ID: PMRREP35079| 198 Pages | 29 Sep 2025 | Format: PDF, Excel, PPT* | Industrial Automation
The U.S. non-destructive testing market size is likely to value at US$5.3 Bn in 2025 and is expected to reach US$8.5 Bn by 2032, growing at a CAGR of 6.9% during the forecast period from 2025 to 2032, driven by the growing concerns over the aging infrastructure in the U.S., including roads, bridges, power plants, and defense installations.
| Key Insights | Details |
|---|---|
| Non-destructive Testing Market Size (2025E) | US$5.3 Bn |
| Market Value Forecast (2032F) | US$8.5 Bn |
| Projected Growth (CAGR 2025 to 2032) | 6.9% |
| Historical Market Growth (CAGR 2019 to 2024) | 5.1% |
The deterioration of roads, bridges, power plants, and defense facilities is driving demand for non-destructive testing (NDT) solutions. The deterioration of roads, bridges, power plants, and defense facilities is driving demand for non-destructive testing (NDT) solutions. The ASCE 2025 Infrastructure Report reported a C-grade, with bridges showing 49.1% in fair and 6.8% in poor condition, emphasizing the need for early detection via ultrasonic and visual inspections.
Federal funding, such as US$27.5 Bn from the IIJA Bridge Formula Program, falls far short of the US$191 Bn needed for rehabilitation, while bridges handle over 4.9 billion daily vehicle trips. Aging maritime, defense, and nuclear facilities face backlogs exceeding US$7 Bn, with NDT methods such as eddy current and phased array ultrasonic testing critical for inspection and life-extension programs.
The resurgence in U.S. upstream exploration and production, particularly across shale-rich basins such as the Permian, Bakken, and Eagle Ford, is a major catalyst. Operators are investing heavily in greenfield and brownfield projects, with critical assets such as pipelines, pressure vessels, storage tanks, and offshore platforms requiring rigorous inspection.
According to FERC, numerous interstate pipeline projects are approved or under review, while DOE-backed initiatives such as Venture Global’s CP2 LNG project and over 100?GW of gas-fired power generation underscore infrastructure expansion through 2030.
EIA reports five major petroleum liquids pipeline completions in 2024, with nine announced and eight under construction, highlighting a construction boom reliant on NDT for safety and performance. Rising rig counts and sustained U.S. crude production at ~13.4?million?b/d in 2025-2026 further stress upstream and midstream infrastructure.
The Matterhorn Express Pipeline began transporting 2.5?Bcf/d of gas in October 2024, with additional Permian pipelines totaling 7.3?Bcf/d scheduled through 2028. PHMSA’s expanding oversight, including emerging fuels such as hydrogen and CO? will accelerate the adoption of advanced NDT technologies.
Radiographic Testing (RT) enables internal inspection of welds, pipes, and materials without damage, but its reliance on radioactive sources such as Ir-192 and Co-60 imposes significant health, safety, and regulatory challenges. The U.S. NRC limits occupational exposure to 5 rem/year, enforcing the ALARA principle, which requires investment in shielding, dosimeters, monitoring, and training, raising operational costs.
Licensing under NRC or Agreement States and DOT-regulated transport further complicates logistics and scalability. Accidental exposures, such as 1.8 rem in Washington (Nov 2024), 2.85 rem shallow dose in Texas (May 2025), and near-miss incidents in Wyoming (June 2025), highlight ongoing risks despite stringent safety protocols. These factors collectively constrain broader adoption of RT in the U.S.
Accurate measurements are essential in NDT to detect defects, assess material properties, and ensure structural integrity. Inaccurate measurements lead to false positives or negatives, resulting in unnecessary repairs or missed defects.
For example, in aerospace, misinterpreted defects can compromise aircraft safety, prompting the FAA to enforce stringent NDT standards. Maintenance downtime periods when equipment is unavailable disrupt operations and raise costs. In sectors such as oil and gas, delays in inspections due to equipment unavailability can jeopardize safety and regulatory compliance, limiting operational efficiency.
The U.S. transition to cleaner energy, driven by federal policies, climate goals, and public demand, has led to the rapid deployment of wind, solar, hydropower, and energy storage installations. In 2024, nearly 50?GWdc of utility-scale solar was added, and renewables accounted for over 90?% of new generation capacity, with wind projected to supply up to 20?% of electricity by 2030.
These high-value assets require frequent NDT inspections using ultrasonic, radiographic, infrared, and acoustic techniques to detect defects, corrosion, or fatigue without damaging components. Remote and automated NDT solutions, including drones, robotics, and AI, are increasingly used to inspect turbines, solar arrays, and hydropower structures in challenging locations, enhancing safety, reliability, and equipment lifespan.
Many U.S. nuclear reactors seek license renewals under the NRC’s Subsequent License Renewal program. NDT technologies are critical for ensuring safe operation over extended lifespans of 60-80 years. Aging components such as reactor vessels, piping, and steam generators face stress, radiation, corrosion, and fatigue, necessitating in-service inspections using ultrasonic, radiographic, eddy current, and acoustic emission testing.
Programs such as NRC’s Aging Management and EPRI initiatives increasingly employ advanced methods such as PAUT and GWUT to detect early defects and plan maintenance. Regulatory compliance with ASME codes and NRC 10 CFR Part 54 standards further drives demand for certified NDT services.
Large-scale projects, such as the steam generator replacement at Palo Verde Nuclear Generating Station, highlight extensive use of NDT for weld inspection, component verification, and structural integrity, promoting innovation in high-precision NDT solutions.
Automated systems, including drones, robotic arms, and crawler robots, are increasingly deployed for inspections in hard-to-access or hazardous sectors. NDT tools enhance precision and safety. AI, machine learning, and advanced analytics enable real-time defect recognition and predictive maintenance, with examples including AI-powered magnetic inspection robots achieving ~85% precision in detecting six corrosion types on steel bridges in 2024.
Government support from the U.S. Department of Energy, NIST, FAA, and NASA further drives adoption by funding research, standardization, and reliable remote-operated systems for nuclear reactors, aircraft, and space vehicles, minimizing downtime while improving asset integrity monitoring.
Based on components, the U.S. non-destructive testing market is divided into equipment and services. Among these, equipment is expected to account for more than 55% share in 2025 as industries require advanced tools for accurate, efficient, and high-speed inspections.
The growing need for real-time data collection, precise defect detection, and portable solutions is driving demand for innovative testing devices. Continuous upgrades in imaging, sensors, and automation technologies further strengthen reliance on equipment. The push for safety compliance and cost-effective maintenance amplifies the preference for reliable testing instruments.
Services are expected to grow at the highest rate of 8.1% due to industries increasingly requiring ongoing inspection, maintenance, and certification to ensure asset integrity and regulatory compliance. The aging infrastructure and expanding pipeline networks demand frequent monitoring to prevent failures.
Several organizations in the U.S. prefer outsourcing NDT services to specialized providers instead of maintaining in-house testing capabilities. This decreased capital expenditure on equipment and training and reduced operational downtime.
In terms of testing methods, the U.S. non-destructive testing market is segregated into ultrasonic testing, radiographic testing, magnetic particle testing, eddy current testing, visual testing, acoustic emission testing, liquid penetrant testing, and others.
Out of these, ultrasonic testing is expected to account for more than 29.6% share, generating revenue of US$1.6 Bn in 2025 due to its ability to deliver highly accurate flaw detection and thickness measurement, meeting the need for precision in safety-critical assets. It provides deeper penetration in materials, ensuring reliable inspection of metals, composites, and welds without damage.
Growing demand for cost-efficient and portable solutions further supports adoption, as industries increasingly require on-site testing in complex and remote environments. Its versatility across different material types strengthens its dominance in the U.S. non-destructive testing market.
Visual testing is expected to grow at the fastest rate of 7.2% due to increasing demand for quick, cost-effective, and reliable inspection methods. It addresses the need for real-time defect detection in structures, pipelines, and critical components without halting operations.
The rising adoption of digital imaging, drones, and AI-assisted inspection tools enhances accuracy and documentation, meeting regulatory and safety requirements efficiently. Its simplicity and portability make it ideal for remote and hard-to-access sites, driving higher uptake.
Based on vertical, the U.S. non-destructive testing market is divided into oil and gas, manufacturing, aerospace and defense, construction & infrastructure, automotive, energy and utilities, healthcare, and others. Among these, oil and gas are expected to account for more than 24.8% share in 2025, due to the critical need for inspection of pipelines, refineries, and storage facilities to ensure safety and reliability.
Aging infrastructure and stringent regulations make frequent testing essential to prevent leaks and accidents. For instance, natural gas pipeline projects completed in 2024 added ~6.5 Bcf/d of takeaway capacity across Appalachia, Haynesville, Permian, and Eagle Ford regions, further increasing the demand for robust NDT solutions. High-pressure operations and the need to minimize downtime reinforce this reliance.
Energy and utilities are expected to grow at a significant rate due to increasing demand for reliable infrastructure inspection and maintenance. Aging power plants, pipelines, and grid systems require frequent monitoring to prevent failures and ensure safety. The shift toward renewable energy installations, such as wind and solar farms, also drives the need for advanced inspection solutions.
Major U.S. utilities are expected to spend heavily on upgrading their electric lines and grids over the next five years to cater to power-hungry sectors. For instance, American Electric Power revised its plan by up to $54 billion, marking a 25.6% increase, the highest since 2016.
The U.S. non-destructive testing market is fragmented, with a mix of global leaders and regional players competing for market share. Companies are integrating IoT technologies to provide real-time monitoring and analysis, enhancing the efficiency and accuracy of inspections.
They are also forming partnerships and pursuing acquisitions to expand their service portfolios and strengthen geographic reach. Businesses are offering portable and mobile NDT solutions to support onsite inspections in sectors such as construction and maintenance, enabling users to conduct tests in remote or hard-to-reach areas.
The U.S. non-destructive testing market is projected to be valued at US$5.3 Bn in 2025.
The rising need for enhanced safety, reliability, and compliance in critical infrastructure, ensuring early defect detection and minimizing costly failures, is a key driver of the market.
The U.S. non-destructive testing market is poised to witness a CAGR of 6.9% from 2025 to 2032.
Integration of AI and IoT for enhanced accuracy and efficiency in inspections and predictive maintenance tools is creating strong growth opportunities.
Mistras Group, Inc., Waygate Technologies, TEAM Inc., EVIDENT, Intertek Group Plc, Acuren Corporation, and Eddyfi Technologies are among the key players.
| Report Attribute | Details |
|---|---|
| Historical Data/Actuals | 2019 - 2024 |
| Forecast Period | 2025 - 2032 |
| Market Analysis | Value: US$ Bn |
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| Report Highlights |
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By Component
By Testing Method
By Vertical
By Zone
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