Metal Roof Restoration
Cut Edge Corrosion
Halt the spread of damaging cut edge corrosion on your metal roof before it's too late. Our specialist treatments restore weathertightness and extend roof life by up to 20 years - at a fraction of the cost of replacement.
What is cut edge corrosion treatment?
Cut edge corrosion treatment is a specialist refurbishment system for profiled metal roofs that have started rusting along the lower exposed edge of the sheets. The process involves removing loose oxide, applying a rust-inhibiting primer, sealing the cut edge with elastomeric mastic tape, and finishing with a reinforced UV-stable polymer topcoat. It typically extends roof life by 20+ years at 60–80% lower cost than full re-sheeting.
Why Specialist Treatment, Not Standard Painting
Cut edge corrosion cannot be solved by simply painting over the rust. The exposed steel core must be mechanically prepared, chemically stabilised with a rust-inhibiting primer, and sealed at the vulnerable cut edge with mastic tape before topcoating, otherwise corrosion continues underneath the paint film and reappears within months.
Generic roof paints lack the elasticity to bridge the active corrosion movement and the UV stability to last on south-facing sheets. Specialist systems use polymer-modified coatings designed specifically for profiled steel and aluminium, tested to recognised independent test standards.
Our 4-Stage Treatment Process
Every treatment follows a strict four-stage sequence: condition survey with photographic record, mechanical preparation of all corroded edges, application of a rust-inhibiting primer plus mastic tape to seal the cut edge, then two coats of reinforced topcoat colour-matched to the existing roof. The work is carried out without disrupting building operations.
Most standard industrial roofs up to 5,000m² complete in five to ten working days. Our rope-access trained operatives eliminate the need for full scaffolding in most cases, significantly reducing project costs and timescales.
Treatment vs Full Re-Sheeting
Full metal re-sheeting typically costs £40–£70 per square metre and requires removal of the existing roof, structural protection of the building interior, and licensed disposal of the old sheets. Cut edge treatment costs £8–£18 per square metre with the building remaining fully occupied throughout, typically 60–80% cheaper for the same long-term weathertight outcome.
Treatment is the correct solution when sheet profiles are still structurally sound and corrosion is in the early to mid stages. Where sheets have perforated or distorted, our survey will recommend partial sheet replacement or over-roofing instead; we provide an honest condition-led recommendation.
What Does Cut Edge Corrosion Treatment Cost?
Cut edge corrosion treatment typically costs £8–£18 per square metre depending on corrosion severity, access requirements, and the system specified. A 3,000m² industrial unit equates to approximately £24,000–£54,000, and includes a 20-year guarantee long-term.
Pricing is fixed in writing following our free condition survey. Where rope access is feasible we eliminate scaffolding costs entirely, which on larger units can reduce project pricing by 20–30% versus competitor quotations that scaffold by default.
Key Features
Stop Corrosion Spread
Our treatments halt the oxidation process and prevent further deterioration of your metal roof sheets.
Seal Exposed Edges
Purpose-formulated coatings seal and protect the vulnerable cut edges where corrosion typically begins.
Restore Weathertightness
Re-establish a watertight seal along eaves, ridges, and flashings that have been compromised by corrosion.
Prevent Costly Replacement
Early treatment can extend roof life by 20+ years, avoiding the expense of complete re-sheeting.
Rope Access Capability
Our trained rope access technicians can treat difficult-to-reach areas without expensive scaffolding.
Colour-Matched Finishes
Treatments can be colour-matched to your existing roof sheets for a seamless aesthetic finish.
The Advantages
Why Choose This Solution?
Our cut edge corrosion service delivers lasting results with minimal disruption to your business operations.
Our Process
From initial survey to final inspection, we follow a proven methodology to ensure quality results every time.
Condition Survey
We photograph and document all areas of corrosion, providing a comprehensive condition report.
Surface Preparation
Loose rust and scale is removed by wire brushing and the surface is cleaned and degreased.
Primer Application
A rust-inhibiting primer is applied to stabilize the metal and provide a key for the topcoat.
Protective Coating
Multiple coats of elastomeric sealant are applied, creating a flexible, long-lasting barrier.
Common Questions
What causes cut edge corrosion on metal roofs?
When profiled metal roof sheets are cut to length during installation, the factory-applied protective coating is removed at the cut edge, leaving raw metal exposed. Over time, moisture, air, and atmospheric pollutants oxidise the exposed metal, creating rust that gradually spreads up the face of the sheet. The galvanised protective layer degrades first, followed by rust propagation into the base steel.
How much does cut edge corrosion treatment cost?
Cut edge corrosion treatment typically costs £8–£18 per square metre depending on the extent of corrosion, roof access requirements, and the system specified. This compares with £40–£70 per square metre for full metal re-sheeting, making treatment 60–80% cheaper in most cases. We provide free condition surveys and fixed-price quotations with no obligation.
How do I know if my commercial roof has cut edge corrosion?
The most visible signs are orange or brown rust staining running down the face of roof sheets from the lower cut edge, dark streaking on external walls below the roofline, and visible pitting or flaking at the sheet edges. In more advanced cases, you may notice water ingress during heavy rain. We offer free condition surveys with a written report and photographic documentation.
Is cut edge corrosion treatment better than replacing the roof?
In most cases, significantly better value, typically 60–80% cheaper than full re-sheeting. Treatment is the correct choice when the sheet profiles are still structurally sound and corrosion is in the early to mid stages. Our free survey will assess the extent of corrosion and give an honest recommendation on whether treatment or replacement is the right course of action.
How long does cut edge corrosion treatment last?
Our treatment systems are guaranteed for 20 years via a guarantee. The treatment halts active corrosion, seals the cut edge with specialist mastic tape and primer, and applies a reinforced polymer topcoat system that prevents moisture re-entry for the full guarantee period.
Can you treat cut edge corrosion without scaffolding?
Yes, in the majority of cases. Our rope access-trained operatives can safely treat most commercial metal roofs without the need for scaffolding, significantly reducing costs and enabling faster project completion. Full scaffolding is only specified where access restrictions make rope access impractical.
How long does cut edge corrosion treatment take?
Most standard industrial roofs can be treated within two to four working days. The treatment involves cleaning, mechanical preparation, rust-inhibiting primer, mastic tape application, and a two-coat topcoat system, typically applied in sequence over consecutive days. The building remains occupied and operational throughout.
Cut Edge Corrosion Across the UK
We deliver cut edge corrosion from our Hellaby, Rotherham headquarters to commercial buildings across England, Scotland and Wales. Explore some of our most active service areas:
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Ready to Get Started?
Contact us today for a free, no-obligation site survey and quotation.