Cut Edge Corrosion Treatment

Cut edge corrosion treatment is a process used to protect and repair the exposed edges of metal roofing or cladding where the protective coating has been compromised. This treatment involves applying specialised coatings to prevent further oxidation and rusting, thereby preserving the metal's integrity. By addressing these vulnerable areas, cut edge corrosion treatment helps extend the lifespan of metal structures and prevents more extensive damage from developing over time.

What Is Cut Edge Corrosion Treatment?

Cut edge corrosion treatment is a specialised process designed to protect the exposed edges of metal roofing and cladding where the original protective layer has been removed during cutting or shearing. This treatment involves applying advanced coatings, such as liquid polyurethane like Desmoflex Fiberfix, to create a resilient barrier against moisture and oxygen, which are the primary drivers of corrosion. Studies by the Building Research Establishment (BRE) indicate that untreated cut edge corrosion can reduce the lifespan of metal roofing by up to 50%, leading to premature failure. The treatment not only halts the progression of existing rust but also prevents future oxidation, preserving the structural soundness of the metal. It is particularly effective in challenging environments, such as coastal regions, where exposure to salt and pollutants can accelerate deterioration by up to 25% compared to inland areas according to the Metal Cladding and Roofing Manufacturers Association (MCRMA). By addressing these vulnerable edges promptly, cut edge corrosion treatment significantly extends the lifespan of metal roofing systems, reducing the need for expensive repairs or replacements. Regular upkeep and timely reapplication of protective coatings are crucial to maintaining the long-term effectiveness of the treatment, as recommended by industry experts, such as the British Coatings Federation (BCF).

This approach not only protects your investment but also ensures your metal roofing continues to perform well under various conditions, giving you peace of mind that your structure is safeguarded for years to come.

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What Is The Process Of Cut Edge Corrosion Treatment?

The process of cut edge corrosion treatment involves cleaning the affected metal edges, applying a protective coating, and ensuring the coating cures properly to prevent further corrosion. Initially, the surface is inspected to assess the extent of damage, followed by thorough cleaning to remove rust, debris, and old coatings. A rust inhibitor may be applied to stop existing corrosion before the protective coating, such as Desmoflex Fiberfix, is applied to create a durable barrier against moisture and oxygen. The coating is then allowed to cure, forming a resilient layer over the metal. Finally, a maintenance plan is developed to ensure the long-term effectiveness of the treatment, with regular inspections and reapplications as needed.

Initial Inspection and Assessment
Surface Preparation
Application of Rust Inhibitor
Application of Protective Coating
Curing
Final Inspection and Maintenance Planning

1. Initial Inspection and Assessment

The first step in cut edge corrosion treatment is a comprehensive examination of the metal roofing or cladding to gauge the extent of the corrosion. This evaluation helps pinpoint the specific areas requiring treatment and determines the severity of the damage. According to the Metal Cladding and Roofing Manufacturers Association (MCRMA), this initial assessment is crucial for devising the appropriate treatment strategy, ensuring all affected areas are adequately addressed.

2. Surface Preparation

Once the affected areas are identified, the next phase involves surface preparation, which is pivotal for the success of the treatment. The surface is meticulously cleaned to eliminate dirt, debris, rust, or old coatings, ensuring it is ready to bond with the new protective layer. This preparation often involves mechanical abrasion or chemical treatments to achieve a pristine and smooth surface. The British Coatings Federation (BCF) emphasises that proper surface preparation is essential to guarantee the protective coating adheres effectively, providing enduring protection against corrosion.

3. Application of Rust Inhibitor

If rust is present on the exposed metal edges, a rust inhibitor is applied to neutralise the existing corrosion. This step is vital to arrest the progression of rust and ensure the longevity of the treatment. The Building Research Establishment (BRE) notes that rust inhibitors are particularly effective in stabilising corroded areas before the application of protective coatings, thereby enhancing the overall durability of the metal roofing or cladding.

4. Application of Protective Coating

After the surface is prepared and any existing rust is neutralised, a specialised protective coating, such as Desmoflex Fiberfix, is applied to the exposed metal edges. This coating creates a robust, elastic barrier that shields against moisture, oxygen, and other corrosive elements. Depending on the product specifications and environmental conditions, multiple layers of coating may be required. The MCRMA advises using high-performance coatings like Desmoflex Fiberfix to ensure durable protection, particularly in harsh environments.

5. Curing

Once the protective coating is applied, it is allowed to cure, forming a solid and resilient layer over the treated areas. The curing process is essential as it solidifies the coating, ensuring it adheres properly and provides long-term protection. Curing times can vary depending on the type of coating used and the environmental conditions during application. The BRE recommends monitoring the curing process closely to ensure the coating achieves its full protective capacity.

6. Final Inspection and Maintenance Planning

After the coating has cured, a final inspection is conducted to verify the treatment has been applied correctly and thoroughly covers all affected areas. This inspection ensures the integrity of the treatment and confirms the metal is fully protected. Following this, a maintenance plan is developed, outlining regular inspections and potential reapplications to ensure the long-term effectiveness of the treatment. Regular upkeep, as recommended by the MCRMA, is key to preventing future corrosion and extending the lifespan of the metal roofing or cladding system.

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How Do I Know If My Industrial Roof Needs Cut Edge Corrosion Treatment?

You can tell your industrial roof needs cut edge corrosion treatment if you see rust, discolouration, or peeling along the edges of the metal roofing. When cut edge corrosion occurs signs include; flaking of the protective coating and leaks or water stains inside the building near roof edges. Regular inspections are crucial, especially in harsh environments, to catch these issues early. If you notice any of these symptoms, a professional assessment is recommended to determine the need for treatment.

Rust or discolouration on metal edges.
Peeling or flaking protective coating.
Leaks or water stains near roof edges.
Exposed metal edges.
Cracks or splits near cut edges.
Deterioration in harsh environments.

1. Rust or Discolouration on Metal Edges

Rust or discolouration along the metal edges of your roof sheets are a clear sign of cut edge corrosion, indicating the protective coating has failed. According to the Metal Cladding and Roofing Manufacturers Association (MCRMA), rust formation begins almost immediately when metal is exposed to moisture and oxygen, particularly in the UK’s humid climate. This discolouration not only impacts the appearance of the roof but also signals a weakening of the metal's structural integrity, potentially leading to further degradation if not addressed promptly.

2. Peeling or Flaking Protective Coating

When the protective coating on metal edges starts to peel or flake, it exposes the underlying metal to environmental elements, accelerating the corrosion process. The British Coatings Federation (BCF) reports poor adhesion of coatings, often due to inadequate surface preparation or prolonged exposure to harsh conditions, is a leading cause of this issue. Once the coating fails, the metal becomes vulnerable to moisture, which can quickly lead to rust and subsequent structural compromise.

3. Leaks or Water Stains Near Roof Edges

Leaks or water stains near roof edges are strong indicators cut edge corrosion may be compromising the integrity of the metal roofing. The Building Research Establishment (BRE) has found water ingress through corroded metal can cause significant internal damage, including to insulation and electrical systems. This type of damage is often more costly to repair than the initial corrosion, making early detection and treatment essential.

4. Exposed Metal Edges

Exposed metal edges where the protective coating has worn away are highly susceptible to corrosion. The MCRMA highlights that once metal is exposed, it only takes a few days of exposure to the UK’s moist environment for oxidation to begin. If left untreated, these exposed areas can rapidly deteriorate, leading to more extensive and expensive repairs.

5. Cracks or Splits Near Cut Edges

Cracks or splits near the cut edges of metal roofing or cladding allow moisture to penetrate deeper into the metal, exacerbating the corrosion process. According to the BRE, thermal expansion and contraction often cause these cracks, particularly in climates with significant temperature fluctuations like the UK. These microcracks, though often difficult to detect without regular inspections, can quickly lead to more severe corrosion if not addressed.

6. Deterioration in Harsh Environments

Deterioration in harsh environments, such as coastal areas or industrial zones, is a common sign cut edge corrosion is taking hold. The BRE notes the presence of salt and industrial pollutants can accelerate the corrosion process by up to 25% compared to inland areas. Regular inspections are especially important in these environments to catch early signs of corrosion before they cause significant damage to the roofing system.

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What Are The Best Cut Edge Corrosion Treatments?

The best cut edge corrosion treatments include liquid polyurethane coatings, elastomeric roof coatings, polymeric coatings, and rust inhibitors, all of which provide robust protection for exposed metal edges.

Liquid Polyurethane Coatings
Elastomeric Roof Coatings
Polymeric Coatings
Rust Inhibitors

1. Liquid Polyurethane Coatings

Liquid polyurethane coatings, such as Desmoflex Fiberfix, are highly effective in treating cut edge corrosion due to their exceptional flexibility and durability. These coatings treat cut edge corrosion by forming a resilient barrier on exposed metal edges. This prevents moisture and oxygen penetration which prevents further corrosion. Particularly in challenging environments like coastal areas, where salt exposure accelerates corrosion, liquid polyurethane coatings offer superior protection, ensuring the longevity of metal roofing systems.

2. Elastomeric Roof Coatings

Elastomeric roof coatings are another excellent option for treating cut edge corrosion. These coatings adhere strongly to metal surfaces, providing a flexible shield that can endure thermal expansion and contraction without cracking. This flexibility is crucial in preventing the formation of cracks that could expose the metal edges to corrosive elements. The Metal Cladding and Roofing Manufacturers Association (MCRMA) often recommends elastomeric coatings for their effectiveness in delivering long-term protection against cut edge corrosion.

3. Polymeric Coatings

Polymeric coatings are widely used in the treatment of cut edge corrosion due to their outstanding resistance to environmental factors. These coatings bond effectively to metal surfaces, creating a protective layer that guards against pollutants and moisture. In industrial settings, where exposure to corrosive substances is common, polymeric coatings are particularly beneficial in preventing the rapid progression of cut edge corrosion, ensuring the durability of the metal roofing.

4. Rust Inhibitors

Rust inhibitors are an essential preliminary step in treating cut edge corrosion. Before applying protective coatings, rust inhibitors are used to neutralise existing corrosion on exposed metal edges. By halting the progression of rust, these inhibitors enhance the overall effectiveness of subsequent treatments. The Building Research Establishment (BRE) highlights the importance of using rust inhibitors in combination with other treatments to provide comprehensive protection against cut edge corrosion, ultimately extending the life of metal roofing and cladding systems.

How Much Does Cut Edge Corrosion Treatment Cost?

Cut edge corrosion treatment costs between £54 and £125 per linear metre. The cost of treating cut edge corrosion is influenced by factors such as the size and severity of the affected area, the type of materials used, access and height challenges, location, labour rates, and environmental conditions. Additional considerations include regulatory requirements and the urgency of the project.

Service	Cost Range
Cut Edge Corrosion Treatment	£54 to £125 per linear metre

*These estimates are advisory. Actual costs can vary based on specific project requirements, location, and market conditions.

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Frequently Asked Questions About Cut Edge Corrosion Treatment

Understanding how to effectively address cut edge corrosion is essential for maintaining the longevity and structural integrity of metal roofing systems. The following questions explore the best methods, ideal treatments, and the importance of regular maintenance in preventing and managing cut edge corrosion. Each answer provides insights into how these practices can protect your investment and ensure the durability of your roof over time.

What are the best methods to prevent cut edge corrosion?

The most effective methods to prevent cut edge corrosion include applying specialised protective coatings, such as liquid polyurethane or elastomeric coatings, which provide a robust shield against moisture and oxygen. Regular inspections and timely upkeep are essential for spotting early indications of corrosion and addressing them swiftly. Moreover, selecting premium, corrosion-resistant materials during installation further diminishes the likelihood of cut edge corrosion, ensuring the metal remains well-protected over time.

Which protective coatings are ideal for cut edge corrosion treatment?

Liquid polyurethane coatings, like Desmoflex Fiberfix, and elastomeric roof coatings are optimal for treating cut edge corrosion due to their exceptional flexibility and resilience. These coatings bond securely to metal surfaces, creating a formidable barrier against environmental elements which instigate corrosion. In industrial environments, where exposure to pollutants can hasten the corrosion process, polymeric industrial roof coatings have demonstrated particular efficacy, as endorsed by the Metal Cladding and Roofing Manufacturers Association.

How does regular maintenance reduce cut edge corrosion?

Regular maintenance mitigates cut edge corrosion by facilitating early detection and rectification of issues such as peeling coatings or fissures. Reapplying protective coatings and addressing minor damage preserves the metal’s structural integrity, impeding corrosion from advancing. This proactive approach, emphasised by the Building Research Establishment, extends the longevity of the roofing system and helps avert costly repairs.

How does cut edge corrosion impact the durability of metal roofs?

Cut edge corrosion significantly undermines the durability of metal roofs by causing rust and degradation along the edges, leading to structural compromise. Over time, this corrosion can result in leaks, diminished protection from the elements, and eventually, the necessity for extensive repairs or even replacement. Addressing cut edge corrosion promptly through appropriate treatment is a critical part of commercial metal roof repair.