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Poultry Farms Sector Polyurethane Foam System

Metal Roof Thermal & Waterproofing Project – Ayad Hatchery

Gamasa Industrial Zone – Dakahlia, Egypt
10 Oct 2020
Ayad Poultry Investment

Across 548 m², EMC rehabilitated and insulated the metal roof of Ayad Hatchery using Polyurethane Foam, including corrosion treatment, damaged-area repairs, and a final protective coating.

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Metal Roof Thermal & Waterproofing Project – Ayad Hatchery

EMC carried out rehabilitation and insulation works for the metal roof of Ayad Hatchery in the Gamasa Industrial Zone, for Ayad Poultry Investment, covering a total area of 548 m².

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


Scope of Work

  • Inspection of the metal roof and identification of damaged and corroded areas.

  • Measurement of temperature before insulation works.

  • Roof washing and cleaning to remove dust and contaminants.

  • Sanding and treatment of rust and corroded areas.

  • Cutting and removal of deteriorated metal sections.

  • Repair and replacement of damaged areas.

  • Application of zinc phosphate primer to treated areas for corrosion protection.

  • Surface preparation before insulation application.

  • Spray application of Polyurethane Foam across the roof and gutters.

  • Formation of a continuous thermal and waterproofing layer.

  • Application of a protective coating over the Polyurethane Foam for UV and weather resistance.

  • Post-insulation temperature measurement.

  • Final inspection and handover.

Case Study

The Challenge

The main challenge was the deterioration of several metal roof areas, including corrosion and damaged sections vulnerable to rainwater ingress, combined with high temperatures reaching 50.1°C before insulation, requiring roof rehabilitation before applying the insulation system.

The Solution

The roof was cleaned, corroded areas were treated, and deteriorated sections were removed and repaired, with zinc phosphate primer applied to affected areas. Polyurethane Foam was then spray-applied to form a continuous thermal and waterproofing layer, followed by a final protective coating.

The Result

The metal roof was rehabilitated and insulated, with the measured temperature decreasing from 50.1°C before insulation to 32.5°C after completion, a reduction of 17.6°C, while improving protection against rainwater ingress and weather exposure.

Project Videos

**Thermal and waterproofing insulation for deteriorated poultry farms using Polyurethane Foam Spray.**

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