- What it is
- Spraying or injecting two-component polyurethane that expands and cures into a rigid, closed-cell insulating foam.
- Best for
- Roofs, walls, cold rooms, tanks, containers, ducts and irregular surfaces.
- Key benefit
- Very low thermal conductivity with no joints or thermal bridges at gaps.
- Typical λ-value
- Around 0.022–0.028 W/m·K for closed-cell PU (per product)
- Where we work
- Dubai, Abu Dhabi, Sharjah, Ajman, Umm Al Quwain, Ras Al Khaimah and Fujairah
- Next step
- Free site inspection and a written, itemised quotation
PU insulation in the UAE for roofs, walls and cold rooms
ESA Technical Services LLC is a Dubai-based technical services company, established in 2006, specialising in GRP works, waterproofing, insulation and installation across the UAE. Our PU insulation in the UAE is applied by trained spray technicians for buildings, industrial facilities and cold storage.
In the Gulf, heat flows into buildings for most of the year, and air-conditioning is the largest energy cost. Closed-cell polyurethane has one of the lowest thermal conductivities of common insulation materials, so it achieves a given insulation value with less thickness. Sprayed in place, it seals gaps and bonds to the surface.
What is PU foam insulation?
PU (polyurethane) foam insulation is made by mixing two liquid components, an isocyanate and a polyol blend, that react and expand on site into a rigid, closed-cell foam. Sprayed onto roofs and walls or injected into cavities, it forms a seamless insulating layer with very low thermal conductivity that also adheres strongly to the substrate.
Closed-cell foam traps a low-conductivity gas in tiny sealed cells, giving strength, low water absorption and high insulation per millimetre. Sprayed foam on roofs must be protected from UV, which degrades the surface, using an elastomeric coating (acrylic or PU) or a covering layer such as screed. Fire performance requirements for the building are met with the right product and protection.
When do you need pu foam insulation?
These are the signs and project triggers we see most often on UAE sites:
- Hot top floors and warehouses. Roofs with little or no insulation
- Metal roofs and walls. Where condensation and radiant heat are problems
- Cold rooms and cold stores. Continuous insulation without joints
- Water tanks and pipes. Reducing heat gain into stored water
- Containers and cabins. Site offices and accommodation units
- Irregular surfaces. Domes, curved roofs, around steelwork
Our step-by-step pu foam insulation process
Survey and design
We assess the substrate, existing layers, moisture and the target thermal performance, then set foam density and thickness.
Preparation
Surfaces are cleaned and dried, and loose material and oil removed. Adjacent areas, equipment and openings are masked.
Priming (if required)
A primer is applied to metal or porous substrates where the system requires it.
Spraying
Foam is sprayed in passes of controlled thickness. Too thick in one pass causes overheating and poor quality, so layers are built up.
Thickness checks
Thickness is probed across a grid and topped up where needed to meet the design.
Protection
A UV-protective elastomeric coating is applied on exposed foam, or a protective covering or screed is installed per the design.
Handover
Thickness records, product data and care guidance are provided.
Technical specifications
Values below are typical ranges. Final specifications are confirmed per project from drawings, operating conditions and the manufacturer's technical data sheets.
| Parameter | Typical specification |
|---|---|
| Foam type | Two-component closed-cell rigid polyurethane |
| Density | Typically ~35–60 kg/m³ depending on application (roof grades often ~40–55) |
| Thermal conductivity (λ) | Around 0.022–0.028 W/m·K (product-dependent, aged value) |
| Closed-cell content | Typically >90% |
| Thickness | Per design, commonly 25–75 mm for roofs |
| Compressive strength | Per product; roof grades suited to maintenance foot traffic |
| Protection | Elastomeric acrylic or PU coating, or screed/covering |
| Fire performance | Per project specification |
Materials and methods
- PU spray systems: two-component isocyanate and polyol from established suppliers
- Primers: where required for metal or porous substrates
- UV coatings: elastomeric acrylic or aliphatic PU
- Spray equipment: heated, proportioned spray rigs for consistent mixing
Benefits of pu foam insulation
High insulation per mm
Low λ-value means strong performance with less thickness and weight.
Seamless
No joints, gaps or fixings to create thermal bridges.
Low water absorption
Closed cells resist moisture, and the roof layer can also help shed water.
Fast application
Large areas covered quickly with minimal disruption.
Follows any shape
Ideal for domes, profiled metal and around steelwork.
Lower cooling costs
Reduced heat gain means less work for air-conditioning.
Applications across the UAE
| Sector | Typical application | Why it fits |
|---|---|---|
| Warehouses & industrial | Metal roofs and walls | Cuts radiant heat and condensation |
| Villas & buildings | Flat concrete roofs | Cooler top floors |
| Cold storage | Cold rooms, freezer stores | Continuous insulation envelope |
| Utilities | Tanks and pipework | Limits heat gain into water |
| Site facilities | Containers and cabins | Liveable temperatures |
Spray PU vs XPS boards vs mineral wool
| Factor | Spray PU foam | XPS boards | Mineral wool |
|---|---|---|---|
| Thermal conductivity | Very low | Low | Moderate |
| Joints | None (seamless) | Board joints | Batt joints |
| Moisture | Low absorption | Very low absorption | Absorbs if wet |
| Irregular shapes | Excellent | Poor | Fair |
| Fire | Needs protection/rated product | Needs protection | Non-combustible |
| Best use | Roofs, metal buildings, cold rooms | Inverted roofs | Walls, fire-rated applications |
Quality control and safety
- Substrate moisture and temperature checked before spraying
- Mix ratio and temperature monitored on the rig
- Pass thickness controlled
- Thickness probed on a grid
- UV protection applied promptly
- Isocyanate controls: PPE, respirators, exclusion zones and ventilation
Why choose ESA for pu foam insulation
- Insulation and waterproofing together. We make them work as one system
- Trained spray crews. Safe handling and consistent foam quality
- Since 2006. UAE building envelope experience
- Measured thickness. Verified, not assumed
PU Foam Insulation: frequently asked questions
How thick should PU foam insulation be on a Dubai roof?
It depends on the thermal target and the rest of the roof build-up. Roofs commonly use around 25–75 mm. We calculate it for your requirement, including green building targets where they apply.
Does PU foam need to be covered?
Yes, on roofs. UV degrades exposed foam, so it's protected with an elastomeric coating or a covering layer such as screed.
Can PU foam also waterproof a roof?
Closed-cell foam is highly water-resistant and, with a proper coating, can form part of a roof protection system. Details and drainage still need proper waterproofing design.
Is spray foam safe for occupants?
Once cured, PU foam is inert. During spraying, occupants and other trades are kept away and the area is ventilated. Our crews wear full respiratory protection.
Written by the ESA Technical Services teamLast updated: