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Agricultural Sector Polyurethane Foam System

Metal Roof Thermal & Waterproofing Project – Star Feed

New Salhia – Sharqia, Egypt
01 Jan 2020
El Tokhy Group

Across 1,900 m², EMC carried out thermal and waterproofing works for Star Feed’s metal roof using Polyurethane Foam, including joint and opening treatment followed by a protective coating.

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Metal Roof Thermal & Waterproofing Project – Star Feed

EMC carried out thermal and waterproofing works for the metal roof of Star Feed in New Salhia, for El Tokhy Group, covering a total area of 1,900 m².

The works included treating joints and openings around chimneys, cables, and pipes before spray-applying Polyurethane Foam to form a continuous insulation layer, followed by a protective coating against UV exposure and weather conditions.


Scope of Work

  • Inspection of the metal roof and identification of joints and openings.

  • Measurement of roof surface temperature before insulation.

  • Sealing and treatment of joints between metal sheets.

  • Treatment of openings surrounding chimneys, cables, and pipes.

  • Sealing of fasteners, connections, and vulnerable roof areas.

  • Surface preparation before insulation application.

  • Spray application of Polyurethane Foam across the entire roof.

  • Insulation of areas surrounding chimneys and roof penetrations.

  • Formation of a continuous thermal and waterproofing layer.

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

  • Post-insulation surface temperature measurements to verify thermal performance.

  • Final inspection and handover.

Case Study

The Challenge

The main challenge was the high metal roof surface temperature caused by direct solar exposure, exceeding 51°C, combined with joints and openings around chimneys, cables, and pipes that created vulnerable points for heat transfer and water ingress.

The Solution

Joints, openings, and areas surrounding chimneys, cables, and pipes were treated and sealed before Polyurethane Foam was spray-applied across the entire roof to form a continuous insulation layer, followed by a protective coating for UV and weather resistance.

The Result

The insulation system significantly reduced the roof surface temperature, with post-installation measurements ranging from 24.2°C to 28.3°C compared with over 51°C before insulation, while also treating joints and openings and improving protection against water ingress.

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