Transforming a Leaking Industrial Roof in Dubai — Before & After

This case study documents a complete industrial roof waterproofing project completed by Dubai Roof Seal at a large manufacturing facility in Dubai Industrial City. The client had been dealing with multiple active leaks during rain events, rust staining on the internal ceiling, and mould growth around the production area — all traced back to a failing corrugated metal roof that had never been properly waterproofed.

The Problem: Original Corrugated Metal Roof

The original corrugated metal roof was approximately 12 years old. On inspection, our team identified the following failure points:

• Failed screw washer seals — hundreds of fastener holes had degraded rubber washers, each acting as a water entry point.
• Open longitudinal lap joints — the seams where panels overlap had completely lost their butyl sealant tape due to UV degradation.
• Surface rust and corrosion — oxidation had eaten through the galvanised coating in multiple locations, thinning the metal.
• Leaking skylights — three polycarbonate skylights had cracked perimeter seals allowing water ingress around their frames.

The Solution: Full Restoration System

Rather than recommending full roof replacement (which would have cost significantly more and required complete production shutdown), our engineers proposed a full restoration system using EPDM and polyurethane technology:

The Result: After

The completed roof transformation delivered a fully waterproofed, seamless surface with zero leak points. The white cool roof topcoat reduced the internal warehouse temperature by an estimated 6–8°C during the summer months — a measurable reduction in the facility's cooling costs.

Left: original corrugated metal roof. Right: after EPDM and polyurethane system applied.

Key Project Details

Lessons for Warehouse & Industrial Facility Owners

This project illustrates a pattern we see repeatedly across Dubai's industrial areas. A metal roof that has never been waterproofed, or was waterproofed cheaply 5–8 years ago, reaches a tipping point where multiple leak sources are all active simultaneously. At that point, patch repairs are ineffective — the only solution is a complete system restoration.

The good news is that a full restoration costs a fraction of full roof replacement, takes days not weeks, and comes with a long-term warranty. If your warehouse roof is over 7 years old and you have not had a professional inspection, we strongly recommend scheduling one before the next rain season.

"The white cool roof topcoat alone reduced our summer cooling costs noticeably. The waterproofing was the priority, but the energy saving was a welcome bonus." — Facility Manager, Dubai Industrial City