Tips for cutting sheet metal onsite

Types of cutting tools for steel sheets

Cutting sheet metal requires specialised cutting tools. These are designed to cut thin- to medium-thick steel sheets cleanly and accurately, avoiding damage to the material. 

What is the best way to cut sheet metal? 

Where possible, you should minimise site work by having sheet metal cut to length in the factory. 

When cutting sheet metal on site, we recommend using a power saw with a metal-cutting blade. This tool produces fewer damaging hot metal particles and leaves less burr than a carborundum disc. 

Alternative cutting tools, such as electric shears and nibblers, are also suitable however, extra care with the straightness of the cut may be required. 

Safety precautions to follow when using cutting tools

It is common sense to work safely, protecting yourself and workmates from accidents on the site. 

Safety includes the practices you follow and the use of PPE, which is essential for reducing health and safety risks. 

Examples of PPE include:

• Heavy-duty cut-resistant gloves: To be worn when cutting and handling steel products, as the products may be sharp and heavy. Its durability and resistance to heat, chemicals, abrasions, punctures and burns helps withstand the demanding nature of construction work.
• Goggles: Proper eye protection is essential when cutting steel sheets, as your eyes are at greater risk from sparks and flying debris. We recommend using goggles and not safety glasses, as goggles provide superior protection against dust, liquids and fine particles.
• Sunscreen: Due to high sun exposure on sites, it is important to protect skin from sunburn. Sunburns can be painful and lead to discomfort, making it difficult to work. Additionally, be sure to check if the sunscreen contains titanium oxides before applying. These have been shown to break down some paint compounds and should be avoided.
• Earplugs or earmuffs: Noise protection is essential for optimal performance on site. For moderate noise levels, consider using earplugs, while earmuffs are more suitable for louder environments. Also prioritise comfort when selecting the right ear protection, as discomfort could lead to incorrect use.

In addition to wearing the right PPE, take special care to clean up swarf after cutting steel sheets. These small, sharp scraps can rust and damage finishes and can cause personal injury. For more information, refer to our Support Article, Cleaning Up After Installation. 

Protecting other site elements when cutting steel sheets

Cut sheet metal over the ground, not over other materials where hot particles can fall and cause damage to finishes, especially COLORBOND® steel pre-painted finishes. 

It is best to have the exterior colour finish of a COLORBOND® steel pre-painted sheet facing down. In this instance, you must protect the paint finish from scratches caused by your work supports. 

If you must cut sheet metal near installed sheets, mask them or direct the stream of hot particles away from them. Reciprocating nibblers are also widely used in the roofing trade, and they produce an excellent cut. 

Other methods to prevent damage to steel sheets

Swarf left on the surfaces of cut sheet metal will cause rust stains, which can lead to reduced life of the material. 

Take special care to clean up these scraps (For more information, refer to our Support Article, Cleaning Up After Installation).