United States Process Safety Services Market Surges at 9.2% CAGR - $4.5 Billion Milestone by 2031, Led by Bureau Veritas and SGS as Top Competitors | DataM Intelligence

Leander, Texas and TOKYO, Japan - Dec. 01, 2025. According to DataM Intelligence, the United States Process Safety Services Market Size is growing from USD 2.1 billion in 2023 to USD 4.5 billion by 2031, registering a robust CAGR of 9.2% during 2024-2031. The surging demand for risk assessment in high-hazard industries, the expansion of regulatory compliance consulting for OSHA and EPA mandates, and advancements in AI-driven hazard analysis tools are fueling the need for enhanced process safety services that minimize accidents, optimize operational integrity, and integrate seamlessly with digital twins without disrupting production lines. Process safety services, encompassing hazard identification, safety instrumented system design, and incident investigation protocols, revolutionise industrial operations by safeguarding against explosions, leaks, and toxic releases in petrochemicals, manufacturing, and utilities, reducing downtime and liability costs while ensuring adherence to PSM standards and ISO 45001 certifications. By combining quantitative risk modeling, virtual reality training simulations, and blockchain-audited compliance records, this market provides proactive, scalable solutions for facility siting analysis, mechanical integrity audits, and emergency response planning throughout refineries in Texas, chemical plants in Louisiana, and power utilities across the United States and beyond.

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Recent Developments

1. Bureau Veritas unveiled an AI-powered PHA software suite at the AIChE Spring Meeting 2024 in New Orleans, enabling 50% faster hazard identification with 98% accuracy in pilot tests as endorsed by process safety expert Dr. Paul Amyotte of Dalhousie University (March 2024).

2. SGS SA acquired a US-based risk management consultancy for USD 95 million to expand its PSM offerings, targeting Gulf Coast petrochemicals and enhancing audit capabilities per analyst insights from Deloitte's industrial sector (July 2024).

3. ABB Ltd. integrated drone-based facility siting inspections into its safety services at the National Safety Council Congress 2025 in San Diego, reducing inspection times by 40% in refinery trials validated by OSHA consultant Dr. Karen Burns of the American Industrial Hygiene Association (October 2025).

4. Intertek Group plc debuted a VR training module for incident response, partnering with ExxonMobil for employee certifications and demonstrating 35% improved response efficacy in a study published in the Journal of Loss Prevention in the Process Industries (May 2025).

5. Rockwell Automation Inc. collaborated on SIS cybersecurity enhancements with NIST guidelines, achieving 28% lower breach risks in a multicenter simulation presented at the Process Safety Management Summit, with experts highlighting its alignment with evolving cyber threats (February 2025).

Competitive Landscape

The market is highly competitive among global certification leaders, engineering consultants, and digital safety innovators.

1️⃣Bureau Veritas expanded its US operations in Houston, Texas, operational since mid-2025, enhancing services for energy firms with 32% improved compliance audit rates.

2️⃣SGS SA acquired the risk consultancy, fortifying its North American PSM portfolio and reporting a 21% revenue uplift in industrial segments according to J.P. Morgan analyst projections.

3️⃣ABB Ltd. partnered with nine manufacturing networks to deploy AI-hazard analytics for utilities, attaining 94% predictive accuracy and securing 30% of premium digital contracts.

4️⃣Intertek Group plc introduced blockchain-verified auditing tools with superior traceability, landing deals with major chemical producers and driving 25% growth in domestic sales.

5️⃣Rockwell Automation Inc. rolled out integrated SIS platforms optimized for e-learning, slashing training costs by 38% and collaborating with regulatory bodies for customized protocols.

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Growth Drivers

✦ The global industrial safety market surpassed USD 80 billion in 2024, with process services accounting for 8% of risk management spends, underscoring the drive for AI-integrated solutions amid accident reduction trends.

✦ US chemical manufacturing revenues exceeded USD 900 billion in 2024, driving over 5 million PSM audits annually and accelerating service adoption for operational resilience.

✦ Safety regulations spurred USD 300 billion in compliance investments by 2025, prioritizing OSHA-aligned services that meet EPA transparency and corporate governance demands.

✦ North American hazard mitigation revenues climbed 16% recently, utilizing more than 100,000 PHA sessions yearly as aging infrastructure fuels preventive overhaul adoption.

✦ Digital twin innovations trimmed incident costs by 24%, forecasting USD 350 million in yearly efficiencies for US operators by 2030 through predictive and simulation-based systems.

🌍Regional Insights

United States (North America): The U.S. Process Safety Services market was valued at USD 2.1 billion in 2023, projected to reach USD 4.5 billion by 2031 at a 9.2% CAGR. It holds nearly 50% of the global market share, driven by stringent PSM regulations and high petrochemical activity. Key players like Bureau Veritas and SGS lead through innovation, digital audits, and expanded consulting networks. Adoption of AI analytics and multiple end-user channels strengthens its dominance. Recent strategic acquisitions and service launches keep the U.S. as the global market leader.

Canada (North America): Canada's market size was USD 420 million in 2023, expected to grow to USD 850 million by 2031 at a 8.9% CAGR, holding roughly 11% of the global market share. Growth is fueled by government funding and regulatory clarity that boost premium, tech-enabled safety demand. Leading U.S. brands are investing in Canadian oil sands operations, accelerating market maturity. Industry preference for integrated, cross-border compliance continues to mount. Canada complements U.S. leadership with a strong adjacent presence.

Europe (Key countries: UK, Germany, France): Europe constitutes 24% of the global Process Safety Services market and is rapidly growing due to expanding regulatory acceptance and rising industrial awareness. While the exact 2023/2031 values are less defined, Europe is the second-largest regional market following North America. The UK, Germany, and France drive expansion through hybrid consulting formulations and diversified safety launches. Market growth is supported by established manufacturing demand and the increased entry of North American brands. Europe's evolving frameworks and expanding operator base make it a crucial growth region.

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Market Segmentation Analysis

By Service Type: Consulting services dominate with a 55% market share, valued at USD 1.155 billion in 2023 and projected to grow to USD 2.475 billion by 2031 at a 9.3% CAGR. Training and certification hold 30% of the market, valued at USD 630 million in 2023 and expected to reach USD 1.35 billion by 2031 at a 9.0% CAGR. The consulting segment's growth is driven by increasing demand for PHA and RMP expertise compliant with OSHA and ISO standards, while the training segment sustains demand through cost-effective applications in workforce upskilling.

By End-User: Process manufacturing leads with a commanding 60% market share, valued at USD 1.26 billion in 2023 and forecasted to reach USD 2.7 billion by 2031, favoured for its high-risk environments and regulatory scrutiny. Utilities hold a 25% share, worth USD 525 million in 2023 and projected to grow to USD 1.125 billion by 2031, attracting operators seeking grid reliability. The remaining 15% comprises automotive and others, growing fastest at 9.4% CAGR to USD 675 million by 2031, catering to niche demands for discrete manufacturing audits and innovative risk tools.

By Application: Hazard analysis and risk assessment constitute the largest segment with 40% market share, valued at USD 840 million in 2023 and expected to expand to USD 1.8 billion by 2031, powered by incident investigation research and compliance trends. Safety instrumented systems hold 30% share, valued at USD 630 million in 2023 and projected to reach USD 1.35 billion by 2031, fueled by SIS design applications. Compliance management and mechanical integrity each account for 15% of the market, reflecting growing awareness of holistic PSM benefits and targeted audit relief.

Innovation and Consumer Trends Fueling Market Expansion

Manufacturers are investing heavily in advanced digital technologies, such as AI modeling and VR simulations, to improve accuracy, reduce accident rates by an estimated 25%, and comply with regulatory expectations. Operator growth is driven by expanding awareness of PSM benefits, integration into operational routines, and market education on premium, tech-enabled safety services. North American markets, particularly the U.S., exhibit the highest adoption rates, supported by empirical research, strategic partnerships, and expert-backed digital compliance blends.

Market Outlook and Opportunities: The Global process safety services market is at a tipping point, driven by risk-averse mandates and every ounce of scientific evolution in hazard mitigation. Valued at USD 4.8 billion in 2023, it is projected to reach USD 10.2 billion by 2031 at a steady 9.3% CAGR. North America, capturing nearly half the global share, spearheads expansion powered by petrochemical demand, while Asia Pacific benefits from manufacturing abundance. Progress in AI sourcing and enhanced analytics align with OSHA sustainability aims, although hurdles like regulatory volatility, skill gaps, and cyber risks remain. Post-pandemic focus on resilient operations and rising embrace of predictive audits and digital twins unlock vast potential for accident prevention and integrity enhancement in chemicals, energy, and utilities sectors.

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