STP ShaliPUF SA
A machine-sprayed, two-component rigid closed-cell polyurethane foam that lays down a seamless, high-R-value thermal insulation blanket on roofs, podiums, walls, cold stores and tanks.
What is it?
A two-component, CFC/HCFC-free rigid closed-cell polyurethane foam that is spray-applied on site to form a jointless thermal insulation layer with a thermal conductivity of 0.022-0.024 W/mK.
Where is it used?
Roof and podium decks, external and internal walls, cold storage envelopes and process-tank insulation across residential, commercial and industrial projects.
Why use it?
It cuts building cooling loads by insulating seamlessly, bonds directly to concrete, steel and wood, and resists moisture thanks to a 95% closed-cell structure, with no joints or fasteners to fail.
How is it applied?
Sprayed by trained applicators using two-component plural-component equipment onto a primed, dry substrate, built up in 10-30 mm passes and then overcoated with a UV-stable PU or polyurea topcoat.
About STP ShaliPUF SA
STP ShaliPUF SA is a spray-applied rigid polyurethane foam engineered for thermal insulation on Indian roofs, walls and process structures. Supplied as two liquid components mixed 1:1 by volume, it is heated and atomised through plural-component spray equipment, then expands and cures within seconds into a rigid, closed-cell foam. Because it is delivered as a continuous spray rather than as boards or rolls, the finished insulation is genuinely seamless: it wraps around parapets, upstands, pipe penetrations and irregular geometry without the cold-bridging joints that plague pre-formed panels. The foam is free from CFCs and HCFCs, making it an environmentally responsible choice for developers chasing energy-efficiency and green-building credentials.
For engineers and applicators, the appeal is the combination of low thermal conductivity (0.022-0.024 W/mK) and a 95% closed-cell content that keeps water absorption below 2%. This lets a relatively thin layer deliver a high R-value while shrugging off incidental moisture during construction. ShaliPUF SA adheses strongly to concrete, steel and timber, tolerates service temperatures across a wide swing without meaningful dimensional change, and carries a DIN 4102 Class B2 fire rating. It is important to treat it as the insulating core of a layered build-up rather than a finished surface: the foam is not UV-stable and must always be protected with a compatible topcoat or wearing course. Space Arc Engineering supplies ShaliPUF SA and its companion primers and topcoats as a coordinated system for Delhi NCR and Pan-India projects.
The technical insight
The insulating performance of ShaliPUF SA comes from its closed-cell morphology. As the polyol (Component A) and isocyanate (Component B) meet at the spray nozzle, an exothermic reaction generates a blowing action that inflates millions of tiny, sealed cells within 15-25 seconds. Roughly 95% of those cells stay closed and trap low-conductivity gas, which is what pushes the thermal conductivity down to 0.022-0.024 W/mK, far below mineral wool or open-cell foam. Those same sealed cells refuse to wick water, so absorption stays under 2% (ASTM D2842) and the foam does not slump or lose R-value when damp. The 320-400 kPa compressive strength and 60 kg/m3 core density give it enough rigidity to accept a screed or tile finish on trafficable decks, while the seamless spray application eliminates the board joints and mechanical fixings that are the usual weak points in roof insulation. In short, it works because it combines a gas-filled insulating matrix, an in-situ moisture barrier and a structurally competent substrate in a single sprayed pass.
Where it is used
- Terrace and podium roof insulation to reduce solar heat gain and air-conditioning loads
- Insulation beneath green or plantation roofs, under the soil and growing medium
- External and internal wall insulation for energy-efficient building envelopes
- Cold storage and refrigerated warehouse walls, ceilings and floors
- Thermal insulation of process and storage tanks
- Industrial shed roofs and metal-deck roofs requiring seamless insulation
- Insulating irregular geometry, upstands and penetrations where boards cannot fit cleanly
Key advantages
- Seamless, jointless coverage that eliminates cold bridges and mechanical fixings
- Very low thermal conductivity of 0.022-0.024 W/mK for a high R-value per mm
- 95% closed-cell structure with under 2% water absorption for built-in moisture resistance
- Strong adhesion to concrete, steel and timber without separate anchors
- Fast machine application that follows complex shapes and speeds up the programme
- Good dimensional stability across a wide temperature range with no sag over time
- DIN 4102 Class B2 fire rating and CFC/HCFC-free, environmentally compliant chemistry
Limitations & considerations
- Not UV-stable; it must always be overcoated with a PU or polyurea topcoat, or protected by a screed or tiles
- Requires specialised two-component plural spray equipment and trained applicators, so it is not a DIY or brush-applied product
- Substrate must be dry (surface moisture below 5%, RH under 80%) and above 10 degrees C, or bond and closed-cell quality suffer
- Needs a compatible primer (ShaliPrime PUM or 2E) as a sealer and moisture barrier before spraying
- As a thermal insulant it is not a standalone waterproofing membrane; it is the insulating core of a layered build-up
Selection & best practice
Start by cleaning the deck: remove loose gravel, dirt, oil and grease with dry compressed air and mechanical grinding, and repair any cracks with a polymer-modified mortar. Confirm the substrate is above 10 degrees C, surface moisture is below 5% and relative humidity is under 80%, as dampness weakens the bond and reduces closed-cell content. Prime with ShaliPrime PUM or ShaliPrime 2E at 0.2-0.3 kg per m2 as a sealer and moisture barrier. Heat both components in the machine chambers (40-70 degrees C) and maintain 1000-1500 psi mixing pressure. Spray in controlled layers of 10-30 mm per pass, building up thicker sections in several passes to the design thickness. Because the foam is not UV-stable, protect it promptly with ShaliUrethane LM or ShaliProtek PuR, and where the area is trafficable finish with a screed or tiles.
Specifications
| Type | Two-component, spray-applied rigid closed-cell polyurethane foam (CFC/HCFC-free) |
| Thermal conductivity | 0.022-0.024 W/mK (ASTM C518:2017) |
| Core density | 60 ± 2 kg/m3 (ASTM D1622) |
| Closed cell content | 95 ± 2% |
| Compressive strength | 320-400 kPa |
| Tensile strength | 400-500 kPa |
| Water absorption | < 2% (ASTM D2842) |
| Dimensional stability | < 2% at -20 degrees C and at +70 degrees C / 95% RH |
| Fire rating | DIN 4102 Class B2; mixing ratio 1:1 by volume; gel time 15-25 s; pack 460 kg (Comp A 210 kg + Comp B 250 kg); shelf life 12 months |
Industry use cases
Commercial and residential roofing
Sprayed over terrace and podium decks to slash cooling loads, then screeded or tiled and waterproofed for a durable, energy-efficient roof.
Cold chain and food processing
Seamless insulation of cold-store walls, ceilings and tank surfaces where continuous closed-cell coverage prevents condensation and thermal leakage.
Industrial buildings
Insulating large metal-deck and shed roofs quickly with machine spray, following ribs and penetrations without cutting boards.
Green and plantation roofs
Laid beneath the growing medium to insulate the slab while its closed-cell structure resists the constant moisture of a planted build-up.
Process and storage tanks
Wrapping curved tank shells with a jointless insulating layer that bonds directly to steel and holds its shape across temperature cycles.
Frequently asked questions
Is ShaliPUF SA a waterproofing product?
Can I apply it myself with a brush or roller?
Why does it need a topcoat?
How thick should the foam be?
What primer does it need?
What surface conditions are required?
How we position STP ShaliPUF SA
Within the STP ShaliMark family, ShaliPUF SA is the insulating core of a layered roof or wall system, not a finish in itself. Pair it with STP ShaliPrime PUM or ShaliPrime 2E as the primer and moisture barrier, and protect it with a UV-stable topcoat such as STP ShaliUrethane LM or ShaliProtek PuR; where the deck is trafficable, follow with a screed or tiles. For projects that need liquid-applied waterproofing over or alongside the insulation, our STP ShalisealPU and ShaliTop PU coatings, along with Dr. Fixit and Fosroc PU membranes, complete the weatherproofing layer. Buyers standardising on a single manufacturer’s ecosystem, or who want a foam explicitly paired with Fosroc’s own topcoats, will find a direct equivalent in Fosroc Nitofoam 45.
Fosroc Nitofoam 45 — Choose the Fosroc option when the project is already specified around Fosroc’s Brushbond Roofguard or polyurea topcoat system and a single-manufacturer warranty for the whole roof build-up is preferred.
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Authorised distribution, technical advice & professional application across Delhi NCR and Pan-India.