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Government Facilities Sector Polyurethane Foam System

Metal Roof Rehabilitation & Polyurethane Foam Insulation | Directorate of Education – Damietta

Damietta, Egypt
06 Jul 2025
Eng. Mohamed El-Bergisy

EMC carried out rehabilitation and waterproofing works for metal roofs covering an area of 283 m² at the Directorate of Education in Damietta, using polyurethane foam (PUF) with a thickness of 3 cm ± 5 mm, along with an Acrylic protective coating to resist ultraviolet (UV) radiation.

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Metal Roof Rehabilitation & Polyurethane Foam Insulation – Directorate of Education, Damietta

EMC carried out rehabilitation, repair, and insulation works for the metal roofs of the Directorate of Education in Damietta, covering a total area of 283 m², under the supervision of Eng. Mohamed El-Borgisy. The project aimed to address widespread rust and deteriorated sections of the metal sheets, restore the roof surface, and prepare it for the application of a thermal and waterproofing insulation system using polyurethane foam.

Scope of Work

  • Inspection of the metal roofs and identification of damaged areas and deteriorated metal sheets.
  • Complete surface cleaning and preparation to remove dust, debris, and surface rust.
  • Cutting and removal of damaged and deteriorated metal sheet sections.
  • Sanding of areas requiring additional treatment and surface preparation.
  • Supply and installation of new metal sheets to replace the removed sections.
  • Fixing and riveting the newly installed metal sheets to ensure proper stability and sealing.
  • Application of Polyurethane Foam (PUF) at a thickness of 3 cm ± 5 mm to provide thermal and waterproofing insulation.
  • Application of an Acrylic protective coating as a final protective layer against UV radiation and weather conditions.

Case Study

The Challenge

The main challenges included widespread rust across the metal roof surfaces, along with deteriorated sheet metal sections requiring removal and replacement. This required proper roof rehabilitation and surface preparation before carrying out the insulation works.

The Solution

The metal roof surfaces were cleaned and prepared, with deteriorated sections removed and replaced with new metal sheets. Sanding was also carried out on areas requiring additional treatment. After rehabilitating the roof and securing the new sheets, polyurethane foam was sprayed at a thickness of 3 cm ± 5 mm, followed by an acrylic protective coating to protect against UV radiation and weather conditions.

The Result

The roof rehabilitation works and polyurethane foam insulation system improved the condition of the metal surfaces while providing thermal and waterproofing insulation. The acrylic protective coating also helps protect the insulation system against UV radiation and weather conditions, contributing to extended roof service life and reduced future maintenance requirements.

Project Videos

Polyurethane Foam Insulation System Suitable for Metal Roofs

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