Spray Polyurethane Foam - Market Share Analysis, Industry Trends & Statistics, Growth Forecasts (2025 - 2030)

The Spray Polyurethane Foam Market size is estimated at USD 2.91 billion in 2025, and is expected to reach USD 3.83 billion by 2030, at a CAGR of 5.64% during the forecast period (2025-2030).

This expansion occurs as building-energy codes tighten, low-GWP regulations take effect, and cold-chain investment accelerates, driving higher-value insulation demand. Manufacturers are swapping high-GWP HFCs for hydrofluoroolefin and other next-generation blowing agents to comply with the EPA's Technology Transitions Restrictions rule that began on 1 January 2025 epa.gov. Consolidation among installers, growing retrofit activity, and ESG-linked financing further reinforce momentum across residential, commercial, and industrial projects, while innovation in CO2-based polyols positions suppliers for long-term sustainability gains.

Global Spray Polyurethane Foam Market Trends and Insights

Strict Building-Energy Codes and Retrofit Mandates

The 2024 International Energy Conservation Code elevates closed-cell spray foam as a preferred air-barrier solution, compelling architects to specify higher R-values and moisture control measures. California's 2023 standards and Florida's 2026 code update both streamline retrofit approvals, lowering removal costs and accelerating demand, particularly for low-slope commercial roofs These rule changes widen the retrofit addressable base, encourage hybrid insulation assemblies, and push contractors toward more training and equipment investment that favors two-component systems.

Rising Concerns Over GHG Emissions

Corporate net-zero goals merge with building-owner cost targets, highlighting spray foam's ability to cut heating-and-cooling energy by up to 10% according to the EPA's Energy Star program. Installed Building Products reported a 55% CO2 reduction from spray foam use since 2020 while materially increasing output, showing the technology's decoupling of growth from emissions. Manufacturers such as Johns Manville logged double-digit drops in absolute emissions even as energy-saving product volumes rose, underscoring alignment between sustainability and profitability.

Competition from Fiberglass and Cellulose

Cost-focused residential builders still default to fiberglass batts, supported by long-standing installer networks and low equipment requirements. Home Innovation Research Labs data showed an 11% to 8% pullback in spray foam share amid multifamily growth and material cost saving, highlighting price sensitivity. Fiberglass makers are narrowing performance gaps with higher-density offerings, while cellulose leverages recycled content branding to appeal to eco-minded consumers. Spray foam suppliers must therefore sharpen value messaging around lifecycle energy savings to overcome higher upfront spend.

Other drivers and restraints analyzed in the detailed report include:

1. Growth in Cold-Chain and Refrigerated Logistics
2. ESG-Linked Green-Bond Financing for SPF Upgrades
3. Regulations and Restrictions on Di-Isocyanates

For complete list of drivers and restraints, kindly check the Table Of Contents.

Segment Analysis

The segment anchored by two-component high-pressure systems held a 37.62% spray polyurethane foam market share in 2024, reflecting consistent on-site mixing, superior R-values, and code acceptance in commercial construction. BASF's new isocyanate and TPU lines in Zhanjiang strengthen local supply chains, reinforcing the segment's dominance in Asia-Pacific. Semi-rigid spray foam is expanding at a 7.19% CAGR as infrastructure projects need flexibility for vibration and temperature swings. One-component cans address small-project convenience, while low-pressure kits cover sensitive substrates where reduced exothermic heat is critical.

A push for integrated brands illustrates competitive strategy: Holcim's Enverge(R) label merges Gaco(TM) and SES(TM) portfolios, giving installers a single specification path for roof, wall, and specialty foams. Product diversification frames cross-selling opportunities, with semi-rigid innovations aimed at solar-ready roofs and bridge decks, and intumescent-infused systems targeting fire-resistance regulations. Suppliers that maintain broad catalogs and regional technical centers remain best positioned to seize specification wins.

The Spray Polyurethane Foam Market Report is Segmented by Product Type (Two-Component High-Pressure Spray Foam, Two-Component Low-Pressure Spray Foam, and More), Application (Insulation, Waterproofing, Asbestos Encapsulation, Sealant, Other Application), End-Use Industry (Residential Buildings, Commercial Buildings, Industrial and More), and Geography (Asia-Pacific, North America, Europe, South America, Middle East and Africa).

Geography Analysis

Asia-Pacific captured 48.19% of spray polyurethane foam market share in 2024 and is forecast to climb at 7.66% CAGR, driven by rapid urbanization, factory expansions, and energy-code adoption. China's real-estate slowdown redirects stimulus toward urban renewal, boosting retrofit insulation spend, while India's HVAC sector is set to hit USD 30 billion by 2030 on a 15.8% CAGR pathway, raising demand for building envelope upgrades. Japan and South Korea enforce stringent envelope requirements in seismic zones, favoring lightweight, high-adhesion insulation such as spray foam. ASEAN nations expand cold-chain capacity for seafood and vaccine storage, pulling regional demand upward. BASF's multi-year USD 19.5 billion Asia-Pacific investment plan exemplifies supplier confidence in the region's absorption capacity.

North America remains a mature but stable arena where federal HFC phase-outs harmonize compliance and keep specification complexity low. Canada's cold climates sustain thick-layer attic spray foam usage, while Mexico emerges as the world's fourth-largest polyurethane consumer on near-shoring momentum and automotive manufacturing growth. Consolidation among contractors enables national builders to standardize envelope solutions across the US and Canada, reinforced by TopBuild's network expansion.

Europe's net-zero directives and renovation wave stimulate demand despite tepid macro-economics. Di-isocyanate training rules introduce friction but ultimately favor well-capitalized manufacturers with robust EHS programs. Covestro's DreamResource project introduces rigid foam containing 20% CO2 as feedstock, demonstrating European leadership in circular chemistry. University of Liege advances isocyanate-free foams with 70-90% biobased content, underscoring regional academic-industry collaboration. In South America and the Middle East and Africa, energy-efficiency codes are tightening gradually; early movers in Brazil, Saudi Arabia, and the UAE adopt spray foam in commercial megaprojects, signaling future volume uplift.

1. BASF
2. Accella Polyurethane Systems
3. Carlisle Spray Foam Insulation
4. Covestro AG
5. Dow
6. FOAM-LOK (Firestone)
7. GACO
8. Huntsman Corporation LLC
9. ISOTHANE LTD
10. Johns Manville
11. NCFI Polyurethanes
12. Rhino Linings
13. SOPREMA Canada.
14. SWD Urethane

Additional Benefits:

• The market estimate (ME) sheet in Excel format
• 3 months of analyst support