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Factories, Warehouses & Cold Storage Sector Polyurethane Foam System

Metal Roof Rehabilitation & Insulation Project – El Sayad Knitting Factory

El Mahalla El Kubra – Gharbia, Egypt
01 Apr 2023
El Sayad Knitting Company

Across 5,700 m², EMC rehabilitated and insulated the metal roof of El Sayad Knitting Factory using Polyurethane Foam, including corrosion treatment, vulnerable-area repairs, and two acrylic protective coats.

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Metal Roof Rehabilitation & Insulation Project – El Sayad Knitting Factory

EMC carried out rehabilitation and insulation works for the metal roof of El Sayad Knitting Factory in El Mahalla El Kubra, for El Sayad Knitting Company, covering a total area of 5,700 m².

The works included roof cleaning, corrosion treatment, and repair of damaged sections and joints, followed by spray application of Polyurethane Foam to form a continuous thermal and waterproofing layer, finished with two acrylic protective coats for UV and weather resistance.


Scope of Work

  • Site inspection and identification of damaged and vulnerable roof areas.

  • Washing and cleaning of the roof to remove accumulated dust and contaminants.

  • Removal and treatment of corrosion from metal sheets.

  • Securing and tightening joints between metal roof sheets.

  • Cutting and removal of severely deteriorated sections.

  • Installation and fixing of new metal sheets in damaged areas.

  • Application of anti-corrosion materials to treated sections.

  • Reinforcement of joints and vulnerable areas using fiberglass.

  • Surface preparation before insulation application.

  • Spray application of Polyurethane Foam across the entire roof.

  • Formation of a continuous thermal and waterproofing layer.

  • Application of the first acrylic protective coat for UV resistance.

  • Application of a second acrylic coat to complete the protective system.

  • Final inspection and handover of the completed works.

Case Study

The Challenge

The main challenge was widespread rust and corrosion across several areas of the metal roof, combined with loose joints, deteriorated and perforated metal sheets, accumulated contaminants, and insufficient existing protection against water ingress and heat transfer.

The Solution

The roof was thoroughly cleaned to expose damaged areas before corrosion was removed, deteriorated sections were repaired, and loose joints were secured. Vulnerable areas were reinforced with fiberglass, followed by Polyurethane Foam application and two acrylic protective coats to complete the insulation system.

The Result

The metal roof was rehabilitated and its corroded, damaged, and vulnerable areas were treated before completing an integrated thermal and waterproofing system, providing protection against water ingress and heat transfer while protecting the foam layer from UV exposure and weather conditions.

Project Videos

**EMC provides advanced thermal and waterproofing solutions using Polyurethane and Polyurea, delivering outstanding insulation performance, durability, and long-lasting protection.**

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