The Best Way to Cut Metal Roofing Panels in 4 Easy Steps

cut roofing panel post

Cutting metal roofing panels accurately is crucial for your project’s success. 

In this blog post, we will teach you the best way to do it. It is important to use the right tools and follow the correct steps, or you could damage your roof and yourself in the process.

So, follow these steps to achieve precise, clean cuts with the right tools and techniques.

Step 1: Gathering the Right Tools

Selecting the right tools is crucial for achieving precision in metal roofing projects, make sure that you have all of the necessary tools and supplies to complete the job.  You don’t want to begin the project only to realize you're missing a crucial piece of equipment or material halfway through the project, so let's run through our checklist.

Here’s what you’ll need for cutting metal panels:

  • Tin Snips: Essential for small, detailed cuts. Choose the right type for the cut direction—straight, left, or right.
  • Electric Metal Shears: Ideal for effortless, long straight cuts.
  • Circular Saw with Metal Cutting Blade: Perfect for handling large panels. Always use a blade made specifically for metal to prevent damage.
  • Angle Grinders: Effective for quickly cutting through metal with precision. Ensure to use appropriate safety guards and handles.
  • Measuring Tape and Marker: Critical for accurate measurement. Use a permanent marker for clear marks.
  • Personal Protective Equipment (PPE): Safety first! Gloves, goggles and ear protection need to be taken into account. We'll discuss the specific types of PPE needed in detail later in the blog.


There are several different types of metal cutting tool that you can use, each with its own pros and cons.

 

 Tools Pros:

  • Tin Nips: Inexpensive, lightweight, and perfect for small, quick cuts. Ideal for thin metal sheets and fine detail work.
  • Electric Metal Shears: Provides a quick and clean cut through thicker metal sheets without much physical effort. Suitable for long, straight cuts.
  • Circular Saw with Metal Cutting Blade: Ideal for cutting large panels and long, straight cuts. When equipped with a metal cutting blade, it offers high precision and clean edges.
  • Angle Grinders: Powerful enough to cut through thicker metal sheets quickly, making them suitable for heavy-duty cutting tasks.

Tools Cons:

  • Tin Nips: Limited to thinner materials. Frequent use on thicker materials can lead to hand fatigue and may damage the snips.
  • Electric Metal Shears: More expensive than tin snips and requires some practice to handle efficiently. Not suitable for intricate cuts or curves.
  • Circular Saw with Metal Cutting Blade: Requires a special blade for metal cutting. Higher risk of injury due to the power of the tool; thus, it demands experience and extra safety precautions.
  • Angle Grinders: Due to their power and the nature of their operation, angle grinders pose higher safety risks, including the potential for sparks and debris.

So, which one should you use? It depends on your project.

If you're working with thin sheets of metal, tin snips may be the best option. But if you're working with thicker sheets, you may want to opt for metal shears or an angle grinder.

Step 2: Measuring and Marking the Panels

Now that you have all of your tools, it's time to prepare the metal panel for the cutting process. The first step is to measure the length and width of the metal sheet so you know how much metal you need to cut. Once you have your measurements, use a marker to draw a line on the metal panel where you will make your cut. This will help you stay on track and avoid any mistakes.

Accuracy here is vital to avoid wastage and ensure a perfect fit, so keep in mind the next tips:

  • Accurate Measurements:Measure twice to ensure accuracy. Incorrect measurements can lead to material waste and improper fits. Use the measuring tape to determine the exact length and width of the area to be covered by the metal panel.
  • Marking the Cut Line: Use a straightedge to draw your cut line. For straight cuts, a chalk line can also be useful. Ensure the line is clearly visible and straight to guide your cutting tool accurately.

Step 3: Making the Cut

Now it's time to actually make the cut! 

  • If you're using tin snips, start by cutting along one side of the line you drew. Then move to the other side and cut along that line as well. Once you have made your cuts, you can use a file to smooth down any rough edges.

  • If you're using metal shears, start by positioning the blade on one side of the line. Then squeeze the handle to cut through the metal. Repeat this process on the other side of the line.

  • If you're using an angle grinder, start by cutting along one side of the line. Then move to the other side and cut along that line as well. Once you have made your cuts, you can use a file to smooth down any jagged edges on the metal sheet.

  • If you're using a circular saw, start by positioning the blade on one side of the line. Then squeeze the trigger to cut through the metal. Repeat this process on the other side of the line.

Step 4: Finishing Touches

Cutting metal panels can get messy! Once you have finished making your cuts, it's important to clean up any metal dust that has been generated. This can be done with a vacuum cleaner or by wiping down the area with a damp cloth.

But, we also need to keep in mind the steps that focus on perfecting your work:

  • Smoothing Edges: After cutting, smooth any rough edges with a metal file or sandpaper. This prevents injury and ensures a clean finish. Check the panel for any burrs or sharp edges and remove them carefully.
  • Double-Checking Fit: Before final installation, double-check the fit of the panel. Make any necessary adjustments to ensure a perfect fit. Ensure the panel aligns correctly with adjacent panels and the overall roofing layout.

Safety Tips 

Ensuring the safety of metal roofers is paramount, which necessitates the proper use of Personal Protective Equipment (PPE) and maintaining an appropriate work environment.

Personal Protective Equipment (PPE):

  • Gloves: Wear heavy-duty gloves to protect your hands from sharp edges and metal shavings. Gloves should have a good grip to handle tools safely.
  • Goggles: Safety goggles are essential to protect your eyes from flying particles and metal shavings, especially when using power tools.
  • Ear Protection: Using tools like electric metal shears and circular saws can generate significant noise, which may damage hearing over time. Ear protection such as earplugs or earmuffs should be used.
  • Respiratory Protection: When cutting metal, tiny particles can become airborne. In such cases, wearing a dust mask or respirator might be necessary to prevent inhalation of metal dust, especially in enclosed spaces.

Suitable Workplace:

  • Flat Surface: Ensure that you have a stable, flat surface to work on, such as a heavy-duty work table or a solid ground area. This helps in securing the metal panels properly and prevents them from moving while cutting, which is crucial for safety and precision.
  • Clean and Organized Space: Keep your work area free of unnecessary objects and debris to avoid accidents. Regularly clean the space to maintain a safe working environment.
  • Work Environment: Maintain a clean and organized workspace to prevent accidents and allow for more efficient operations.
  • Fire Safety: Keep a fire extinguisher nearby when using tools that generate sparks, like angle grinders and circular saws.

Main Considerations:

  • Material Thickness: Choose the tool based on the thickness of the metal. Tin snips are sufficient for light gauges, while shears, grinders, and saws are better for heavier gauges.
  • Cut Type: Consider the type of cuts you need to make—whether they are straight, curved, or require removal of large sections of metal.

Congratulations, you have now successfully cut a metal roofing panel!

The next step is attaching the metal roof panels to the roof. Need help? We've got a guide for that: How to Attach Metal Roof Panels: The Step-by-Step Guide.

AMSI Supply is dedicated to providing everything for the metal roofer. Our blog is filled with guides and tips on everything the metal roofer needs from underlayment to metal roof types.

With the right tools and techniques, cutting metal roofing panels can be straightforward and precise. Contact us for more expert advice and quality tools—we’re here to help you excel in every project with top-quality materials and reliable advice.

Posted in Metal Roofing