How To Cut Corrugated Metal Roofing

In residential, commercial, and industrial contexts, corrugated metal roofing is a reliable and affordable roofing material. It can survive severe weather and is lightweight and straightforward to install. Yet, cutting corrugated metal roofing can be difficult, particularly if you need more equipment or knowledge. Correct corrugated metal roofing cutting is essential to prevent material damage and structural integrity issues. This is a step-by-step guide on how to cut corrugated metal roofing to assist you:

  • Measure the Length of the Roofing Panel

The first step in cutting corrugated metal roofing is to measure the panel length you need to cut. You can do this using a measuring tape and marking the cut line with a pencil.

  • Secure the Panel

Next, you need to secure the panel that you will be cutting. You can do this by clamping the panel onto a stable work surface. Ensure that the clamps are tight enough to hold the panel in place.

  • Choose the Right Tool

The next step is to choose the right tool for cutting the corrugated metal roofing. You can use a circular saw, a jigsaw, or a metal shear. Use a tool with a fine-toothed blade that can cut through metal cleanly for best results.

  • Install the Cutting Blade

Once you have chosen the right tool, install the cutting blade. Ensure that the blade is sharp and securely attached to the tool.

  • Start Cutting

Now you are ready to start cutting the corrugated metal roofing. Begin by aligning the cutting blade with the marked cut line. Use a steady hand to guide the tool along the line. Cut slowly and carefully to avoid damaging the panel or injuring yourself is essential.

  • Repeat the Process

Repeat the cutting process for each panel that you need to cut. Remember to take breaks if you feel fatigued or the tool starts to overheat.

  • Finish the Edges

After cutting the panel, you may notice rough or jagged edges. To finish the edges, use a metal file to smooth them out.

Tools and Materials Required for Cutting Corrugated Metal Roofing

Corrugated metal roofing is a popular choice for roofing material due to its durability, low maintenance, and resistance to weather conditions. However, cutting corrugated metal roofing can be challenging, especially for those who have never worked with this material before. Fortunately, cutting corrugated metal roofing can be made easier and safer with the right tools and materials.

The following are the essential tools and materials required for cutting corrugated metal roofing:

  • Measuring Tape: A measuring tape is essential to accurately measure the length and width of the metal roofing.
  • Pencil And Chalk Line: A pencil and chalk line mark the metal roofing before cutting.
  • Circular Saw: A circular saw with a metal-cutting blade is ideal for cutting corrugated metal roofing. A saw with a blade size of 7 ¼ inches or larger is recommended.
  • Tin Snips: Tin snips are designed to cut through thin metal and are ideal for cutting small sections of corrugated metal roofing.
  • Power Shears: Power shears are ideal for cutting longer sections of corrugated metal roofing and provide a straight, clean cut.
  • Safety Equipment: Safety goggles, earplugs, and gloves are essential when cutting corrugated metal roofing. They protect the eyes, ears, and hands from flying debris.
  • Ladder: A sturdy ladder is necessary to reach the roof safely and comfortably.

Before cutting the corrugated metal roofing, it is essential to prepare the work area. The area should be clean, dry, and free of any debris. It is also essential to secure the metal roofing with clamps or weights to prevent it from moving while cutting.

Safety Precautions When Cutting Corrugated Metal Roofing

Cutting corrugated metal roofing can be a dangerous task if not done with proper safety precautions. The sharp edges of the metal can cause severe cuts, and the metal itself can be heavy and unwieldy, making it a potential hazard. Here are some safety precautions to take when cutting corrugated metal roofing:

  • Wear Protective Gear

Before cutting the corrugated metal roofing, wear appropriate protective gear such as gloves, safety goggles, and respirators. Gloves will protect your hands from sharp edges and flying debris. Safety goggles will shield your eyes from metal chips and dust. A respirator protects your lungs from breathing in harmful particles or fumes.

  • Use the Right Tools

It is essential to use the right tools when cutting corrugated metal roofing. A circular saw or reciprocating saw with a metal cutting blade is recommended. Avoid using abrasive cutting tools such as a grinding wheel or angle grinder. They can create sparks that may ignite nearby materials.

  • Secure the Metal Sheet

Before cutting the metal sheet, ensure it is secured to prevent it from moving or falling. You can use clamps or a vice to hold the sheet firmly.

  • Cut in a Safe Location

Choose a safe location to cut the corrugated metal roofing. It should be well-ventilated and away from any flammable materials. Avoid cutting near power lines or other electrical equipment.

  • Cutting Techniques

When cutting the metal sheet, slow and steady movements prevent the blade from binding or overheating. Ensure the saw blade is fully engaged with the metal sheet before cutting. Use a metal file or sandpaper to smooth out sharp edges once you have completed the cut.

Common Mistakes to Avoid When Cutting Corrugated Metal Roofing

Corrugated metal roofing is a popular and durable option for residential and commercial buildings. However, cutting corrugated metal roofing can be challenging, even for experienced DIYers and professionals. Mistakes made during the cutting process can compromise the roof’s integrity and result in leaks and other issues. 

  • Using the Wrong Tools

One of the most common mistakes when cutting corrugated metal roofing is using the wrong tools. It is essential to use tools designed specifically for cutting metal, such as tin snips or a metal-cutting circular saw. Using tools not intended for cutting metal can result in jagged edges and uneven cuts, compromising the roof’s integrity.

  • Incorrect Measurements

Another common mistake is taking incorrect measurements. Taking precise measurements and marking the metal accordingly before cutting is crucial. Please do so to avoid uneven cuts and wasted material, leading to additional costs and delays in the project.

  • Ignoring the Direction of the Corrugations

Corrugated metal roofing has a specific pattern of ridges and valleys that provides strength and stability. Cutting against the direction of the grooves can weaken the roof’s structure and compromise its ability to withstand harsh weather conditions.


Water Damage and Roofing of Round Rock is located at 30 Woodland Ln, Round Rock, TX. From Austin-Bergstrom International Airport(AUS) head east toward E McNeil Rd, and then turn left toward S Brown St. Continue straight onto S Brown St and then turn right onto E McNeil Rd. Turn left at the 2nd cross street onto S I-35 Frontage Rd/Morrow St and then take the ramp on the left onto I-35 S. Merge onto I-35 S. Afterwards, take the exit toward US-183 Hwy S and then take the ramp to U.S. 183 S. Merge onto US-183 Hwy S and then keep left to continue on 183 Toll. Continue onto S Hwy 183 (signs for Texas 71 W/Ben White Blvd/Riverside Dr) and then use the left 2 lanes to turn left to merge onto State Hwy 71 E. Exit onto Spirit of Texas Dr and after 0.4 miles you have arrived at Water Damage and Roofing of Round Rock.

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For additional questions, call us at (512) 566-5511.

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Water Damage & Roofing of Round Rock is located in Round Rock, Texas. We can be reached on Yellow Pages and Go My Local. If you would like a more personalized experience you can call us at (512) 566-5511 any hour of any day.

We value the needs of our clients and we always make sure that we meet them with utmost care and excellent results.

No matter how simple the roofing service may be, our highly skilled and trained staff members always give their best.