STP ShaliPatch
Ready-to-use, cold-applied pothole repair from STP Limited — shovel it straight from the bag, compact, and open to traffic. Workable from 0–50°C, monsoon included.
What is it?
A ready-to-use, cold-applied pothole repair material — graded crushed aggregate coated with a modified all-weather bitumen paste — supplied by STP Limited in 25 kg poly bags.
Where is it used?
Filling and levelling potholes in bituminous roads and concrete surfaces; also along railway tracks at level crossings and tram lines.
Why use it?
No hot-mix plant, no heating, no heavy machinery. Works across 0–50°C ambient year-round, bonds instantly, and the patch takes traffic straight after compaction.
How is it applied?
Clean the hole (compressed hot air preferred), pre-fill holes deeper than 100 mm with 25–50 mm rock, shovel in 50 mm layers, crown slightly, compact with a rammer, then seal with two coats of ShaliSeal RS TC.
About STP ShaliPatch
ShaliPatch is STP Limited’s ready-to-use answer to the pothole problem on India’s flexible pavements. Each 25 kg poly bag holds graded crushed aggregate — sieved, pre-washed and dried in controlled-temperature hot air — coated with a modified all-weather bitumen paste carrying anti-stripping agents and performance additives. Nothing is heated and nothing is batched on site: the material goes from bag to pothole with a shovel and is finished with a hand rammer or wooden mallet. Space Arc Engineering stocks and supplies ShaliPatch across Delhi NCR and Pan-India, with applicator support for road-maintenance contracts.
The case for a cold patch is strongest exactly when potholes are worst. When hot-mix plants shut for the monsoon, a small gang with a few bags and a compactor can attend complaints the same day — the material stays workable anywhere between 0°C and 50°C ambient. The repair itself is clean, with no smoke, fumes or plant noise, and needs no traffic diversion because the compacted patch carries vehicles immediately. Since the binder bonds on contact, passing wheels do not scatter the material out of the hole, and it does not pick up on tyres — the two failure modes that finish off most makeshift jelly-and-dust fills within days.
The technical insight
ShaliPatch works on aggregate interlock plus chemical adhesion rather than heat. The sub-5 mm graded aggregate is pre-washed and hot-air dried before coating, so the polymer-modified bitumen film grips clean stone instead of dust. In the bag, additives keep that film soft and workable across the 0–50°C window; once the mix is rammed into a confined pothole, the particles lock together mechanically while anti-stripping agents hold the binder onto the aggregate and the hole walls even in damp conditions. Traffic then does useful work — every wheel pass densifies the patch further and drives off residual volatiles, stiffening the repair over time. With an apparent density of 2.20 g/cc and a flash point above 150°C, the placed material behaves like a dense, stable mini hot-mix layer without a plant ever being involved.
Where it is used
- Pothole filling and levelling on bituminous city roads, colony streets and service lanes
- Emergency patching on highways and expressways under live traffic, with no lane closure beyond the work spot
- Monsoon-season repairs when hot-mix plants are closed and pothole complaints peak
- Filling and levelling potholes on concrete surfaces where a black bituminous patch is acceptable
- Repairs along the edges of railway tracks at level crossings and tram lines
- Internal roads of factories, refineries, ports and townships maintained by in-house teams
- Small reinstatements under annual maintenance and O&M contracts where mobilising hot mix for a few square metres makes no sense
Key advantages
- Genuinely ready to use — no heating, no mixing, no batching; a shovel and a compactor complete the job
- Applies across 0–50°C ambient, so the same bag works in a Delhi summer and a hill-station winter
- Patch takes traffic immediately after compaction — no diversion, no barricading for days
- Binder bonds instantly, so material is not thrown out of the hole by passing wheels
- Does not stick to tyres — a common failure of makeshift cold fills — which extends patch life
- Clean and quiet: no smoke, fumes or plant noise, so night work in residential areas is practical
- 25 kg poly bags are crew-portable and easy to stock at ward stores, toll plazas and plant depots
Limitations & considerations
- It is a patching material, not a resurfacing one — widespread cracking, base failure or rutting still needs conventional reconstruction
- Needs roughly 50 mm minimum pothole depth to key in; it is not meant for shallow ravelling or surface scaling
- Holes deeper than 100 mm must first be part-filled with 25–50 mm hard rock or pebbles and compacted, which adds a preparation step
- Patch life depends heavily on compaction effort and on sealing with two coats of ShaliSeal RS TC — skipping either shortens life under heavy, slow traffic
- Shelf life is 6 months in sealed bags, and stock kept in heat or direct sun can harden, so stores need rotation discipline
Selection & best practice
Start with the hole, not the bag. Clean out all loose and foreign material — compressed hot air is the preferred method — and square up to a depth of at least 50 mm so the patch can key in. If the hole is deeper than 100 mm, part-fill it with 25–50 mm hard rock or pebbles and compact that layer first. Shovel ShaliPatch straight from the poly bag, placing in layers of no more than 50 mm and finishing slightly crowned above road level. Compact thoroughly with a rammer or wooden mallet — compaction, more than anything else, decides how long the patch lasts. For maximum life, brush on two coats of ShaliSeal RS TC over the finished patch and let them dry, then open to traffic. Wear gloves and eye protection, and keep ventilation adequate when working in enclosed areas.
Specifications
| Physical form | Granular solid |
| Appearance | Black, tarry |
| Application temperature | 0°C to 50°C ambient |
| Aggregate size | Below 5 mm, graded |
| Apparent density | 2.20 g/cc |
| Flash point | Above 150°C |
| Moisture content | 0.20% |
| Packing | 25 kg poly bag |
| Shelf life | 6 months in original sealed bags, stored at 5–35°C |
Industry use cases
Highway O&M Concessionaires
Routine and emergency pothole attendance on NH and state-highway stretches under performance-based maintenance, without mobilising a paver or plant for scattered defects.
Municipal Bodies & PWD
Ward-level gangs stock bags at section stores and close pothole complaints the same day, including through the monsoon when hot-mix supply stops.
Industrial Plants & Ports
In-house maintenance of internal bituminous roads at factories, refineries and container yards, where repairs must be quick, clean and done between vehicle movements.
Railways & Tram Corridors
Levelling repairs along track edges at level crossings and tram lines, where hot work near the track is unwelcome and possession windows are short.
Townships & Facility Management
Gated communities, campuses and toll plazas keep a small stock for immediate patching — night application is feasible since there is no smoke or plant noise.
Frequently asked questions
Can ShaliPatch be applied during the monsoon?
How soon can the repair take traffic?
Does it need a primer or tack coat?
How much does a 25 kg bag cover?
How should bags be stored, and for how long?
Can it be used on concrete roads or only bituminous ones?
How we position STP ShaliPatch
ShaliPatch is the pothole workhorse within STP’s road-maintenance family, and it performs best as part of a system. Pair it with ShaliSeal RS TC — the topcoat STP itself specifies over the compacted patch — and with ShaliMulsion bituminous emulsions where your maintenance programme also involves tack and fog seals. For crack and joint treatment, which a granular patch cannot address, ask us about STP’s mastic and sealant lines. And where the defect is in a rigid concrete pavement or industrial floor rather than a flexible road, we would steer you to our Fosroc Renderoc concrete-repair range instead — Space Arc supplies and applies both, so you get the right chemistry for the pavement, not just the nearest bag.
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