Cutting corrugated metal can be a tricky task, but with the right tools and techniques, you can get the job done quickly and easily. In this article, we’ll show you the best way to cut corrugated metal, whether you’re using a circular saw, reciprocating saw, or hand shears.
The first step is to choose the right tool for the job. If you’re cutting thin corrugated metal, you can use a circular saw or reciprocating saw. For thicker corrugated metal, you’ll need to use a hand shears. Once you have the right tool, you can start cutting the metal. Here are some tips to help you get the best results:
1. Make sure to wear safety glasses and gloves when cutting corrugated metal.
2. Use a sharp blade. A dull blade will make it more difficult to cut the metal and can cause the blade to bind.
3. Cut in a straight line. If you cut at an angle, the metal may buckle or tear.
4. Be careful not to cut too deeply. If you cut too deeply, you may damage the metal.
Essential Tools for Corrugated Metal Cutting
Selecting the right tools for cutting corrugated metal is crucial to ensure efficient and clean results. The following list outlines the essential tools necessary for successful corrugated metal cutting:
1. Circular Saw with a Metal-Cutting Blade
A circular saw with a carbide-tipped metal-cutting blade is the most versatile and precise tool for cutting corrugated metal. The blade should have at least 8 teeth per inch (TPI) to provide a smooth, burr-free cut. Choose a blade with a diameter that is suitable for the thickness of the metal being cut.
The table below outlines recommended blade diameters for different corrugated metal thicknesses:
| Corrugated Metal Thickness | Blade Diameter |
|---|---|
| 26 gauge (0.019 inches) | 7-1/4 inches |
| 24 gauge (0.023 inches) | 7-1/4 inches or 8-1/4 inches |
| 22 gauge (0.029 inches) | 8-1/4 inches |
| 18 gauge (0.048 inches) | 10-1/4 inches |
2. Shears
Snips or aviation shears are handheld tools that can be used for straight cuts or curves. They are particularly useful for cutting small pieces or making intricate cuts. Choose a pair of shears that are designed for cutting metal and have hardened jaws.
3. Jigsaw
A jigsaw with a metal-cutting blade is suitable for cutting intricate curves or irregular shapes in corrugated metal. Select a blade with a high number of TPI (10-14 TPI) for a fine cut.
4. Nibbler
A nibbler is a power tool that utilizes a punch and die to quickly and cleanly cut corrugated metal. It is ideal for creating curves, cutouts, or notches.
5. Angle Grinder
An angle grinder equipped with a metal-cutting disc can be used for cutting corrugated metal. However, it is important to note that angle grinders produce sparks and debris, so proper safety measures should be taken.
Safety Precautions for Cutting Corrugated Metal
Before Cutting
- Wear appropriate personal protective equipment (PPE) including safety glasses, earplugs, gloves, and a dust mask.
- Secure the corrugated metal firmly to a stable surface using clamps or a vise to prevent it from shifting during cutting.
- Ensure the cutting area is well-ventilated to minimize dust and metal fumes.
- Keep the work area clear of obstructions and potential hazards.
During Cutting
- Use the appropriate cutting tool for the thickness and type of corrugated metal.
- Hold the tool firmly and cut in straight or smooth lines, avoiding sharp turns or excessive force.
- Keep a sharp blade or bit to ensure clean cuts and reduce the risk of kickback.
- Be aware of potential pinch points and keep hands clear of the cutting area.
- If using power tools, ensure they are well-maintained and operated according to manufacturer’s instructions.
- Take regular breaks to avoid fatigue and ensure alertness.
Additional Precautions
- Avoid cutting near edges or corners: These areas can be more prone to tearing or buckling.
- Use a lubricant: Applying a light oil or soap to the cutting blade can help reduce friction and extend the blade’s life.
- Handle cut edges carefully: They can be sharp and may pose a laceration hazard.
- Dispose of metal cuttings properly: Sharp edges or fragments should be disposed of in a designated metal recycling bin to prevent injury.
Cutting Corrugated Metal with Shears
Shears are hand-held tools that are used to cut corrugated metal. They come in a variety of sizes and shapes, and can be used to make both straight and curved cuts. Shears are a relatively inexpensive way to cut corrugated metal, and they are easy to use.
To cut corrugated metal with shears, follow these steps:
- Mark the area where you want to cut the metal.
- Place the shears on the metal, with the blades aligned with the mark.
- Squeeze the handles of the shears together to cut the metal.
Here are some tips for cutting corrugated metal with shears:
- Use sharp shears. Dull shears will not cut through the metal cleanly, and they may cause the metal to tear.
- Cut slowly and carefully. Trying to cut the metal too quickly may cause the shears to slip, and this could result in injury.
- Wear gloves and safety glasses when cutting corrugated metal. The metal can be sharp, and it may contain sharp edges that could cause injury.
- Circular saw
- Metal cutting blade
- Safety glasses
- Hearing protection
- Clamps or vices
- Straight edge or guide
- Mark the cutting line with a straight edge or chalk line.
- Place the metal on a stable surface, such as a workbench or sawhorse.
- Secure the metal using clamps or a vice.
- Choose the appropriate cutting tool, such as aviation snips, a circular saw, or a reciprocating saw.
- Hold the cutting tool perpendicular to the metal.
- Start cutting along the marked line, applying even pressure.
- Cut through the ribs cleanly and without damaging the metal.
- Use a sharp cutting tool to reduce the amount of force required.
- Support the metal well on both sides of the cut to prevent bending.
- Cut slowly and carefully, especially when cutting through thicker ribs.
- If using shears, use aviation snips with a high leverage ratio.
- Accuracy: They provide precise cuts with minimal burrs or deformations, making them ideal for intricate or detailed work.
- Efficiency: Electric shears cut quickly and effortlessly, saving time and labor compared to manual methods.
- Safety: They eliminate the risk of injury associated with using hand tools, such as slips or cuts.
- Aviation snips: These hand-operated tools require manual effort and may not be suitable for large-scale cutting.
- Circular saw with a metal-cutting blade: This method is suitable for straight cuts but requires careful handling to avoid damaging the metal.
- Angle grinder with a metal-cutting wheel: This option offers versatility but requires skill to achieve clean cuts.
- Wear appropriate safety gear, including gloves, safety glasses, and earplugs.
- Secure the metal firmly to a stable surface to prevent movement during cutting.
- Maintain a clean work area and regularly remove cut-off pieces to avoid tripping hazards.
- Dispose of metal shavings and scraps responsibly.
Types of Shears
There are three main types of shears that can be used to cut corrugated metal:
| Type of Shears | Description |
|---|---|
| Compound shears | Compound shears are the most powerful type of shears, and they are capable of cutting through thick metal. They have a compound action, which means that the blades move in a scissor-like motion. This gives them a lot of leverage, and it makes them easy to use. |
| Lever shears | Lever shears are less powerful than compound shears, but they are still capable of cutting through most types of corrugated metal. They have a lever action, which means that the blades move in a straight up-and-down motion. This gives them less leverage than compound shears, but it also makes them easier to control. |
| Snips | Snips are the smallest and least powerful type of shears. They are designed for cutting thin metal, and they are not capable of cutting through corrugated metal. However, they can be used to make small cuts or to trim the edges of corrugated metal. |
Using a Circular Saw for Precise Cuts
A circular saw offers a quick and efficient method for making precise cuts in corrugated metal. Here’s a detailed guide on how to use one:
Tools and Materials
1. **Prepare the Work Area**: Ensure the work area is well-ventilated and has sufficient lighting. Wear appropriate safety gear, including safety glasses, hearing protection, and gloves.
2. **Set the Blade Depth**: Adjust the circular saw’s blade depth to cut through the corrugated metal without damaging the surface beneath. As a general rule, set the blade to extend approximately 1/4 inch beyond the material.
3. **Use a Guide**: For straight cuts, use a straight edge or guide to ensure accuracy. Clamp or hold the corrugated metal securely to prevent movement during cutting.
4. **Cut the Corrugated Metal**: Start the circular saw and guide it along the desired cut line, taking care to maintain a steady hand. Apply gentle pressure to the saw and avoid forcing it, as this can cause the blade to bind or damage the metal. For uneven surfaces, adjust the cutting angle accordingly.
5. **Finish the Cut**: Once you have completed the cut, turn off the circular saw and allow the blade to come to a complete stop. Inspect the cut to ensure it is clean and free of burrs or jagged edges. If necessary, use a file or deburring tool to smooth the cut.
Cutting Corrugated Metal with a Nibbler
A nibbler is a handheld power tool designed specifically for cutting corrugated metal. It features a high-speed reciprocating blade that rapidly punches small holes in the material, creating a clean and precise cut.
Corrugated metal is a versatile material often used in roofing, siding, and other building applications due to its strength, durability, and corrosion resistance. Cutting corrugated metal requires a specialized tool that can handle its unique shape and structure, and a nibbler is well-suited for this task.
Here are the steps involved in cutting corrugated metal with a nibbler:
Safety Precautions
Always wear appropriate safety gear, including safety glasses, work gloves, and ear protection, when using a nibbler.
Choosing the Right Nibbler
Select a nibbler with a cutting capacity that is appropriate for the thickness of the corrugated metal you will be cutting. Nibblers are typically rated for cutting thicknesses up to 0.125 inches (3.175 millimeters).
Setting Up the Nibbler
Before cutting, adjust the nibbler’s speed and pressure settings according to the manufacturer’s instructions. Proper settings will help ensure clean cuts and minimize blade wear.
Cutting the Corrugated Metal
Secure the corrugated metal firmly in a vise or on a stable surface. Begin cutting by placing the nibbler’s blade on the edge of the metal and applying gentle pressure. Guide the nibbler along the desired cut line, allowing the blade to punch holes and create a clean, continuous cut.
Avoiding Common Errors
To avoid common errors and ensure successful cutting, consider the following tips:
| Error | Solution |
|---|---|
| Ripping or tearing of the metal | Reduce the blade speed and pressure, and ensure the metal is securely clamped. |
| Uneven cuts | Maintain a consistent cutting speed and pressure, and avoid applying excessive force. |
| Blade overheating | Allow the blade to cool down periodically to prevent damage. |
| Metal shavings buildup | Clean the nibbler’s blade and base regularly to remove metal shavings and maintain cutting efficiency. |
Utilizing Angle Grinders for Clean Edges
Angle grinders are an effective tool for cutting corrugated metal, providing precise cuts with minimal burring.
6. Blade Selection and Cutting Technique
Selecting the appropriate blade is crucial for clean cuts and extended blade life. Use a thin (1/16 – 1/8 inch), flat abrasive cut-off wheel with a high RPM rating.
When cutting, angle the grinder slightly towards the side of the cut to avoid snagging and minimize burring. Hold the grinder firmly and apply even pressure throughout the cut to prevent chatter or vibration.
Here’s a table summarizing the key blade and cutting techniques:
| Blade Type | Blade Thickness | Cutting Angle | Pressure Application |
|---|---|---|---|
| Flat Abrasive Cut-Off Wheel | 1/16 – 1/8 inch | Slight angle towards the side of the cut | Even pressure throughout the cut |
Following these guidelines will ensure clean and precise cuts with an angle grinder, making it an excellent option for cutting corrugated metal.
Employing a Plasma Cutter for Complex Shapes
Plasma cutting is an excellent technique for intricate cuts in corrugated metal. It utilizes a superheated plasma arc to melt and separate the metal, enabling precise and detailed designs. Here’s a guide to using a plasma cutter for complex shapes in corrugated metal:
1. Prepare the Metal
Clean the corrugated metal by removing any dirt, rust, or paint. Ensure it is securely clamped or held to prevent movement during cutting.
2. Set Up the Plasma Cutter
Select a plasma cutter with sufficient power for the metal thickness. Calibrate the machine according to the manufacturer’s instructions and set the cutting speed and gas pressure appropriately.
3. Use a Template or Stencil
For complex shapes, consider using a template or stencil to guide the plasma cutter. This ensures accuracy and consistency in the final cut.
4. Start Cutting
Hold the plasma cutter perpendicular to the metal and start cutting along the desired line. Maintain a steady hand and avoid excessive pressure to prevent damage to the metal.
5. Control the Arc Length
Adjust the arc length to achieve the desired cut quality. A shorter arc produces finer cuts, while a longer arc provides deeper penetration.
6. Use Multiple Passes
For thicker corrugated metal, multiple passes may be necessary to cut through the material. Ensure the cuts overlap slightly to prevent gaps or weak spots.
7. Additional Tips
| Tip | Benefit |
|---|---|
| Use a water table | Reduces heat build-up and minimizes distortion |
| Choose the right consumables | Ensures optimum cutting performance and extends nozzle life |
| Protect the surrounding area | Sparks and molten metal can damage nearby objects |
Proper Techniques for Cutting Along Ribs
When cutting along ribs, it’s important to follow proper techniques to ensure a clean, precise cut. Here are the steps involved:
Avoiding Rib Crushing
One of the challenges when cutting corrugated metal along ribs is avoiding rib crushing. This can occur when the cutting pressure is too high or the ribs are not supported properly. To avoid rib crushing, follow these tips:
| Cutting Tool | Advantages | Disadvantages |
|---|---|---|
| Aviation Snips | Portable, easy to maneuver, precise cuts | Requires more force, not suitable for thick metal |
| Circular Saw | Fast, efficient, can cut through thick metal | May require additional cleanup, can be bulky |
| Reciprocating Saw | Versatile, can cut through various materials | May produce less precise cuts, can tear the metal |
Tips for Cutting Corrugated Metal at Angles
1. Use a Straight Edge and Sharp Blade
A straight edge and sharp blade will help you make precise cuts. Use a metal ruler or straight edge to guide the blade, and ensure that the blade is sharp to avoid tearing or bending the metal.
2. Use a Power Tool for Large Cuts
For large cuts, use a power tool such as a circular saw or jigsaw. A circular saw provides a clean, straight cut, while a jigsaw is more suitable for intricate cuts.
3. Avoid Cutting Multiple Layers
If possible, avoid cutting multiple layers of corrugated metal at once. This can cause the metal to bind on the blade and make it difficult to cut.
4. Use a Backing Board
Place a backing board behind the metal when cutting to prevent the metal from bending or vibrating.
5. Cut in the Direction of the Corrugations
Always cut in the direction of the corrugations, as this will reduce the risk of tearing or bending the metal.
6. Use a Lubricant
Applying a lubricant to the blade can help reduce friction and make the cut smoother.
7. Clamp the Metal
Clamping the metal firmly in place will prevent it from moving during the cut.
8. Use a Speed Square
A speed square can be used to ensure that the cut is made at the desired angle.
9. Cutting Corrugated Metal at Compound Angles
To cut corrugated metal at compound angles, you will need to use a combination of the following techniques:
| Step | Description |
|---|---|
| 1 | Mark the desired angle on the metal. |
| 2 | Clamp the metal firmly in place. |
| 3 | Cut the first angle using a circular saw or jigsaw. |
| 4 | Rotate the metal to the desired second angle. |
| 5 | Align the previous cut with the blade and clamp the metal securely. |
| 6 | Make the second cut to complete the compound angle. |
Finishing and Post-Cut Treatment
1. Deburring
After cutting, corrugated metal may have sharp edges. Deburring removes these edges, making the material safer to handle and preventing injury.
2. Painting or Coating
To protect corrugated metal from corrosion and improve its appearance, apply a paint or coating. This should be done before installation.
3. Rust Prevention
Corrugated metal is susceptible to rust. To prevent this, apply a rust-inhibiting primer or coating after deburring but before painting.
4. Bending
Corrugated metal can be bent to create curves or angles. Use a bending brake or a manual bending tool to achieve desired shapes.
5. Joining
Corrugated metal can be joined using rivets, bolts, or screws. Select the appropriate method based on the application and load requirements.
6. Sealing
Seal any joints or seams in the corrugated metal to prevent moisture penetration and rust.
7. Flashing
Install flashing around openings, such as windows or doors, to prevent water seepage and ensure a watertight seal.
8. Grounding
If the corrugated metal is used as a roof or exterior cladding, ensure it is properly grounded to protect against lightning strikes.
9. Insulation
Add insulation behind the corrugated metal to improve energy efficiency and reduce temperature fluctuations inside the building.
10. Maintenance
Inspection and Cleaning
Regularly inspect the corrugated metal for signs of damage, rust, or other issues. Clean it annually to remove dirt and debris that can accumulate over time.
Repairs
If damage or rust occurs, make repairs promptly to prevent further deterioration. Replace damaged sections or apply a rust-inhibiting coating.
Repainting or Coating
Over time, the paint or coating on the corrugated metal may deteriorate. Repaint or apply a new coating as needed to maintain its protective properties and appearance.
The Most Effective Way to Cut Corrugated Metal
Corrugated metal is a sturdy and versatile material that finds applications in various industries. Its unique design, featuring alternating ridges and valleys, provides strength and stability. However, cutting corrugated metal requires a precise approach to ensure clean and efficient results.
The most recommended method for cutting corrugated metal is using an electric shear. This specialized tool features two opposed blades that generate a shearing force to cut through the metal. Electric shears offer several advantages:
People Also Ask About the Best Way to Cut Corrugated Metal
What are some alternative methods to cut corrugated metal?
Apart from electric shears, several other methods can be used to cut corrugated metal, including:
What safety precautions should be taken when cutting corrugated metal?
Handling corrugated metal and cutting it safely requires the following precautions:
