How To Cut Corrugated Plastic Roofing

How To Cut Corrugated Plastic Roofing

Corrugated plastic roofing is a lightweight and durable material commonly used for roofing applications such as carports, sheds, and patio covers. Its flexibility, affordable cost, and ease of installation make it a popular choice among homeowners and DIY enthusiasts. One of the key steps in any roofing project is cutting the material to the desired size and shape. In this article, we will guide you through the process of cutting corrugated plastic roofing, providing you with easy-to-follow instructions and tips for a successful outcome.

What You Will Need

Before you begin cutting corrugated plastic roofing, gather the necessary equipment and tools. Here is a list of items you will need to complete the task:

1. Corrugated plastic roofing sheets
2. Measuring tape or ruler
3. Marker or pencil
4. Straight edge or ruler
5. Utility knife or circular saw with a fine-toothed blade
6. Safety goggles
7. Work gloves
8. Sawhorses or a sturdy work surface

Step-by-Step Guide

Now that you have your tools ready, follow these steps to cut corrugated plastic roofing:

1. Measure and mark: Start by measuring the dimensions of the area where you need to install the roofing sheets. Use a measuring tape or ruler to accurately determine the required size. Mark the measurements directly on the plastic sheets using a marker or pencil. Double-check your measurements to ensure accuracy.

2. Prepare your work area: Set up a sturdy work surface such as sawhorses or a flat table. Ensure that the surface is level and provides adequate support for the corrugated plastic roofing sheets.

3. Select the cutting method: Depending on your personal preference and the tools available, you can choose between a utility knife or a circular saw with a fine-toothed blade. A utility knife is a versatile and cost-effective option for small projects, while a circular saw allows for quicker and more precise cuts, especially for larger jobs.

4. Cutting with a utility knife: If using a utility knife, position the straight edge or ruler along the marked line you want to cut. Apply firm pressure as you run the knife along the edge of the ruler, scoring the plastic sheet multiple times until you reach the desired depth. Once scored, carefully bend the sheet along the scored line, and it should snap cleanly. Repeat this process for each cut you need to make.

5. Cutting with a circular saw: When using a circular saw, make sure you have a fine-toothed blade installed. Set the blade depth to slightly deeper than the thickness of the corrugated plastic sheet. Position the sheet on the sawhorses and start cutting along the marked line, maintaining a steady and controlled motion. Take care not to force the saw, as it may cause the plastic to crack or break. As with the utility knife method, repeat the process for all necessary cuts.

6. Finishing touches: After cutting the sheets, inspect the edges for any roughness or unevenness. If needed, use sandpaper or a file to smooth out any imperfections. This step will not only improve the aesthetic appeal but also ensure a better fit during installation.

Safety Precautions

While cutting corrugated plastic roofing is a relatively simple task, it is important to prioritize safety. Here are a few precautions to keep in mind:

1. Always wear safety goggles to protect your eyes from flying debris, especially when using power tools.
2. Use work gloves to prevent cuts and abrasions while handling the sharp edges of the corrugated plastic sheets.
3. Ensure that you are working in a well-ventilated area to avoid inhaling any dust or fumes generated during the cutting process.
4. Follow the manufacturer’s guidelines for the safe and proper use of power tools.
5. Take breaks as needed and stay hydrated to maintain focus and prevent accidents.


Cutting corrugated plastic roofing doesn’t have to be a daunting task. By following the steps outlined in this article, you can confidently and effectively cut the material to meet your project requirements. Remember to gather the necessary tools, mark and measure accurately, choose the appropriate cutting method, and prioritize safety throughout the process. With a bit of patience and precision, you’ll be well on your way to successfully completing your roofing project.

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