STP ShaliPoxy CTE 406
Two-component, 100% solids, solvent-free modified epoxy that builds 400+ microns in a single spray pass — the high-build lining STP’s CTE family reaches for when pipelines, tanks and intake tunnels must go back into immersion service fast.
What is it?
A 2K, 100% volume solids, solvent-free modified epoxy from STP’s CTE lining range (formerly sold as ShaliPoxy CTE 403), designed for plural-component airless spray at very high film builds on steel and concrete.
Where is it used?
Internal and external lining of water and process pipelines, steel and concrete water storage tanks, sea-water intake tunnels, coastal structures, and vessels exposed to water, mild chemicals, oil or lubricant spillage.
Why use it?
Zero solvent means the applied thickness is the retained thickness — no shrinkage, no solvent entrapment, and safe working in confined pipe interiors. It passes 5,000 hours of salt spray and conforms to AWWA C-210, SSPC Paint 16 and Corps of Engineers C-200/C-200a.
How is it applied?
Blast the substrate to Sa 2½, preheat Component A to 60–75°C and Component B to 50–60°C, then spray with plural-feed airless equipment at 2,500–4,000 psi. Theoretical coverage is 2.50 m²/L at 406 micron DFT.
About STP ShaliPoxy CTE 406
ShaliPoxy CTE 406 is STP Limited’s spray-grade answer to a familiar problem on Indian pipeline projects: how to put a thick, immersion-resistant barrier onto steel or concrete without the fumes, film shrinkage and multi-coat delays that come with solvented coal-tar epoxies. Being 100% solids and fully solvent-free, the material gels fast and hangs on vertical surfaces at over 400 microns in one pass — sag-tested to 420 microns — so a pipeline interior that would need three conventional coats can often be lined in a single visit.
The trade-off for that speed is equipment discipline. CTE 406 is dispensed through a plural-component airless spray gun with both components preheated, which keeps the 3:1 volume ratio locked and the fast-setting mix out of the pot until the moment of atomisation. Space Arc supplies the material in project-scale 200 L drum sets and, as an applicator, fields the heated plural-component rigs and blasting crews the specification demands — anywhere in Delhi NCR or pan-India.
The technical insight
Every solvented coating loses volume as it dries: a 400-micron wet film may leave barely half that behind, and the escaping solvent leaves micro-channels that become blister sites under immersion. CTE 406 sidesteps the mechanism entirely. With 100% volume solids there is nothing to evaporate — wet film equals dry film — and the cross-linked matrix that forms is dense enough to hold water vapour transmission to 0.10 g/m² over 24 hours. Preheating the components drops their viscosity for atomisation while accelerating gel on the substrate, which is how the film stands at 420 microns without sagging. The result is a barrier with pull-off adhesion above 10 MPa on blasted steel, Shore D hardness of 85, and a clean pass through 30-day immersion in deionised water, 1% sulphuric acid and 1% caustic soda.
Where it is used
- Internal lining of steel water transmission and distribution pipelines to AWWA C-210
- External coating of pipelines in aggressive, coastal and buried-service environments
- Internal coating of concrete and steel water storage tanks and reservoirs
- Sea-water intake tunnels and marine hydraulic structures
- Process pipework and vessels in pulp and paper plants
- Steel and concrete surfaces exposed to oil and lubricant spillage in plant areas
- Rehabilitation of abrasion-prone pipeline invert and slurry-carrying lines
- Confined-space recoating works where solvent vapour cannot be tolerated
Key advantages
- 100% volume solids and solvent-free — applied DFT is retained DFT, with no VOC hazard in confined pipe interiors
- Builds over 400 microns in a single spray coat (sag-tested to 420 microns), collapsing multi-coat programmes into one pass
- Fast setting: touch dry within 2 hours and hard dry in 8–10 hours at 27°C, so lined sections progress quickly
- Pull-off adhesion above 10 MPa on blasted steel and 3 MPa on concrete (ASTM D4541)
- Passes 5,000-hour salt spray (ASTM B117) and 30-day immersion in DIW, 1% H2SO4 and 1% NaOH without blistering or peeling
- Very low permeability — water vapour transmission of just 0.10 g/m² per 24 hours (ASTM E96)
- Hard-wearing film: under 50 mg abrasion loss at 1,000 cycles (ASTM D4060) with Shore D hardness of 85
- Conforms to AWWA C-210, SSPC Paint 16 and Corps of Engineers C-200/C-200a
Limitations & considerations
- Demands plural-component heated airless spray equipment and a trained crew — this is not a brush-and-roller product
- Pot life is short at 30 ± 3 minutes (28°C, 100 g mix), so material outside the plural-feed system must be used immediately
- Performance depends on Sa 2½ blast preparation; poorly prepared substrates will not achieve the rated adhesion
- Application window is 10–60°C with relative humidity below 75%
- Supplied only in 200 L drum sets (three drums of Component A per drum of B) — sized for pipeline projects, not small patch repairs
- Needs 7 days to full cure before immersion service, and the brownish-black glossy finish is functional, not decorative
Selection & best practice
Get the substrate right first: remove oil, grease and loose material, then abrasive-blast steel to Sa 2½ — adhesion figures on the datasheet assume this profile. Condition the material before spraying: stir Component A with a spiral-blade drill mixer at 400–600 rpm, preheat Component A to 60–75°C and Component B to 50–60°C, and feed both through plural-component airless equipment at the correct 3:1 volume ratio. Set tip pressure between 2,500 and 4,000 psi with a 27–35 thou orifice, adjusting until atomisation is clean. Spray to the specified DFT — 406 microns is achievable in one pass, with additional passes for higher builds — and verify with a gauge while wet. Keep ambient conditions within 10–60°C and RH under 75%, flush tools immediately with STP cleaner, and hold the lining out of immersion for the full 7-day cure.
Specifications
| Mixing ratio (by volume, A:B) | 3:1 |
| Volume solids | 100% |
| Pot life (28°C, 55% RH, 100 g) | 30 ± 3 minutes |
| Theoretical coverage at 406 micron DFT | 2.50 m²/L |
| Drying time (27°C, 55% RH) | Touch dry within 2 h; hard dry 8–10 h; full cure 7 days |
| Adhesion, pull-off (ASTM D4541) | > 10 MPa on steel; > 3 MPa on concrete |
| Abrasion resistance, 1,000 cycles (ASTM D4060) | < 50 mg loss |
| Salt spray resistance (ASTM B117) | Passes 5,000 hours |
| Packing | 200 L drums — 1 drum Component B per 3 drums Component A |
Industry use cases
Water Infrastructure
Internal lining of steel transmission mains and WTP storage — the AWWA C-210 conformance and single-coat 406-micron build keep shutdown windows short on municipal and Jal Jeevan-type works.
Marine & Coastal
Sea-water intake tunnels, jetty piping and coastal pipeline exteriors, where the 5,000-hour salt-spray pass and near-zero permeability earn their keep against chloride attack.
Industrial Process Plants
Pipe and vessel linings in pulp & paper and mild-chemical service — the film shrugs off 30-day immersion in 1% acid and 1% caustic while resisting slurry abrasion.
Oil & Lubricant Handling
Steel and concrete containment surfaces around oil and lubricant spillage zones in plants, terminals and workshops.
Pipeline Rehabilitation
Recoating aged water and process lines in confined interiors, where the zero-solvent formulation removes the ventilation and fire-permit burden of solvented coal-tar epoxies.
Frequently asked questions
Is ShaliPoxy CTE 406 the same as the old ShaliPoxy CTE 403?
Can I apply CTE 406 by brush or roller?
How much material do I need per square metre?
When can a lined pipeline go back into service?
Does it meet water pipeline coating standards?
What pack sizes does it come in, and what is the shelf life?
How we position STP ShaliPoxy CTE 406
Within STP’s CTE family, CTE 406 is the high-build spray grade: choose ShaliPoxy CTE 306 for the same 100% solids, solvent-free platform where plural-component spray is not available, or the solvented CTE 103/203/303 grades for conventional brush and spray work at 135–300 micron builds. For coal-tar mastic protection and pipeline wrapping, STP’s ShaliMastic HD and PipeWrap tapes round out the system. From our Fosroc range, Nitocote ET402 covers brush-applied coal-tar epoxy duties, while Nitocote EP405 suits damp-tolerant tank lining. Space Arc supplies and applies all of these pan-India, so we can match the grade to your equipment and shutdown window rather than force one product onto every job.
Fosroc Nitocote ET402 — Specifiers choose Nitocote ET402 when the job calls for a brush- or roller-applied coal-tar epoxy at conventional film builds — smaller areas, maintenance repaints, or sites without plural-component spray equipment.
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