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Factories, Warehouses & Cold Storage Sector Polyurethane Foam System

Metal Roof Treatment & Insulation – Warehouse 11 | Arma Detergents & Soap Company

10th of Ramadan City, Sharqia, Egypt
15 Dec 2024
ARMA Detergents & Soap Company

**EMC** completed the treatment and insulation of **4,600 m²** of metal roofing at Warehouse 11, ARMA Detergents & Soap, using **polyurethane foam**, with rust treatment, replacement of deteriorated sections, and rainwater gutter protection.

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Metal Roof Treatment & Insulation at Warehouse 11 – Arma Detergents & Soap Company

EMC carried out comprehensive metal roof treatment and insulation works at Warehouse 11 of Arma Detergents & Soap Company in 10th of Ramadan City, Sharqia, covering a total area of 4,600 square meters. The project utilized a Polyurethane Foam insulation system to treat deteriorated sections, limit rust development, improve roof performance, and provide integrated thermal and waterproof insulation, while protecting the metal surface against UV radiation and weather conditions.

Scope of Work

  • Cutting and removing deteriorated metal sheets, followed by installation and riveting of new replacement sheets.
  • Sanding all rust-affected areas and preparing them for treatment.
  • Applying Zinc-Rich Primer to rust-affected areas to help limit corrosion and protect the metal surface.
  • Complete washing and cleaning of the roof surface before insulation.
  • Cleaning and sanding the rainwater drainage channel and treating it with zinc primer.
  • Installing a fiberglass-reinforced polyester system for the rainwater drainage channel to provide additional protection and reduce the risk of water leakage.
  • Spray application of 30 mm ± 5 mm Polyurethane Foam across the entire roof area for thermal and waterproof insulation.
  • Application of two acrylic protective coating layers to protect the Polyurethane Foam from UV radiation and weather conditions.
  • Final inspection to ensure completion of the treatment and insulation works and delivery of the fully treated and insulated roof.

Case Study

The Challenge

The main challenges included extensive rust across the metal roof, along with corroded and deteriorated sections that required removal and replacement before the insulation works. The rainwater drainage channel also required treatment and preparation to protect it and minimize the risk of water leakage, requiring comprehensive roof treatment before applying the insulation system.

The Solution

The roof was comprehensively treated and prepared by removing deteriorated sections, replacing them with new metal sheets, and securing them with rivets. Rust-affected areas were thoroughly sanded and treated with zinc primer to help limit corrosion and protect the metal surface. The rainwater drainage channel was also treated and reinforced with a fiberglass-reinforced polyester system to provide additional protection and minimize the risk of water infiltration.

After completing the surface preparation, 30 mm ± 5 mm Polyurethane Foam was spray-applied across the 4,600-square-meter roof area, followed by two acrylic protective coating layers to provide UV and weather resistance and protect the insulation system.

The Result

The insulation system helped reduce heat transfer and lower the temperature of sun-exposed roof surfaces by approximately 20–30%, improving the building’s thermal performance and reducing the impact of heat on interior spaces. It also provides effective protection against UV radiation and weather conditions, helping minimize potential deterioration and future maintenance requirements.

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