Cut-edge corrosion: why it’s a problem, and how we can solve it

Cut-edge corrosion is the breakdown of the edge of metal cladding sheeting. It is a common problem. In fact, it’s the result of a design fault in the manufacture of coated metal cladding sheet types (including Plastisol and Pvf2, amongst others).

When the visible edge of the metal cladding is exposed to the elements, it begins to peel back and deteriorate. Not only does this look unsightly, it causes weaknesses in the structure that allow water to enter your property, resulting in a wealth of damage.

Left untreated, cut-edge corrosion can cause irreversible damage that will leave costly and disruptive cladding replacement as your only option. (In fact, the average cost of cladding replacement is three times more than the cost of refurbishment and repair.)

Why does cut-edge corrosion occur?

When the faulty coated metal cladding was cut to size in the factory (before it arrived with builders on site), a thin, uncoated line of metal was unveiled. This left this area unprotected; it is, unfortunately, also the area of the roof most likely to succumb to peeling and corrosion.

Furthermore, when the metal expands, the factory coating can lift, which exposes the uncoated metal edge even further. This exposure can lead to entire coating delamination, resulting in the cut-edge corrosion eating further through the metal. At this point, replacement is the only possible solution.

In addition to faulty metal cladding, the weather is key cause of cut-edge corrosion. The British climate means buildings encounter a great deal of moisture from cold and wet weather, expediting corrosion.

How do we treat cut-edge corrosion?

Our cut-edge corrosion work begins by inspecting your property to measure the extent of the damage. The area on or around the corrosion is cleaned using specialist equipment with a variety of spray nozzles suitable for the surface and the level of dirt accumulation.

Once dry, we then mechanically remove corrosion with a hand-held grinder. This gets rid of loose particles and leaves a smooth edge ready for treatment, with the peeling feathered back to remove ridges. We can then apply the repair and paint systems which often means beginning with a primer and using a layer of fibre tape to provide a reinforced seal.

After the chosen paint system is installed, a topcoat is applied by brush to cover the tape and finish the watertight seal of the cut edge. If required the roof can be re-sprayed entirely so that it all matches and looks like a new roof.

We use various tried and tested paint systems, each selected based on your specific property’s requirements and supplied by our trusted partners:

Tor Elastaseal™ Fibretex: an effective, durable flexible system, applied by brush. It is safe and easy to install, and suitable for most roof types.
7500 AlkythaneⓇ: an anti-corrosion system, with an exceptionally corrosion-resistant topcoat. It is highly-efficient in areas of high-salinity (e.g. coastal properties).
Advantage Graphene: a hybrid system for industrial and commercial roof refurbishment. It is designed to target metal roof rust whilst providing corrosion protection.
Sharmans Seamsil: a silicone-based system and treatment formulated specifically to prevent the adverse effects of rust and chemical corrosion, industrial pollution, ageing, and weathering, and is particularly effective in marine/coastal environments.

Take a look at the video of cut-edge corrosion repair, which includes before and after results of our work. You can also find some images of the team in action here.

What do you need to do next?

With trusted supplier relationships, multiple years of cut-edge corrosion repair expertise, and all work backed by a ten-year guarantee, our team here at Cladding Coatings confidently repair your damaged cladding, treating your building with industry-leading systems to ensure it remains watertight.

If you’re worried about the cut-edge of your metal cladding sheeting corroding, and the subsequent damage it can cause, give our team a call. We’d be happy to advise you on next steps and visit your site to provide a free survey and no-obligation quote.

You can find out more about the way we work, and see more images of our team doing their specialist jobs, in our compact Cut Edge Corrosion Leaflet.