The Cost of Cut Edge Corrosion Repair

How much does cut edge corrosion repair cost? On average, treatment costs range from £45 to £85 per linear metre, depending on factors like roof access, coating type, and condition severity. For full cladding or roof sheet edge restoration, the total project price can vary from £2,000 to £25,000+ depending on scale. T

his article explains what influences these costs, how the process works, and why investing in professional treatment can save thousands in future roof replacement costs.

What Is Cut Edge Corrosion?

Cut edge corrosion is a common issue on industrial and commercial metal roofing and cladding systems.

It typically occurs where the protective coating at the edges of steel roof sheets has deteriorated, exposing the bare metal beneath to oxygen and moisture.

Over time, this causes rusting and delamination, leading to leaks, compromised structural integrity, and ultimately, expensive roof replacements if left untreated.

Why Treat Cut Edge Corrosion Early?

Early treatment prevents further water ingress and extends the lifespan of metal roof sheets by 10–15 years.

It’s particularly important in the UK’s wet climate, where frequent rainfall accelerates corrosion. Timely cut edge corrosion repair also improves a building’s appearance and resale value, while keeping it compliant with health, safety, and insurance requirements.

Average Cost of Cut Edge Corrosion Repair

While prices vary by region and project size, you can expect the following guide costs:

• Small localised repair: £45–£60 per linear metre
• Moderate corrosion with partial coating: £60–£75 per linear metre
• Full edge restoration or coating system: £75–£85+ per linear metre

For an average commercial roof, these figures translate into £2,000–£25,000+ depending on the size of the roof, access requirements, and level of corrosion.

Regular inspections can help reduce costs by identifying damage before it spreads.

Factors Affecting the Cost of Cut Edge Corrosion Repair

• Extent of Damage: Heavier corrosion or delamination requires additional preparation, cleaning, and treatment, increasing overall costs.
• Access Requirements: High or complex roofs may need scaffolding, access platforms, or safety barriers, adding to labour and equipment expenses.
• Coating System Used: Premium coating systems, such as Giromax or Tor Coatings, offer longer warranties but come at a higher initial price point.
• Surface Preparation: Pressure washing, corrosion removal, and priming can make up a significant portion of the cost, particularly for older roofs.
• Roof Condition and Age: Older roofs often have multiple layers of deterioration requiring full re-coating or edge encapsulation.

Typical Process for Cut Edge Corrosion Treatment

At TessCon, our expert roofing team follows a precise, manufacturer-approved process to ensure lasting protection and compliance with all safety standards:

1. Inspection and Survey: A detailed roof survey identifies corrosion levels and the best repair system for the site.
2. Surface Preparation: Cleaning and removing loose rust or coatings using mechanical abrasion and degreasers.
3. Application of Treatment System: High-performance products like Giromax or Tor Elastaseal are applied to seal edges, stop further rusting, and provide UV resistance.
4. Finishing and Quality Control: A top-coat ensures colour matching, durability, and an aesthetically clean finish.

Cost Comparison: Repair vs. Replacement

Replacing an entire metal roof can cost upwards of £120–£180 per square metre, making repair and coating a far more cost-effective alternative.

A well-executed cut edge corrosion treatment can extend a roof’s life by over a decade at a fraction of the replacement cost, typically saving businesses 60–70% overall.

Why Choose TessCon?

TessCon is one of Birmingham’s leading specialists in industrial and commercial roofing. We provide professional cladding and roof coating services across the Midlands and throughout the UK. Our team uses only certified coating systems and follows full safety compliance under the Building Safety Act 2022.

We also offer free site surveys and quotations for property owners and facility managers looking to maintain or restore metal roofing systems.

Conclusion

The cost of cut edge corrosion repair ultimately depends on the size of your roof, the coating system chosen, and the extent of the damage.

However, it remains one of the most cost-effective ways to preserve your metal roofing system and prevent full-scale replacement. Investing in professional treatment now can save substantial costs — and disruption — in the future.