Techniques for Cutting Metal Roofing

A metal roof is a durable and long-lasting option for any building, be it residential or commercial. However, when it comes to cutting metal roofing, many people find themselves at a loss. It’s not a difficult task, but it does require the right tools, techniques, and safety measures. In this guide, we will walk you through everything you need to know about cutting metal roofing.


What You Will Need

Before we get started, let’s take a look at the tools and equipment you will need to cut metal roofing.

  • Cut Off Wheel:The most common tool for cutting metal roofing is a cut-off wheel. These are abrasive wheels that come in different types and sizes, but the most commonly used is a 5-inch cut off wheel.
  • Safety Gear: You’ll also need some safety gear, including gloves, eye protection, and a face shield or mask. Metal shavings can be dangerous, and the sparks created during cutting can cause eye injuries or burns.
  • Measuring Tape:It’s essential to take accurate measurements before cutting metal roofing, so a measuring tape is a must-have.
  • Marker: You’ll need a marker to mark the cut lines on the metal roofing.
  • Sawhorses:You’ll need something to support the metal roofing while cutting, and sawhorses are a great option.


A Guide on How to Cut Metal Roofing

Now that you have all the necessary tools and equipment let’s move on to the cutting process.

  1. Measure and Mark the Cut Lines

The first step in cutting metal roofing is to measure and mark the cut lines accurately. You can use a measuring tape and marker to do this. Make sure to measure twice and mark once to avoid any mistakes.

  1. Secure the Metal Roofing

Once you have marked the cut lines, it’s time to secure the metal roofing. Place it on top of sawhorses or any other suitable support, ensuring that it is stable and won’t move during the cutting process.

  1. Put on Safety Gear

Before you start cutting, put on your safety gear, including gloves, eye protection, and a face shield or mask. It’s crucial to protect yourself from metal shavings and sparks that may fly off during the cutting process.

  1. Select the Right Cut Off Wheel

Choosing the right cut-off wheel is crucial to get clean and accurate cuts. For cutting metal roofing, we recommend using a 4.5-inch diameter abrasive wheel. There are various types of abrasive wheels available, including aluminum oxide, silicon carbide, and zirconia alumina. For cutting metal roofing, a zirconia alumina wheel is recommended.

  1. Install the Cut Off Wheel

Once you have selected the right cut-off wheel, it’s time to install it on your angle grinder. Follow the manufacturer’s instructions for installing the wheel, and make sure it’s securely in place.

  1. Start Cutting

Now it’s time to start cutting the metal roofing. Hold the angle grinder firmly with both hands and start cutting along the marked lines. Use a light touch and let the weight of the angle grinder do most of the work. Avoid putting too much pressure, as this can cause the cut-off wheel to break or wear down quickly.

  1. Follow the Cut Lines

Make sure to follow the marked cut lines closely to get a clean and accurate cut. If you need to make any adjustments, stop the grinder, and make the necessary changes before continuing.

  1. Finish the Cut

Once you have cut all the way through the metal roofing, turn off the angle grinder and remove the cut-off wheel. Use a file or sandpaper to smooth out any rough edges or burrs.

  1. Repeat the Process

If you need to make additional cuts, repeat the process of securing the metal roofing, measuring and marking the cut lines, putting on safety gear, selecting the right cut-off wheel, installing the wheel, and starting the cutting process.


Tips for Cutting Metal Roofing

  • Use the Right Angle Grinder:A high-quality angle grinder is essential for cutting metal roofing. Look for a grinder with a powerful motor and a comfortable grip that’s easy to control.
  • Keep the Angle Grinder Cool:Cutting metal roofing generates a lot of heat, so it’s essential to keep the angle grinder cool. Take frequent breaks to allow the grinder to cool down and prevent it from overheating.
  • Cut in a Well-Ventilated Area: Cutting metal roofing generates dust and fumes, so it’s important to work in a well-ventilated area. Open windows or doors and use a fan to circulate the air.
  • Avoid Cutting in Wet Conditions:Wet metal roofing can be challenging to cut, so it’s best to avoid cutting in wet conditions. If you have to cut wet metal roofing, make sure to dry it thoroughly first.
  • Take Your Time:Cutting metal roofing requires patience and precision. Don’t rush the process, and take your time to ensure that you get clean and accurate cuts.
  • Practice Safety Measures:Always wear your safety gear and practice proper safety measures to avoid any accidents or injuries.



Cutting metal roofing may seem daunting at first, but with the right tools, techniques, and safety measures, it’s a straightforward process. Remember to take accurate measurements, mark the cut lines, secure the metal roofing, put on your safety gear, select the right cut-off wheel, and start cutting. Take your time, follow the cut lines closely, and use the tips mentioned above to get clean and accurate cuts. With these guidelines, you can confidently cut metal roofing for any project.