01559192562 01030503551 01555441359 0572060545 info@emcegy.net 315/34 13 ST, Abu Al-Kheir, New Damietta, Egypt
Government Facilities Sector Polyurethane Foam System

Metal Roof Rehabilitation & Insulation – Al Khayata School

Al Khayata – Damietta, Egypt
01 Jan 2023
General Authority for Educational Buildings

Across 340 m², EMC rehabilitated and insulated the metal roof of Al Khayata School in Damietta by treating corrosion, openings, and joints, followed by Polyurethane Foam insulation and two protective acrylic coats.

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Metal Roof Rehabilitation & Insulation – Al Khayata School

EMC carried out rehabilitation and insulation works for the metal roof of Al Khayata School in Damietta, for the General Authority for Educational Buildings, covering a total area of 340 m².

The works included repairing deteriorated metal sections and treating corrosion, openings, and joints, followed by Polyurethane Foam application to create a continuous thermal and waterproofing layer, two acrylic protective coats, and a final water test before handover.


Scope of Work

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

  • Roof cleaning and washing to remove dust and debris.

  • Sanding and removal of corrosion from metal sheets and fixing points.

  • Application of anti-corrosion coating to treated areas.

  • Cutting and removal of deteriorated metal sections.

  • Securing joints between adjacent metal sheets.

  • Installation of new metal patches over damaged areas.

  • Sealing of large openings using pre-sprayed Polyurethane sections.

  • Reinforcement of joints, openings, and vulnerable areas using fiberglass.

  • Spray application of Polyurethane Foam across the entire roof.

  • Measurement and verification of the required foam thickness.

  • Application of the first acrylic protective coat for UV resistance.

  • Application of the second acrylic coat for complete protection.

  • Water spray testing to simulate rainfall and verify waterproofing performance.

  • Final inspection and handover.

Case Study

The Challenge

The main challenge was corrosion across several metal roof areas, combined with deteriorated and perforated sheets, unsecured joints, and vulnerable areas around corners and openings, requiring extensive rehabilitation before applying the insulation system.

The Solution

The roof was cleaned, corrosion was treated, and deteriorated sections were repaired or replaced. Joints were secured, openings were sealed, and vulnerable areas were reinforced with fiberglass before applying Polyurethane Foam, verifying its thickness, adding two acrylic protective coats, and conducting a final water test.

The Result

The metal roof was rehabilitated with a continuous thermal and waterproofing system and additional UV and weather protection. A final water test was conducted to verify the waterproofing performance before handover.

Project Videos

EMC Company – The Ultimate Thermal and Waterproofing Solutions Using Polyurethane and Polyurea

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