How To Stop Cut Edge Corrosion On Industrial Buildings In The United Kingdom

Cut edge corrosion is one of the most common and costly forms of deterioration affecting profiled metal roofing sheets across industrial buildings in the UK. It typically occurs at the exposed edges of factory-coated steel sheets—especially where they’ve been cut during installation or along overlaps. Over time, exposure to the elements causes the protective plastisol or PVDF coating to peel back, allowing moisture to penetrate the underlying steel. If left untreated, this can lead to severe rusting, sheet failure, and eventually internal leaks or structural compromise. Thankfully, there are effective, proven ways to stop cut edge corrosion in its tracks and extend the life of your roof.

1. Identify Early Warning Signs

Early detection is key. Common indicators include peeling or curling of the coating along sheet overlaps, brown rust stains trailing from edges, and bubbling or cracking of the finish. On buildings over 10 years old—especially in coastal, exposed, or industrial pollution-heavy areas—roof inspections should be scheduled annually. Professional roofing contractors use drones or detailed walkover surveys to detect the onset of corrosion before it spreads.

2. Thoroughly Prepare the Affected Areas

Stopping cut edge corrosion begins with thorough preparation. This involves removing all loose rust, flaky coating, and contaminants. Wire brushing or abrasive pad sanding is typically used, followed by power washing or solvent wiping to ensure a clean substrate. Proper preparation is vital—applying coatings over poorly cleaned surfaces will trap moisture and accelerate corrosion beneath the surface.

3. Treat and Prime with Anti-Corrosion Products

Once cleaned, the exposed metal must be treated with a high-performance rust converter or primer. In the UK, many specialists use zinc-rich or epoxy-based primers that bond directly to bare metal and inhibit future oxidation. These products chemically stabilize rust and create a solid base for the final coating system. This stage also ensures better adhesion and long-term durability of the topcoat.

4. Apply a Flexible Cut Edge Corrosion Treatment Coating System

The next step is the application of a cut edge corrosion treatment system—typically a two- or three-part flexible coating designed to seal the joint and prevent further degradation. Cut edge corrosion treatment systems such as Desmoflex Thix, Giromax® EdgeProtect or Tor Coatings Elastaseal are commonly used across UK industrial estates due to their longevity and resistance to UV, rain, and temperature fluctuations. These coatings remain elastic, allowing them to expand and contract with the sheet, preventing cracking and peeling over time.

For severe corrosion where the underlying sheet is already weakened, reinforcing tapes or scrim may be embedded into the coating during application. This creates a waterproof and weather-resistant barrier over the compromised edge.

5. Seal End and Side Laps

Side and end laps are the most vulnerable junctions where capillary action can draw moisture between sheets. After coating the top surface, professional contractors also treat the sheet edges and fasteners with a compatible sealant. This prevents further water ingress and adds a second layer of protection. In some cases, specialist fastener caps or over-banding systems may be used to reinforce heavily corroded zones.

6. Routine Maintenance to Prevent Recurrence

Even after treatment, industrial roof maintenance and inspections will ensure the problem doesn’t return. Any minor coating damage caused by tradespeople, wildlife, or weather should be quickly repaired to maintain the integrity of the system. In the UK climate, annual roof surveys—especially in autumn—are a wise investment.

In Summary

Cut edge corrosion is preventable and treatable, but only if tackled early and correctly. The combination of skilled inspection, proper surface preparation, and application of flexible corrosion-resistant coating systems is the gold standard for UK industrial buildings. Whether managing a logistics warehouse in Birmingham or a manufacturing plant in Leeds, investing in proper cut edge corrosion treatment can extend your roof’s life by 10–20 years and save thousands in future repairs or replacements.

David Simmons Cut Edge Corrosion Prevention Expert Cut Edge Corrosion UK