Overview
Closed-cell water-blown spray polyurethane foam (SPF) applied on site by Wedge Industries Limited’s own trained and certified crew. Supply, application, quality records and thickness mapping are included in the rate.
Closed-cell SPF gives the highest thermal resistance per millimetre of any commonly specified insulation — initial thermal conductivity 0.020–0.023 W/m·K — and forms a continuous air and vapour seal in a single operation. It is the fastest route to insulating an existing metal roof, cold room or terrace without dismantling the structure.
Technical Specifications
| Property | Value | Basis |
|---|---|---|
| Foam type | Closed-cell rigid polyurethane, water-blown | 2-component, 1:1 by volume |
| Thermal conductivity (initial) | 0.020–0.023 W/m·K | System PDS |
| Closed-cell content | > 90% | System PDS |
| Sprayed in-place density | 35–38 kg/m³ | Supplier recommended spray density |
| Compressive strength | 276 kPa parallel / 166 kPa perpendicular | System PDS |
| Fire behaviour | UL 94HF-1, FMVSS 302 (system dependent) | Certificate supplied with the system used |
| Thickness range applied | 50 / 80 / 100 mm standard; 20–55 mm per pass | Multi-pass build above 55 mm |
| Chemical consumption at 50 mm | 2.13 kg/m² including 12% wastage | Density × thickness × wastage |
| Crew output | Approx. 186 m²/day at 50 mm | 3-person crew, single rig |
| Substrate temperature window | 21–43 °C | Flash coat below 21 °C |
| Service temperature | Not continuously above 107 °C | System PDS |
Applications
- Warehouse and factory metal roofs — heat gain and condensation control, no dismantling required
- Cold storage and cold rooms — walls, floors and vapour sealing; the fastest retrofit route
- Poultry and dairy sheds — 40–50 mm roof foam is the emerging standard across Haryana and Punjab
- Terrace and roof heat-proofing — with an acrylic, elastomeric or polyurea UV top coat
- Pre-engineered buildings — envelope sealing to meet ECBC and Eco-Niwas U-value targets
Installation Method
- Site survey, substrate check and thickness specification against the project U-value.
- Substrate cleaned and dried; masking 2 m beyond the spray zone; overspray screens outdoors.
- Chemicals preconditioned to ≥27 °C; heater and hose set 43–52 °C; pressure ≥82 bar balanced within 10% A to B.
- Test spray on a sacrificial board — cream and tack-free times checked against the system TDS before production spraying.
- Applied in uniform passes with 50% overlap; 50 mm in two passes, 80 mm in two, 100 mm in three, with full inter-pass cool-down to control exotherm.
- Pin-gauge thickness recorded every ~10 m²; one density coupon cut per 250 m² or per drum set.
- Exterior work top-coated for UV protection; interior large areas receive a thermal barrier per building code.
Why buy from Wedge Industries Limited
- Manufacturing and sourcing bases in India, UK, Spain and China; exports to 45+ countries.
- Own Graco-class high-pressure rig and directly employed certified crew — not subcontracted labour.
- Dual-sourced chemical supply (imported spec-grade plus a local fast-replenishment line) so committed jobs are not held up by a shipment delay.
- Supplied-air respirators and documented MDI safety procedure on every job.
- Thickness map, density coupon record, batch numbers and photographs issued as a closing document set.
- Gulf, UK and Africa export enquiries served through our sister export consultancy, ZJELL Limited.
Frequently Asked Questions
How much does spray foam insulation cost per square foot in India?
Indicative applied rates are ₹90–95/sq ft (₹970–1,025/m²) at 50 mm, ₹132–139/sq ft at 80 mm and ₹160–169/sq ft at 100 mm, supply and application included, excluding GST. Confirmed after site survey.
What thickness of spray foam do I need?
50 mm for warehouse roofs, poultry sheds and terraces; 80 mm for cold rooms and chillers; 100 mm for deep-freeze. Final thickness follows the project U-value.
How much area does one drum set cover?
Approximately 188 m² at 50 mm from a 400 kg set, or 207 m² from a 440 kg set, at 38 kg/m³ sprayed density with 12% wastage.
Is the foam closed-cell and water-blown?
Yes — over 90% closed-cell, water-blown chemistry, avoiding HFC blowing-agent phase-out exposure.
What quality records do I receive?
A pin-gauge thickness map, density coupons, chemical batch numbers and site photographs with every job.
Do you cover areas outside Delhi NCR?
Direct crew across Delhi NCR, Chandigarh and Jaipur; trained partner applicators elsewhere in India; Gulf export enquiries welcome.
Request a site survey and firm quotation. Rates above are indicative, exclude GST and are confirmed after survey. Minimum billable area 200 m². Contact Wedge Industries Limited or see our cold storage insulation and roof insulation ranges.
