Accredited. Insured. Nationwide coverage across England, Scotland and Wales.

Cut Edge Corrosion Repair for Commercial and Industrial Metal Roofs Across the UK

Cut edge corrosion is the number one cause of metal roof failure on UK commercial buildings. Left untreated, it spreads from exposed sheet edges into lap joints, compromises weatherproofing and eventually forces a full roof replacement. Caught in time, it can be treated, sealed and protected in days at a fraction of replacement cost.
GET A FREE ROOF SURVEY VIEW ALL SERVICES

ProClad Coatings is Accredited By:

What Is Cut Edge Corrosion and Why Does It Matter?

When metal roofing sheets are manufactured, they are coated with a protective layer that prevents the underlying steel from corroding. When those sheets are cut to size during installation, the cut edges are left uncoated and unprotected. Those raw edges are then exposed to moisture, oxygen and atmospheric pollutants for years on end.

Over time, the original factory coating begins to peel back from those unprotected edges. Rust develops, creeps under the coating and spreads inward along the sheet. What starts as a surface problem at the edge of a roof panel becomes a structural problem that works its way across the entire sheet.

This is cut edge corrosion. It is particularly prevalent across UK commercial buildings because of the country's damp, variable climate, which accelerates the corrosion process considerably. Buildings from the 1980s, 1990s and early 2000s are especially vulnerable, as their original coating systems were not as advanced as modern formulations.

The good news is that when caught early, cut edge corrosion is entirely treatable. The bad news is that most building owners and facilities managers do not notice it until it has already spread significantly.

The ProClad Approach to Cut Edge Corrosion

How to Tell if Your Roof Has Cut Edge Corrosion

You do not need to be on the roof to spot the early warning signs. These are the indicators to look out for
  1. Rust Streaks Running Down the Roof or Walls
     Reddish-brown staining streaking down from roof level is a tell-tale sign that corrosion is active at the sheet edges or fixings above.
  2. Peeling or Blistering Coating at Sheet Edges
     The protective coating lifting away from sheet edges means the bond has failed and the metal beneath is now exposed and corroding.
  3. Visible Orange Discolouration at Sheet Overlaps
     Sheet laps are one of the most common locations for cut edge corrosion to develop. Any discolouration here needs assessment.
  4. Rust Around Fixings and Screw Heads
     Where washers have degraded or fixings have loosened, water ingress causes corrosion to spread outward from each fixing point.
  5. Internal Damp Patches or Staining
     If water is tracking along corroded lap joints and entering the building, you will see damp patches or staining on internal walls and ceilings below the affected area.
  6. Eave Edge Deterioration
     The bottom edges of roof sheets at eaves level are particularly vulnerable because water collects there. Coating breakdown here moves quickly.

If you can see any of these signs, the earlier you act, the lower the cost. Once corrosion reaches the lap joints and compromises the weatherproofing of the sheet, the scope and cost of repair increases significantly.

OUR PROCESS

 How We Treat Cut Edge Corrosion

We follow a proven, structured process on every project. Preparation is where the quality of a cut edge corrosion repair is won or lost. A coating applied over inadequately prepared surfaces will fail quickly. We do not cut corners here.

Step 1 — Free Site Survey

We carry out a thorough inspection of your roof, identifying all areas where cut edges are compromised, where corrosion is active and how far it has spread. You receive a written condition report and a clear, fixed-price quotation before any work is agreed.

Step 2 — Surface Preparation and Rust Treatment

All loose coatings, rust and surface contamination are removed using mechanical abrasion or high-pressure jet washing. Every area of active corrosion is treated and stabilised before any coating is applied.

Step 3 — Corrosion-Inhibiting Primer

 A specialist corrosion-inhibiting primer is applied across all treated edges and overlaps. This reinstates the anti-corrosion protection that the original factory coating has lost and provides the foundation for a long-lasting seal.

Step 4 — Flexible Edge Sealant

A reinforced flexible sealant is applied to all sheet edges, lap joints and vulnerable fixing points. This seals the exposed metal against water ingress and accommodates the thermal expansion and contraction of the metal sheets, which is what causes cheaper repair methods to fail prematurely.

Step 5 — UV-Resistant Protective Topcoat

A UV-resistant protective topcoat is applied to match the existing roof colour and provide long-term waterproof protection. The finish restores the appearance of the roof as well as its performance.

Step 6 — Inspection and Documentation

On completion, we carry out a full inspection and issue your completion certificate, guarantee documents, photographic report and schedule of works carried out.

Cut Edge Corrosion Treatment vs Full Roof Replacement

For most commercial buildings with cut edge corrosion, treatment is far more practical and cost-effective than replacement. Full re-sheeting is only necessary when the metal substrate has lost its structural integrity, which is rare if corrosion is caught and treated in time.

Cut Edge Corrosion Treatment

Full Roof Re-Sheeting

Cost per m2

50 to 70% less than replacement

Full replacement cost

Project duration

Days to weeks

Weeks to months

Business disruption

Minimal

Significant

Roof sheets removed

No

Yes

Waste to landfill

None

High

Lifespan added

15 to 20 years

20 to 25 years

Roof sheets removed

Yes

Not necessary

If your roof sheets are physically compromised beyond treatment, we will tell you that honestly at survey. We do not apply coatings over surfaces that cannot deliver a lasting result.

RESTORING BUILDINGS. PROTECTING ASSETS.

Every Industry. Every Building. One Commitment to Lasting Protection.

Commercial buildings across every sector face the same challenge. Years of weather exposure take their toll on roofs, cladding, gutters and external surfaces. We work with businesses across the following sectors to stop that deterioration before it becomes a costly structural problem.

Commercial Premises and Retail Buildings

 Office buildings, retail units and business park properties where maintaining a watertight, professional exterior is essential.

Warehouses & Distribution Centres

Large-scale profiled metal roofs with extensive sheet overlaps and eave edges. We plan phasing around continuous operations and can work in phases to avoid shutting down loading bays or disrupting stock movement.

Agricultural Buildings

Barns, storage buildings and farm structures in rural environments where coastal or high-moisture exposure accelerates corrosion rates.

Manufacturing Facilities

We work safely in active production environments, coordinating access and timing around shift patterns and operational requirements.

Industrial Estates

Single and multi-unit industrial sites where deteriorating roofs affect both the structural performance and the property value of the estate.

 What Makes ProClad Coatings Different

There is no shortage of painting contractors in the UK. The difference is that we specialise exclusively in commercial and industrial buildings. That focus means better results, better products and site teams who understand the demands of working on occupied commercial properties.

Specialist Commercial Roofing Focus

We work exclusively on commercial, industrial and agricultural buildings. Cut edge corrosion repair is a core part of what we do, not an occasional add-on.

Proven Coating Systems

 We use specialist cut edge corrosion systems from proven manufacturers including Giromax, Liquasil and Tor Coatings, backed by manufacturer warranties of up to 20 years.

Honest Survey Process

We give you a real condition assessment, not just a price for spraying. If treatment is not the right option for your roof, we tell you clearly.

Minimal Disruption

All work is completed from the roof. Your building stays operational throughout. Internal operations are not affected.

Nationwide Coverage

Teams across England, Scotland and Wales. We cover the whole of mainland UK.

Full Documentation on Completion

You receive a photographic completion report, product data sheets, guarantee certificate and schedule of works for your building records and insurance file.

Cut Edge Corrosion Repair — Frequently Asked Questions

If you manage a commercial property and are considering coating or refurbishment work, these are the questions we get asked most often. If your question is not here, call us or submit an enquiry and we will get back to you within one working day.
What exactly is cut edge corrosion?

 It is the rusting that develops along the raw, uncoated edges of metal roofing sheets. When sheets are cut to size during installation, those edges are left without protective coating. Over time, moisture and oxygen attack the exposed metal, causing rust that spreads inward under the coating and along sheet overlaps.
How do I know if my building has cut edge corrosion?

Look for rust streaks on the roof or walls, peeling or blistering coating at sheet edges, orange discolouration at sheet overlaps, rust around fixing points or internal damp patches below the roof. Any of these are signs you need a professional survey.
How long does cut edge corrosion treatment last?

A professionally applied specialist system lasts 15 to 20 years depending on the roof condition and environmental exposure. Systems from leading manufacturers carry warranties of 10 to 20 years.
Will the repair disrupt our operations?

No. All work is carried out from the roof. Your building remains fully operational throughout. We coordinate timing and access to minimise any impact on your day-to-day activities.
Is treatment always better than replacing the roof?

For most buildings, yes. Treatment costs 50 to 70% less than full re-sheeting, takes days rather than weeks and keeps your building operational throughout. Replacement is only necessary when the metal substrate has lost structural integrity, which is rare when corrosion is caught early.
Can you treat cut edge corrosion at the same time as cladding spray painting?

Yes. In many cases we carry out both as part of the same programme of works. Treating cut edges first, then completing the cladding respray, gives the building a comprehensive refurbishment in a single managed project.
How much does cut edge corrosion repair cost?

Cost depends on the size of the roof, the extent of corrosion and the access requirements. We provide a fixed-price quotation after the site survey. There are no hidden charges.
What systems do you use?

We use specialist cut edge corrosion systems from proven manufacturers including Giromax, Liquasil and Tor Coatings. The correct system is specified based on your roof substrate, condition and environmental exposure.

Get a Free Survey Before the Corrosion Spreads Further

The earlier cut edge corrosion is treated, the lower the cost. Every season it goes untreated, it spreads further along the sheet edges and deeper into the lap joints. At some point, treatment is no longer enough and full replacement becomes the only option.

If your roof is showing any of the signs above, book a free site survey. We will assess the condition of your roof, tell you honestly what needs to be done and give you a clear, fixed-price quotation.

No obligation. No pressure. Just an honest assessment.