**Insulation and surface treatment were completed for 3,940 m² of metal roofing at El-Warda Tea Factory – El-Anany Group, using polyurethane foam to ensure effective insulation, surface protection, and extended service life.**
Integrated Metal Roof Restoration & Insulation – El Warda Tea Factory
EMC carried out the rehabilitation and insulation of the metal roofs at El Warda Tea Factory, El Anany Group, in 6th of October City, covering a total area of 3,940 m². The project focused on resolving existing roof defects and installing an integrated polyurethane foam system to provide effective thermal and waterproof insulation while protecting the metal roof against moisture, rainfall, and weather exposure.
Scope of Work
- Cutting and removing excess metal sheet sections and preparing the roof for treatment.
- Bending metal sheet edges into the rainwater drainage channels to prepare for a continuous insulation layer between the roof sheets and drainage system.
- Thorough sanding of affected areas to remove corrosion and prepare the metal surface.
- Complete cleaning of the roof surface.
- Additional sanding to remove excess material and hardened debris where required.
- Cleaning and preparation of rainwater drainage channels.
- Covering large openings and holes with metal sheet patches and securely fixing them to eliminate movement beneath the insulation system.
- Securing junctions between the metal sheets and skylight openings using reinforced duct tape to minimize movement between adjoining elements.
- Treating corroded areas with a zinc phosphate-based coating to limit further corrosion.
- Reinforcing treated areas with duct tape and applying an additional anti-corrosion protective coating.
- Treating rainwater drainage channels to protect them against corrosion.
- Treating skylight edges with geotextile-reinforced acrylic coating for additional protection and stabilization before polyurethane foam application.
- Applying polyurethane foam in three layers, 1 cm per layer, to achieve a final thickness of 3 cm (±5 mm).
- Applying the first acrylic protective coat manually to ensure detailed surface coverage.
- Spray-applying the second acrylic protective coat to achieve complete and uniform coverage and protect the polyurethane foam against UV radiation and weather exposure.
