31/12/2025
Why Grinders Are Discouraged (But Sometimes Used)
Damage to Coating: Heat from the abrasive disc burns off protective galvanization or paint, leading to rust.
Swarf: Creates metal shavings (swarf) that stick to the roof, rust, and stain it.
Safety: Sparks are dangerous (fire hazard) and fragments fly off; gloves and goggles are essential.
Rough Edge: Leaves a burred, sharp edge that needs filing.
How to Do It (If You Must)
Safety Gear: Wear safety goggles, gloves, and protective clothing.
Tools: Use a 4-inch (115mm) grinder with a 1.2mm or thinner metal cutting disc.
Mark: Draw a straight line with a marker and level.
Secure: Clamp the sheet down to prevent flapping.
Cut: Start with a small nick, then slowly follow the line, letting the grinder do the work.
Finish: Use a file to smooth sharp edges and remove all swarf immediately.
Recommended Alternatives (Better Options)
Tin Snips/Shears: Best for straight cuts, clean edges, no heat/rust issues.
Nibbler/Shear Attachment: Fits an impact driver, makes clean cuts, great for curves.
Circular Saw: With a fine-tooth blade for plastic/polycarbonate sheets.
For longevity and safety, especially with coated metal roofing, use shears or snips to avoid damaging the protective finish.