How to Cut Corrugated Roofing

Corrugated roofing sheets are widely used in a multitude of applications throughout the roofing industry. They are highly durable, versatile in design and easy to use by both seasoned professionals and avid DIYers. Within the installation process, it will sometimes be necessary to cut your corrugated roofing to perfectly accommodate the size of your roof structure. Thankfully, with the correct tools and techniques, this can be done quickly, easily and safely.

Corrugated roofing sheets are available in a multitude of different material types. In this handy article, we will talk you through the cutting methods for a variety of materials to ensure you achieve a high-quality, professional looking finish for your roof.

Table of Contents

Health & Safety

  • PPE – Always ensure you are using appropriate PPE when cutting any type of corrugated roofing sheet. This may include protective gloves, goggles, dust mask as well as appropriate footwear and clothing.
  • Stick to Guidelines – Although the steps we have provided are typical for each type of corrugated sheet, always ensure that you are reading and sticking to any further advice and guidelines provided by the manufacturer.
  • Clear Space – Keep your workspace clear and tidy to avoid possible injury. Once a piece of the sheet has been cut, move across to a safe place out of the way before continuing.
  • Tools – Use all tools with appropriate caution and care. Some of the tools mentioned can be very sharp, so protect your hands and use sensibly.

Handy Tips

  • Placing a sheet of cardboard or plywood beneath the corrugated sheet on the workbench, will help to protect the surface from scratches and marks.
  • Take your time to accurately measure and mark up your corrugated roofing sheet. Once cut, there is no way of patching the sheets back together.

How to Cut Plastic Corrugated Roofing

Best Tool to Use

A Stanley knife is the most simplistic and practical option for cutting PVC corrugated sheets, especially for DIYers. This tool will give you optimum control for a more accurate cut.

What Else Will I Need?

  • Workbench
  • Pen
  • Straight edge Ruler
  • Tape measure

Step-by-Step

  1. To ensure the PVC sheet stays in place whilst cutting, secure to a flat stable workbench surface.
  2. Create a guideline for the cuts on the covering film using a pen. Take your time doing this to ensure the measurements are as accurate as possible. Make pen marks on both ends of the sheet and use a straight edge ruler to join with a line across.
  3. Use a sharp Stanley knife to carefully cut along the pen marks.
  4. If you find a thicker area of the sheet when cutting, you can use a band saw and fine blade to finish off the cut and create a clean finish.

How to Cut Corrugated Polycarbonate Roofing

Best Tool to Use

Although corrugated polycarbonate can be cut using power tools, it is recommended that a fine tooth saw is used instead. A tool such as this will provide enhanced accuracy and control, lessening the chance of error and sheet damage.

What Else Will I Need?

  • Workbench
  • Air-compressor/vacuum
  • Pen
  • Straight edge ruler
  • Tape measure

Step-by-Step

  1. To prevent movement and vibration whilst cutting, secure the polycarbonate sheet to a stable workbench.
  2. Using a measuring tape, carefully measure the sheet and make pen marks at each end on the cover sheet. Join the marks together, creating a straight, precise line along a straight edge ruler.

TIP! – The cover sheet should not be removed during the cutting process. Polycarbonate sheets typically have one side which is UV protected. This is the external face. The cover sheet will help you to indicate which side this.

  1. Cut along the marked pen line using a fine tooth saw. Maintain careful control over the saw, making sure not to stop once started to create a clean and consistent edge.
  2. After trimming the sheet, you may notice that swarf has entered the sheet. To remove, use an air-compressor or vacuum to blow the fillings out.

How to Cut Corrugated Fibre Cement Roofing Sheets

Best Tool to Use

There are a variety of tools that are well-suited to cutting corrugated fibre cement. You could use a score and snap knife, fibre shears or even a hand guillotine.

What Else Will I Need?

  • Workbench
  • Pen
  • Pencil
  • Tape measure

Step-by-Step

  1. Position and secure the fibre cement sheet onto a stable workbench.
  2. Carefully measure the sheet using a measuring tape, then mark out the cutting area using a pen or pencil. Using a straight edge ruler to join the marks will provide you with a more accurate cutting line.
  3. Using a score and snap knife, hand guillotine or fibre shears, cut along the cut marks you have created. Position the sheet so that any dust blows away from your person instead of towards.

How to Cut Corrugated Bitumen Roofing

Best Tool to Use

When cutting along the length of corrugated bitumen sheets, it is recommended to use a coarse bladed saw or Stanley knife. For width wise cutting, use either a circular saw or coarse bladed saw instead. If you are working with a more complex shape, tin snips provide better control over the cut.

What Else Will I Need?

  • Workbench
  • Pencil/chalk line
  • Straight edge ruler
  • Tape measure

Step-by-Step

  1. Carefully measure the bitumen sheet using a measuring tape and mark out a cutting guide. Create precise markings at each end of the sheet, then join with a pencil or chalk line.
  2. When cutting through a bitumen sheet you have multiple tool options. For tricker shapes, use well oiled tin snips to cut.
  3. Alternatively, you can use a course bladed saw or Stanley knife to cut along the length of the sheet.
  4. When cutting across width wise, make the cut carefully using a course bladed saw or circular saw.

How to Cut Corrugated Metal Roofing Panels

Best Tool to Use

The recommended tool to use when cutting corrugated metal roofing will differ dependant on the type of metal. If the metal is aluminium, use tin snips to cut. However, if the sheet metal is steel, it is advised that you use a pair of straight edge snips instead.

What Else Will I Need?

  • Workbench
  • Magnet
  • Pencil
  • Straight edge ruler
  • Tape measure

Step-by-Step

  1. To ensure optimum stability whilst cutting, lay the corrugated metal sheet onto a flat and secure workbench surface.
  2. Use a tape measure to carefully measure out the cutting area. Make marks at both ends of the sheet (length or width wise), then join using a pencil line.
  3. Before cutting, it is important to identify whether the metal sheet made from is steel or aluminium. If you do not already know, you can easily determine by holding a magnet up to the sheet. If the magnet is attracted, then the sheet is steel, however if it is not, then sheet is made of aluminium.
  4. Use either tin snips or straight edge snips to cut along the previously made cut line.

How to Cut Corrugated Fibreglass Roofing Panels

Best Tool to Use

To cut corrugated GRP sheets, it is recommended that you use a circular saw with a plywood blade.

What Else Will I Need?

  • Workbench
  • Utility knife
  • Pencil
  • Straight edge ruler
  • Tape measure

Step-by-Step

  1. Position the GRP sheet onto a stable and secure workbench surface.
  2. Measure across or along the corrugated sheet using a measuring tape, then mark out cutting points with a pencil. Use a straight edge ruler to join the pencil marks and create a cutting guideline.
  3. Line up the blade with the pencil mark on one side of the sheet, then begin cutting carefully, moving the saw slowly towards the edge to start. Make sure you keep a steady pace whilst cutting, don’t push too fast and hold the sheet loosely.

TIP! – Allowing the sheet to bounce whilst cutting will minimise the chances of the GRP cracking.

  1. As you reach the end of the cut line, increase the speed that you are moving the circular saw. Once the GRP section is completely cut, move this piece to the side.
  2. Remove the cutting bur by pulling a utility knife along the cut edge of the sheet.

What Is the Best Saw to Use for Cutting Corrugated Plastic Roofing?

The best saw to use for cutting corrugated plastic roofing is a circular saw with a general-purpose, carbide-tipped blade. Whilst using this tool, you must fully secure the plastic sheet to the workbench to avoid binding saw or moving it from the cutting guideline.

What Is the Best Saw to Use for Cutting Corrugated Sheet Metal Roofing?

The two best saws to use when cutting corrugated sheet metal roofing are an angle grinder or circular saw. An angle grinder gives you more control when cutting corrugated metal so you can make freeform and round cuts. It also leaves a smoother edge for a professional looking finish. When using an angle grinder, it is best to use a diamond wheel. Although a standard wheel can be used, the corrugated metal may wear this down. You may also use a circular saw with a blade designed for metal. A diamond blade is recommended for the best results. A circular saw is best for cutting longer lengths in straight lines.

To Conclude

With the correct tools and knowledge, cutting your corrugated roofing sheets can be a simple and easy task for anyone. If this post has inspired you to start your own corrugated roofing project, take a browse through our high-quality range of corrugated sheets to get you started. We stock an affordable selection in a wide range of materials from leading brands you can trust.

Alternatively, if you have any other questions or queries, don’t hesitate to get in touch with our friendly customer service team who will be more than happy to help. Simply give them a call on 01295 565565, email sales@roofingmegastore.co.uk, or leave a message in our handy live chat.