How to Cut Aluminum Composite Roof Panels

Written by kimberly johnson
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How to Cut Aluminum Composite Roof Panels
Aluminium is a common material for shed roofs. (Jupiterimages/ Images)

Aluminium composite roofing comes in standard sheet sizes and typically has raised ridges, call corrugation, which allows water to run off. The material is often used as roofing for exterior structures such as sheds, carports and other non-residential structures. Because they come in standard sizes, you must cut the aluminium panels to fit your roof size. You can cut the panels with either power tools or handheld tools, depending on the orientation of the cuts.

Skill level:

Things you need

  • Tape measure
  • Pencil
  • Saw horses
  • Utility knife
  • Work gloves
  • Safety glasses
  • Ear plugs
  • Circular saw with metal cutting blade
  • Oil

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  1. 1

    Measure the roof to determine the proper length and width of the aluminium composites panel that you need. Typically you only need to trim one end to finish off the installation. However, you may need to trim the length to shorten the overhang along the eaves as well.

  2. 2

    Lay the aluminium panel on top of two saw horses and use the tape measure and a pencil to transfer the needed measurements onto it. When possible, make the cuts inside one of the ridges.

  3. 3

    Place a straight edge along the pencil line and use it as a guide to make a cut line all the way along the pencil mark using a sharp utility knife. When you reach the end of the pencil line, repeat the process at least two more times.

  4. 4

    Put on work gloves and bend the aluminium panel back and forth along the cut line until it breaks off cleanly.

Tips and warnings

  • To cut across the ridges instead of inside of them, put on safety lasses and ear plugs. Cut along the pencil line using a circular saw with a metal cutting blade. Apply three to four drops of oil to the saw blade before cutting to allow it to easily slide through the aluminium.

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