A brick saw may seem like a highly specialized piece of equipment, but many people find themselves needing to cut bricks, pavers, concrete blocks, and other materials at some point—even people who are not professional masons. If you have never used this type of saw before, it can seem like a daunting task because of how different brick saws are from the saws used to cut wood, for example.
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To remove some of the scary “unknown”, this post has some tips for cutting with a brick saw that novices and DIYers may find helpful.
Masonry saw, brick saw or block saw?
First, let’s sort out some terminology. Most people know that masonry is brickwork, so things can quickly get confusing when they are presented with options under the name of masonry saw, brick saw, block saw, etc. Sometimes, depending on the manufacturer, some of these terms may be used interchangeably. But usually, these can be considered three different varieties of a similar type of machine, with the main difference being power and cutting depth.
Masonry saws usually have the smallest cutting depth/blade diameter of the three, which makes them good all-purpose machines that are very versatile and more budget-friendly. The maximum cutting depth is generally 3-5 inches, but this is just for a single pass; you can make deeper cuts by going back over the cut again. If you have to cut through bricks that are 6 inches thick, a masonry saw will likely do the job just fine in two passes.
Brick saws are able to make deeper cuts in a single pass, with a maximum cutting depth of 8-11 inches in most cases. Finally, some block saws have cutting depths up to 18 inches, making them suitable for very heavy duty projects and something that most DIYers will not have to tackle.
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Wet cutting vs. dry cutting with a brick saw
Bricks, pavers, stone, etc. can be cut wet or dry using most masonry or brick saws, but wet cutting is by far the preferred method. It is safer, faster, requires less special equipment, and is much easier on the diamond blade doing the cutting.
Most masonry saws and brick saws will have a water pan with a pump to make water flow over the blade during cutting, or else they will have an attachment to be hooked up to a hose and external water supply. The water keeps the diamond blade cool as it grinds through the bricks, so you can cut for a longer period of time without overheating the blade. You also prevent the blade from going dull too quickly and, perhaps most importantly, you minimize the amount of harmful dust that is produced as you cut through the material.
Dry cutting with a brick saw or masonry saw, on the other hand, requires some special equipment and special technique. First of all, you must use a blade that is specifically designed for dry cutting (this should be clearly indicated on the package). Also, because you will be kicking up a lot of dangerous silica dust, you will need to wear a respirator mask to prevent lung damage. For this same reason, dry cutting can only be done in well-ventilated, open areas. Finally, you will need to make short, shallow cuts and give the blade frequent breaks to cool down.
Simplest and cheapest? Brick chisel or just a masonry hammer. Not the 'cleanest' cuts always though. Put the cut ends/edges in the mortar joint and not the 'exposed' end joint. YMMV.
Want to actually cut the bricks? Then a blade (abrasive or diamond) in the appropriate tool (angle grinder, circular saw, or brick saw) is the way to go. Can be loud, dusty (unless using a wet saw/blade), and usually slower than a hammer/chisel, but you can (or should be able to) get nice straight cut lines.
Rent the brick saw for the $50 and be done with it.
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