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Factories, Warehouses & Cold Storage Sector Polyurethane Foam System

Metal Roof Thermal & Waterproofing Project – Tri-Chem Chemicals Factory

6th of October City – Giza, Egypt
01 Apr 2022
Tri-Chem Chemicals Factory

Across 3,800 m², EMC rehabilitated and insulated the metal roof of Tri-Chem Chemicals Factory using Polyurethane Foam, including corrosion, joint, and skylight treatment followed by a protective coating.

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Metal Roof Thermal & Waterproofing Project – Tri-Chem Chemicals Factory

EMC carried out rehabilitation and insulation works for the metal roof of Tri-Chem Chemicals Factory in 6th of October City, covering a total area of 3,800 m².

The works included roof cleaning, corrosion treatment, and rehabilitation of joints and skylight areas, followed by Polyurethane Foam application at a thickness of 3 cm ± 5 mm to form a continuous thermal and waterproofing layer, finished with a protective coating for UV and weather resistance.


Scope of Work

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

  • Removal of accumulated dust, debris, and contaminants from the roof and gutters.

  • High-pressure washing and surface preparation.

  • Cutting and removal of deteriorated sections.

  • Securing metal sheets, joints, screws, and fixing points.

  • Sanding and removal of rust from corroded areas.

  • Application of zinc-based anti-corrosion primer to treated sections.

  • Treatment and reinforcement of joints and vulnerable areas.

  • Treatment of skylights and surrounding areas using fiberglass reinforcement.

  • Spray application of Polyurethane Foam across the entire roof at 3 cm ± 5 mm thickness.

  • Formation of a continuous, seamless thermal and waterproofing layer.

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

  • Final inspection of the roof and drainage areas.

  • Completion and handover of the insulation system.

Case Study

The Challenge

The main challenge was the accumulation of dust and debris across the roof and gutters, corrosion of metal sections, open joints, damaged skylight areas, and vulnerable fixing points that could increase the risk of water ingress and heat transfer.

The Solution

The roof was cleaned and washed, corroded areas were treated with zinc-based primer, and metal sheets, joints, skylights, and vulnerable areas were repaired and reinforced. Polyurethane Foam was then applied at 3 cm ± 5 mm thickness, followed by a final protective coating.

The Result

The roof was rehabilitated with a continuous, highly adherent thermal and waterproofing layer without joints or seams, while protecting roof connections, skylight areas, and gutters and improving resistance to water ingress, heat transfer, and weather exposure.

Project Videos

Thermal and Waterproofing Insulation Using Polyurethane Foam for the Roof of One of the Steel Structures at Tri-Chem Construction Chemicals Factory

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