Cut Edge Corrosion Repair

Project overview

The site is a rugby club with a profiled metal roof where cut edge corrosion had broken through the coating along the seams. The brief was to repair the affected laps and restore a protected finish. Work ran over a short programme using the roof's existing stair ladder access, with edge protection in place.

The challenge

The corrosion was concentrated at the seams of the corrugated metal sheeting, where rust had broken through the original coating along the cut edges. No client activity was taking place below or on the roof during the works, so the main constraints were height, weather and keeping the roof surface safe to walk.

Site constraints

• Roof edge protection installed by others, checked before each shift
• Materials raised and lowered by hoist line, not carried up
• Work stopped in wind, rain or on wet sheeting
• No client staff or activity in or below the work area during roof works

Our approach

Our approach here was pretty standard, Access was simple either from fixed stairs or a tower the scaffolders put up alongside the edge protection.

Preparation and delivery

The whole roof was pressure washed first, with washing directed away from operatives and freshly washed sheeting left to dry before being walked on. Corroded seams were then prepared by hand, removing loose rust, scale and flaking coating back to a sound, keyed surface, with debris collected and bagged as it was removed.

System

The prepared seams were coated with a Noxyde Plus base coat, with Noxyde tape bedded into the affected laps once it had dried. Two further coats of Noxyde Plus were then applied over the tape, giving three coats overall across the treated seams.

Before and after

Seams before washing and reinforced Noxyde system and after.

Project gallery

Result

The affected seams now carry a full three-coat Noxyde Plus system with tape reinforcement, sealing the cut edge corrosion and giving a consistent finish across the roof. The roof was left clean and uniform, with all plant, waste and barriers cleared and the site handed back to the club's site contact.

Related services

• Industrial Coatings
• Roof Repairs & Coatings
• Building Maintenance