Cut edge corrosion is a common problem on industrial and commercial metal roofs. It usually starts around the exposed edges of coated roof sheets, especially where sheets overlap or where the factory coating has started to break down.
At first, it may only look like surface rust. Over time, if left untreated the corrosion will spread under the coating and weaken the roof sheet. This will lead to holes and perforations within the sheet material – which will ultimately lead to leaks.
Early signs of cut edge corrosion developing along exposed roof sheet edges.
What Is Cut Edge Corrosion?
Cut edge corrosion happens when the exposed edge of a metal roof sheet starts to rust. Metal roof sheets are usually supplied with a protective coating, but the cut edges and overlaps can become more exposed as the roof ages.
Once moisture gets beneath the coating, corrosion can begin.
What Causes Cut Edge Corrosion?
Most cases are caused by long-term exposure to weather. Rain, frost, sunlight and standing water all contribute to coating breakdown.
Older industrial buildings throughout Birmingham, Wolverhampton, Walsall and the wider West Midlands often show signs of cut edge corrosion due to ageing roof systems and lack of maintenance.
Early Signs to Look For
Cut edge corrosion is easier and cheaper to treat when it is caught early, failing to treat failing sheets early can result in new replacement sheets being needed.
Surface rust and coating failure along roof sheet laps.
- Rust along roof sheet edges
- Flaking or lifting coating
- Orange or brown staining
- Corrosion around sheet overlaps
- Blistering paintwork
- Small areas of exposed metal
- Leaks near roof laps or gutters
Why You Should Not Ignore It
Cut edge corrosion rarely stays in one place. Once the protective coating fails, water can easily travel beneath it and affect a much larger area of the sheet. Leaving the issue untreated can lead to roof leaks, damaged insulation, internal water staining and higher repair costs.
How Cut Edge Corrosion Is Treated
The correct treatment depends on the condition of the roof, this is why we highly recommend getting a specialist in as soon as you notice any potential cut edge corrosion.
Roof Inspection
The first step is to inspect the affected areas, including sheet laps, gutters, fixings and roof edges.
Cleaning and Preparation
The roof surface is cleaned to remove dirt, debris and loose coating.
Preparation work carried out before corrosion treatment and coating application.
Rust Treatment
Corroded areas are mechanically prepared to remove loose rust before specialist primers are applied.
Protective Coating
A roof coating system is then applied to provide long-term protection.
Protective coating system applied to treated roof sheets.
When Is Treatment the Best Option?
Cut edge corrosion treatment is usually suitable when the roof sheets remain structurally sound and the corrosion has not become severe.
You can learn more about our roof coating systems and industrial roofing services.
When Might Roof Sheets Need Replacing?
If corrosion has become widespread or the roof sheets have lost structural integrity, replacement may be the better option.
Recent Cut Edge Corrosion Project
During a recent project, corrosion had developed along several exposed sheet edges. The affected areas were prepared, treated and coated to extend the life of the roof without requiring replacement.
Completed cut edge corrosion treatment project on an industrial roof.
Cut Edge Corrosion Treatment in the West Midlands
Robinsons Roofing & Cladding works with factories, warehouses, landlords and facilities managers throughout the West Midlands and across the UK.
Our services include cut edge corrosion treatment, gutter coating and lining, rooflight replacement and industrial roof refurbishment.
Frequently Asked Questions
Is cut edge corrosion serious?
It can become serious if left untreated. Early intervention is normally much more cost-effective.
Can cut edge corrosion be repaired?
Yes. Many roofs can be successfully repaired and protected using specialist treatment systems.
Does cut edge corrosion mean I need a new roof?
Not necessarily. Many roofs can be refurbished and protected without full replacement.
How often should an industrial roof be inspected?
At least once a year, although older roofs may benefit from more regular inspections.
Book a Roof Inspection
If you’ve noticed signs of cut edge corrosion, rust or coating failure, arranging an inspection now could help avoid more expensive repairs later.
Robinsons Roofing & Cladding provides industrial roofing services across the West Midlands and throughout the UK.
Call: 01902 475388
Email: info@robinsonsroofingandcladding.co.uk
Book an inspection today to find out the most cost-effective way to protect your roof.
Information on roof coating systems can also be found through the HD Sharman website.
