The materials used to build, protect and enhance structures are becoming more innovative and efficient, and nonwovens play a crucial role in roofing and construction thanks to their unique combination of strength, durability and versatility. As sustainability becomes an increasingly important focus in the construction industry, nonwovens are gaining attention for their environmentally friendly properties, such as recyclability, reduced waste and the potential for renewable raw materials.

According to Smithers, a consultancy for the paper, packaging, and nonwovens industries, building and construction is the largest sector for industrial nonwovens, accounting for 24.5% of contemporary demand by weight. This includes durable materials for building construction, such as house wrap, insulation and roofing substrates, as well as interior carpeting and other flooring.

With increasing demand for energy-efficient buildings, advanced materials like house wraps and spunlaid or wetlaid fiberglass insulation are gaining traction. Additionally, a nascent market is developing for airlaid pulp as a low-cost, sustainable building insulation option, according to Smithers. Meanwhile, modern interior design trends favor nonwoven-based underlays for laminate and luxury flooring, driving further growth.

Calum Mayland, marketing manager at Ahlstrom, says the global nonwovens market for construction is expected to grow significantly over the next five years, fueled by the increasing demand for lightweight and durable construction materials, the rising adoption of 3D printing technology in construction, and the growing need for next-generation buildings that are more sustainable, easier, faster and more cost-effective to build. “Development of eco-friendly nonwoven materials from recycled fibers is gaining traction, aligning with green building initiatives,” he says.

The shift towards sustainability is favoring eco-friendly nonwovens made from recycled or biodegradable materials, he adds. “Our nonwovens also enhance our customers’ capability to reinvent how buildings shall be designed and erected for a more sustainable world. This development aligns with global sustainability goals and regulatory requirements, positioning nonwovens as a key player in green building initiatives. The adoption of such materials will help reduce the environmental impact of construction projects.”

Developments include products that are formaldehyde-free and PFAS-free, as well as solutions with bio-based content. These innovations support the industry’s growing emphasis on safer, more environmentally responsible materials.

Ahlstrom produces wetlaid glass fiber tissue and needlepunch nonwovens for the construction industry, with applications including flooring, acoustic ceilings, plasterboard and thermal and acoustic insulation, among others.

For the past few years, Ahlstrom has been rolling out its FibRoc Portfolio for the construction segment. FibRoc is a high-performance product platform for durable applications, currently offering solutions for plasterboard, flooring and ceilings.

FibRoc Flooring consists of a wide range of high-performance fiber-based solutions for heavy duty, cushion vinyl and luxury vinyl flooring, as well as solutions for carpets and carpet tiles. FibRoc Ceiling is a comprehensive range of nonwovens for perforated plasterboard ceilings, mineral wool and wet felt ceilings, as well as perforated wood and metal ceilings. Meanwhile, advancing on the combination of glass, synthetic and natural fibers, FibRoc Plasterboard delivers excellent dimensional stability, good protection, durability, and reduced environmental impact. The portfolio fits various application areas, including fire resistance in garage and elevator shafts; moisture resistance in wet rooms, kitchen, sauna, swimming pool; fire and moisture resistance in porches or balconies; and fire and moisture resistance in rigid air barrier systems.

Hempitecture: Localizing the Supply Chain

Sun Valley, ID-based Hempitecture began its venture in the nonwovens business by importing and selling a hemp-based thermal insulation product to the U.S. market just before the start of the coronavirus pandemic. When the pandemic hit, the company quickly realized the importance of localizing and regionalizing its supply chain and manufacturing technology in the U.S.

“When Covid happened, the cost of transportation skyrocketed, which made us aware of supply chain vulnerabilities and how deeply our business could be impacted by unforeseen changes,” says Mattie Mead, founder and CEO of Hempitecture.

Before 2018, cultivating industrial hemp wasn’t federally legal in the U.S. However, as the industrial hemp supply chain began to grow and gain legitimacy in the U.S., Hempitecture saw an opportunity to bring the entire supply chain onshore.

Before closing a fundraising round in April 2022, Hempitecture had already begun testing different production lines and technologies, moving quickly to commission its first line in December 2022. Located in Jerome, ID, Hempitecture’s facility became the first nonwoven manufacturing plant of its kind in the U.S. By January 2023, the company began producing HempWool Batt using nonwoven technology.

The hemp fiber used for production is sourced locally from Hempitecture’s partners IND Hemp in Montana and Idaho Hemp Processors in Idaho. With the growing demand for U.S.-grown and U.S.-manufactured products, Hempitecture’s facility has created a natural fiber bio-based supply chain that helps lower the carbon footprint of sustainable building and insulation materials.

Mead admits that being first to market was a challenge, with many setbacks. “We really had to focus on operational efficiency, product performance and improving output off the line,” he says. “Natural fibers, particularly with hemp fiber, represent so much variation from lot to lot, and there’s so much to consider, so 2023 was a massive learning curve for us. Towards the end of 2023, we really got our feet underneath us and production became more reliable. Then enter 2024, which was a transformative year for us. We had really worked out the kinks of the year prior.”

While hemp batt insulation was a core component of why Hempitecture built its nonwoven line, the company also aimed to explore the possibilities of what could be done with natural fibers like industrial hemp, as well as other materials and fibers, Mead says. This has led to the development of additional new products.


The first product to be fully commercialized this year is PlantPanel, a rigid continuous insulation material used in exterior above-grade applications. With an R-value of 3.25 per inch, PlantPanel enhances thermal and acoustic comfort and performance. It is used in split-insulation wall and roof assemblies with either a rain screen cladding or roofing material, depending on the application. Made from 100% bio-based and recycled content, PlantPanel offers a sustainable, low-carbon continuous insulation solution that’s easy to install and safe to handle.

Another new product from Hempitecture is Fiberpad, a natural fiber carpet and wood floor underlayment material that can help reduce sound transmission as well as increase thermal comfort in floor systems. It’s sold as a nonwoven roll good material and is installed similarly to conventional carpet underlayments, but with a high percentage of natural fibers. Mead says this innovation in low loft roll goods has inspired a new segment beyond construction, including erosion control, growing media and geotextiles.

“We’re continually developing value-enhanced products,” he says. “This includes improving fiber characteristics, improving fiber blends and identifying different materials that can create high-performing, low-carbon material products. Beyond building materials, we’re always open to innovating for other industries, leveraging our technology and supply chain to help decarbonize additional sectors. We’re eager to forge new partnerships.”

Mead is optimistic that demand for sustainable construction materials will continue to grow.

“In terms of Hempitecture, our sales grew 80% year-over-year from 2023 into 2024, and that’s just a microcosm of what’s happening in the bio-based building materials world as a whole,” he says. “The writing is on the wall that natural fiber materials and nonwovens will see greater market adoption in the United States. Just look across the pond to see what’s happening in Europe to understand the market trends likely to take place here. Europe serves as a barometer for what’s coming in the next five to 10 years. Major corporations in Europe are acquiring natural fiber insulation manufacturing companies, and there’s increasing market demand for more sustainable materials—driven in part by consumer sentiment but also by state and country-level policies within the European Union.”

Freudenberg Sees Growing Opportunities

As a technology company built on innovation and continuous improvement, Freudenberg Performance Materials is constantly looking for ways to further develop and improve its products and solutions, according to Federico Pallini, SVP Division Building & Construction at Freudenberg Performance Materials.

For Freudenberg, an increasingly important application is the implementation of green roof systems. Freudenberg nonwovens are used in green roof systems to support vegetation, manage water drainage and improve urban biodiversity. Innovations such as green roof solutions enhance thermal performance and reduce energy consumption, Pallini says. The company also recently developed specialties such as nonwovens and composites for underlayment, as well as root and vapor barriers.

The use of nonwovens in construction applications is increasing, with the market continually developing products that add value for the end user, he adds. “This growth is driven by continuous innovation and new ways to apply nonwovens in the construction industry, leveraging their diverse features,” he explains. “A new generation of composite technology is finding new applications to enhance the protection of buildings and improve the quality of life in living spaces.”

Overall, the demand for nonwoven materials in construction is expected to continue to grow, driven by sustainability, urbanization and technological advancements.

At the same time, nonwoven producers face significant challenges. Volatility in raw material and energy prices can affect production costs and pricing strategies, and keeping up with changing regulations in different regions remains an ongoing concern. “Ensuring compliance while maintaining cost efficiency is a major challenge,” he continues.


However, rapid urbanization and infrastructure development—especially in emerging markets— represent a major opportunity for nonwovens. “Nonwovens are well suited to meet these demands due to their adaptability and performance,” Pallini explains. “By addressing these challenges and capitalizing on these opportunities, nonwovens can play a vital role in the future of construction, providing sustainable, high-performance solutions that meet the evolving needs of the industry.”

Magnera Expands Typar Line

In the building materials category, Magnera—formed last year as a result of the merger between Glatfelter and Berry Global’s Health, Hygiene and Specialties Global Nonwovens and Films business—develops products under the Typar and Fabrene brands.

Typar offers a complete Weather Protection System with a full lineup of weather-resistive barriers (wraps), flashings, tapes and sealant. Its BuildingWrap, DrainableWrap and DrainableWrap Peel & Stick products are all polypropylene nonwoven technologies designed for the residential building market.

Meanwhile, Typar’s Commercial lineup includes Typar Commercial and Typar DrainableWrap Commercial, including a new commercial-grade peel-and-stick product that Magnera previewed at the 2025 International Builders’ Show (IBS) in Las Vegas. Typar’s new Commercial Peel & Stick addresses the need for the application of building wrap without the use of manual fasteners, but on a commercial scale—four stories and above. Typar already offers the Peel & Stick technology to the residential market with the DrainableWrap Peel & Stick product. Now, however, the technology with an adhesive-coated backing can be used in commercial construction, according to Andrew Irvine, director of Product Line Management—Infrastructure & Specialties, Magnera Corporation.

Typar continues to innovate with nonwoven technology in its wraps designed for drainability performance. Typar Drainable Wrap features a layer of “meltshot” polypropylene fibers that is integrated into the housewrap material, leading to a 94.8% drainage efficiency. “Due to their durability and ease of installation, building wraps made of polyethylene or polypropylene fabric have been a popular method of protecting against moisture intrusion since the 1970s, Irvine explains. “But as building assemblies have gotten tighter, building wraps have taken on a new function—helping to remove trapped water from the building enclosure. Their unique functionality enables them to both block moisture from the outside, while also allowing walls to ‘breathe’ to prevent vapor buildup.”

Typar is also innovating in the roofing sector. For this category, Typar’s Surround VR and Surround Pro products are 110gsm and 100gsm synthetic roofing underlayments, respectively. These products are designed to deliver a balance of high performance, enhanced safety and streamlined installation for contractors. Complementing these, Magnera’s Fabrene business provides a variety of roofing underlayment products under the Matrix product line. Matrix XL is a premium, breathable roofing underlayment laminate membrane made from polypropylene nonwovens, and Matrix UL is a synthetic roofing underlayment membrane created by polypropylene nonwoven, coated on two sides with polyethylene.

Irvine highlights the benefits of nonwovens compared to traditional roofing underlayment options such as woven and felt materials. “For example, Surround VR Synthetic Roofing Underlayment is a stronger and lighter weight material than traditional 30# felt roofing underlayment,” he explains. “With a tensile strength that’s 10 times greater than 30# felt, it’s unlikely to rip or tear underfoot. And, since one roll covers the same area as five rolls of 30# felt (and weighs seven times less), it’s much easier to handle and install.”


Looking ahead, Magnera sees continued innovation in nonwoven roofing and construction materials driven by key industry trends. Shifts within the labor force are driving innovation for products that save time, money and energy in installation. Meanwhile, trends in housing availability/affordability can be correlated to the increase in multi-family development and the need for innovation in the multi-family/light commercial space. Sustainability and code changes around the U.S. are also driving innovation for the company.

Additionally, while market uncertainties and competition from alternative materials present challenges, advancements in nonwoven manufacturing and building science are some of the biggest opportunities in the space. “By keeping innovation in every conversation, we’re committed to generating original solutions that provide value, reduce environmental impacts, and improve outcomes like barrier efficacy, comfort and cleaning efficiency,” Irvine says. “We continue to be dedicated to the roofing and construction industry as we develop and innovate new technologies for the market.”

RadiciGroup Focuses on Sustainability

RadiciGroup, which has been operating in nonwoven fabric production for over 30 years, offers semi-finished products that contribute to the quality and efficiency of modern construction, ensuring heat insulation, waterproofing and durability. For the construction industry, its nonwoven fabrics can be used for applications such as breathable membranes, vapor barrier membranes, heat insulation, adhesive backing, flexible sealing, bituminous membranes, and roof and façade insulation.

RadiciGroup’s product portfolio is highlighted by the brands Dylar and Radimelt. Dylar, the flagship brand for the roofing sector, encompasses a wide range of high-performance spunbond nonwoven fabrics with high mechanical strength and tear resistance and, where required, excellent for printing and bonding processes. Radimelt offers a range of highly breathable meltblown products.

“In general the construction and roofing sector is quite conservative,” says Stefano Frione, head of Business Nonwovens, RadiciGroup. “Nevertheless, in recent years, we have noticed more attention to sustainable products as well as to products with energy-saving/superior performance.”

Sustainability is now a fundamental pillar of RadiciGroup’s strategy. The company has expanded its range of spunbond nonwoven fabrics with Respunsible, a sustainable solution containing up to 100% recycled polypropylene and certified by SCS Global Services, resulting in a reduction of more than 50% in CO2 emissions as measured by Life Cycle Assessment (LCA) methodology. Additionally, RadiciGroup has joined the ISCC PLUS (International Sustainability and Carbon Certification) scheme to ensure traceability throughout its supply chain and verify adherence to high environmental and social standards.

According to Frione, the construction sector experienced significant fluctuations due to the pandemic, with governmental incentive policies boosting demand in 2020-2021, followed by a sharp decline in 2022-2023 due to inflation and the war in Ukraine. However, the market began to recover in 2024, and the company expects normalization beginning this year.