The construction foam market is projected to grow from USD 32.03 billion in 2024 to USD 43.96 billion by 2030, at a CAGR of 5.4% during the forecast period. The construction foam market is primarily driven by rising demand for lightweight, energy-efficient, and durable materials for modern buildings and infrastructure. The use of polyurethane, polystyrene, and phenolic foams for insulation, roofing, and flooring applications is mainly driven by the global sustainability goals and stricter energy-efficiency standards. In the US and Canada, infrastructure modernization and government incentives are the primary reasons for the increased use of foam in eco-friendly buildings; in Europe, circular-economy initiatives; and in the Asia Pacific, rapid urbanization and housing projects are the main drivers of growth in those regions.
Based on resin type, the polyurethane segment is expected to register the fastest growth in the construction foam market during the forecast period. The primary reasons behind this trend are the growing demand for sustainable building materials, energy efficiency, and thermal insulation, all of which are performing well in the case of the mentioned types of buildings (residential, commercial, and industrial). The good strength-to-weight ratio, low thermal conductivity, and high moisture resistance make the polyurethane foams the first choice for wall insulation, roofing, flooring, and even prefabricated construction components. These properties are achieved by using either the rigid or spray foam forms, allowing builders to meet different design and performance requirements while minimizing total energy consumption. The increasing adoption of green building certifications, along with government initiatives promoting energy-efficient infrastructure, is also helping the market grow.
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Based on region, the Asia Pacific is projected to register the fastest growth in the construction foam market during the forecast period, driven by rapid urbanization, industrial growth, and massive investments in infrastructure in the emerging markets of the region. This demand is not only coming from the construction of buildings, but also from the rapidly developing construction sector, which consists of residential, commercial, and industrial projects, all striving for high-performance foams that will upgrade their thermal insulation, structural strength, and energy efficiency. China, India, and Indonesia are the countries contributing significantly to this growth, which is being supported by massive government programs, including Housing for All by 2025, the Smart Cities Mission, and Make in India, that are driving substantial environment-friendly construction activity. The presence of inexpensive raw materials, rising factory capacities, and skilled workers is making it easier for big international companies to set up production centers in the region. Factors such as increased incomes, younger and more educated consumers, and the need for materials that last longer and consume less energy are driving the increased use of polyurethane and polystyrene foams in roofing, insulation, and prefabricated structures.
Opportunities in the North American construction foam market continue to grow, supported by investments in sustainable infrastructure, energy-efficient housing, and advancements in polymer technology, among others. In 2024, several foam manufacturers based in the US and Canada began collaborating with construction and insulation companies to produce high-performance, recyclable foam materials in accordance with the green building standards established by the construction companies. The main objective of these relationships is to improve the thermal insulation, acoustic performance, and durability of residential and commercial buildings. The increasing use of LEED-certified and ENERGY STAR-rated buildings, combined with government incentives for low-emission construction, has driven up demand for polyurethane and polystyrene foams. Besides, the region’s retrofitting and renovation activities are another source of new opportunities for spray and rigid foam in roofing, wall insulation, and HVAC systems. Moreover, the decarbonization and circular construction trends, as well as the development and recycling of foam technology, will make North America a leading innovation center in the global construction foam industry.
Leading companies in the global extruded foam market, including BASF (Germany), Owens Corning (United States), Armacell (Luxembourg), Kingspan Group (Ireland), and Zotefoams plc (United Kingdom), are driving innovation by means of the latest material technologies, increased production capacities, and strategies focused on sustainability. These companies are promoting the use of energy-efficient and recyclable foam solutions designed specifically for the construction, automotive, and packaging sectors. The ongoing investments in research, recycling infrastructure, and low-emission polymer development are not only improving product performance but are also contributing to global carbon reduction targets. The cooperation with end-use industries and the expansion of manufacturing operations in different regions are making the supply chain even more robust, thus securing the position of these companies as the front-runners of the next generation of foams and ultimately leading to innovation in their extruded foam products.
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Armacell produces and distributes advanced insulation and engineered foams for the equipment insulation market. The company is a major solution provider for flexible technical (mechanical) insulation materials and products based on foam technologies. It offers numerous products, including insulation materials, fire protection products, acoustic solutions & covering systems for building equipment and industrial installations, as well as foam cores used as composite materials and special foams for various industrial applications. The company operates in two business segments: Advanced Insulation and Engineered Foams. The Advanced Insulation segment tackles equipment protection and optimization with innovative, flexible foam solutions. Its focus lies on ensuring technical equipment stays well-insulated and protected.
Sheela Foam Limited has carved a niche as the frontrunner in India’s polyurethane (PU) foam industry. Its manufacturing footprint spans the entire nation, solidifying its position as a domestic leader. Over the past five decades, Sheela Foam Limited has built an unwavering reputation for excellence. The company’s commitment to quality and innovation has yielded an impeccable track record, earning the trust of customers nationwide. The company operates through four business segments: mattress, technical foam, furniture foam, comfort foam, and home care products. Sheela Foam Limited’s success is further solidified by its winning portfolio of brands. SLEEPWELL, its flagship brand, is at the forefront and synonymous with mattresses and comfort accessories. It is a household name trusted by many for a good night’s sleep and overall well-being.
Kingspan Insulation, LLC is a subsidiary of Kingspan Group plc, a leading insulation solutions provider for residential and non-residential applications. It operates five business segments: Insulated Panels, Insulation, Roofing & Waterproofing, Light, Air & Water, and Data & Flooring. It has more than 22,000 employees worldwide and 212 manufacturing sites globally. The insulation boards segment provides industrial insulation materials, including mineral wool and foam, to the power, petrochemical, and food & beverage industries. Kingspan understands the link between sustainable construction and human health. It ensures that its building solutions promote healthy and comfortable living spaces. Its commitment to ethical practices and research into new technologies to reduce environmental impact keeps it at the forefront of sustainable construction.
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Owens Corning is a global fiberglass manufacturing company that offers high-, mid-, and low-temperature thermal and acoustic products. The company operates through the Roofing, Insulation, and Composites segments. It provides insulation solutions to commercial, industrial, and residential sectors. Owens Corning operates in 33 countries and sells its insulation products to the US, Canada, Europe, Asia Pacific, and Latin America. It has OEM manufacturing facilities in the US, Mexico, and China, as well as OEM fabrication facilities in the US, Mexico, Italy, and Poland.
Zotefoams plc is one of the leading manufacturers of closed-cell cross-linked polyolefin foams for use in sports, construction, marine, automation, medical equipment, and aerospace industries. The company has two manufacturing plants, one in Croydon, UK, and the other in Kentucky, US. It also has a joint venture to distribute its AZOTE foams in Asia. The company has a worldwide network of regulated distributors who sell Zotefoam’s products. It also established a joint venture in Nagoya, Japan, to serve the block foam market in Asia, as well as the Kunshan ZOTEK KingLai business in China, to develop the T-FIT insulation system. It operates under three business segments: Polyolefin Foams, High-performance Products (HPP), and MuCell Extrusion, LLC (MEL).
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