primary research from the expert interviews. This includes telephonic interviews, focus groups, face to face interviews, and questionnaires to validate our research from all aspects. The industry experts we approach come from the leading firms, involved in the supply chain ranging from the suppliers, distributors to the manufacturers and consumers so as to ensure an unbiased analysis.
We are in touch with more than 15,000 industry experts with the right mix of consultants, CEO's, presidents, vice presidents, managers, experts from both supply side and demand side, executives and so on.
The data validation involves the primary research from the industry experts belonging to:
- Leading Companies
- Suppliers & Distributors
- Manufacturers
- Consumers
- Industry/Strategic Consultants
Apart from the data validation the primary research also helps in performing the fill gap research, i.e. providing solutions for the unmet needs of the research which helps in enhancing the reports quality.
For more details about research methodology, kindly write to us at info@strategymrc.com
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