How do you cut a thick pipe?

Cutting thick pipes can be challenging, but with the right tools and technique it can be done safely and efficiently. Thick pipes are generally considered 2 inches or larger in diameter and require more powerful equipment than standard hand tools. The main considerations when cutting thick pipe are choosing the proper cutting method, using the correct blade or bit, managing the high torque required, and minimizing burrs. Proper preparation and setup are also key to getting clean, straight cuts. This article provides step-by-step instructions on how to cut thick pipes using the most common methods.

What are the different ways to cut thick pipes?

There are several options for cutting thick steel and plastic pipes:

– Abrasive chop saw – An abrasive chop saw with a specialized metal cutting blade is the fastest and often preferred method for cutting thick pipes accurately and cleanly. It can handle large diameters easily.

– Reciprocating saw – A heavy duty reciprocating saw with a bi-metal blade can cut through thick pipes up to around 6 inches in diameter. Saber saws and portable band saws can also work.

– Circular saw with abrasive discs – Sturdy circular saws outfitted with special abrasive metal cutting discs can cut large diameter thick-walled pipes. High RPMs are required.

– Pipe cutters – Large ratchet-style pipe cutters with hardened rollers can cut pipes up to around 6 inches. It takes time and effort but makes a nice straight cut.

– Powered pipe cutters – Similar to standard pipe cutters but with an electric, hydraulic, or pneumatic power assist. Much faster for large diameters.

– Plasma cutters – Plasma cutters use a superheated electric arc to melt metal. They can cut any thickness rapidly but require skill.

What tools and supplies do you need to cut thick pipe?

Here are the essential tools and accessories for cutting thick pipe:

– Cutting tool – This will be an abrasive chop saw, reciprocating saw, circular saw, pipe cutter, or plasma cutter depending on the method chosen.

– Marking tools – Felt tip pen, soapstone pencil, scribe, or center punch for marking cut lines.

– Pipe stand – To securely hold long pipe sections stationary for cutting

– Cutting fluid – Helps lubricate and extend blade life. More critical for reciprocating and circular saws.

– Eye protection – Safety glasses or face shield are mandatory.

– Work gloves – Leather gloves protect hands from sharp edges and hot metal chips.

– Hearing protection – Cutting pipes produces very high noise levels. Ear plugs or muffs are necessary.

– Metal cutting blades – The proper abrasive chop saw and reciprocating saw blades designed for cutting thick metal.

– Face shield – Provides facial protection from sparks and shards when plasma cutting.

How to Cut Thick Plastic Pipe

Cutting plastic pipe over 2 inches in diameter requires specialized power tools because the thick pipe walls are too large for standard saws or PVC cutters. Here are the main methods used to cut thick plastic pipes and piping such as PVC, CPVC, ABS and galvanized plastic.

Chop Saw

The quickest, easiest way to cut thick plastic piping is with a power chop saw:

Steps:

1. Mark your cut line around the full circumference of the pipe with a felt tip pen.

2. Secure the pipe horizontally in a vice or clamp to prevent movement.

3. Put on safety glasses and hearing protection before powering up the saw.

4. Position the pipe directly over the chop saw base so the cutting path aligns with your marked line.

5. Turn on the saw and allow the blade to reach full speed.

6. Slowly lower the chop saw blade through the pipe, keeping the blade speed steady.

7. Support the offcut end of the pipe as the cut nears completion.

8. Turn off saw and remove cut sections once completely cut through.

9. Use a file or sandpaper to smooth any burrs or rough edges on both sections.

Circular Saw with Abrasive Blade

For long plastic pipes that can’t be moved easily, a portable circular saw with an abrasive grit edge blade is handy:

Steps:

1. Secure the pipe to saw horses or a steady work table at a comfortable height.

2. Mark the cut line completely around the pipe.

3. Fit the circular saw with an appropriate abrasive metal cutting blade.

4. Position the saw line on your cut mark, keeping the blade fully perpendicular.

5. Start cutting, allowing the blade to reach full speed before advancing forward.

6. Cut slowly and steadily through the full wall thickness.

7. Support the cut end as it separates fully from the pipe.

8. Smooth any rough edges with a file, sandpaper, or deburring tool.

Reciprocating Saw

For cutting plastic pipes up to around 6 inches in diameter, a heavy-duty reciprocating saw with a bi-metal blade can be used:

Steps:

1. Secure the pipe firmly at a comfortable working height on saw horses.

2. Mark the full circumference at the cut location.

3. Fit the reciprocating saw with a suitable bi-metal blade at least 1 inch longer than the pipe diameter.

4. Position the reciprocating saw on the cut line keeping the blade perpendicular.

5. Start cutting using firm pressure and allow the blade to reach full speed.

6. Cut slowly through the pipe wall thickness without twisting the blade.

7. Release pressure and allow blade to stop fully before removing from cut.

8. Use a half round file to remove any burrs from the cut edges.

Ratchet Pipe Cutter

For pipes up to 6 inch diameter, a heavy duty ratchet pipe cutter with hardened rollers can also cut through thick plastic piping:

Steps:

1. Mark the cut line fully around the pipe circumference.

2. Open the cutter handles fully and position the cutting wheel on the cut mark.

3. Tighten the cutter handle so the wheel just contacts the pipe surface.

4. Rotate the cutter one full turn around the pipe further tightening the handle slightly.

5. Repeat rotating and tightening until the wheel cuts fully through the pipe wall.

6. Loosen the cutter handle and remove it from the cut pipe.

7. File the ends smooth to remove any burrs or shards.

How to Cut Thick Steel Pipe

Cutting steel pipe larger than 2 inches in diameter requires heavy duty power tools due to the thick walls. Here are the recommended methods for cutting thick steel pipes.

Chop Saw

The fastest, cleanest way to cut through thick steel pipe is with an abrasive chop saw:

Steps:

1. Mark the cut line fully around the pipe with a felt pen or soapstone pencil.

2. Clamp the pipe horizontally in a pipe vice or other sturdy support.

3. Install an abrasive metal cut-off blade suitable for steel in the chop saw.

4. Put on safety glasses and hearing protection and start the saw.

5. Allow the abrasive blade to reach full speed before starting cut.

6. Align the cut mark with the blade path and slowly lower into the spinning blade.

7. Cut steadily through the pipe wall keeping downward pressure constant.

8. Support the pipe end past the cut as it nears separation.

9. Turn off saw and remove cut sections after fully cut through.

10. Carefully file any burrs smooth on the cut ends.

Circular Saw with Abrasive Blade

For cutting very long or immobile steel pipes, a portable circular saw with an abrasive blade can be used:

Steps:

1. Secure the pipe horizontally on saw horses or work tables at comfortable height.

2. Mark the cut line around entire pipe circumference.

3. Install appropriate abrasive metal cutting disc on circular saw.

4. Align saw blade on marked cut line keeping blade fully perpendicular.

5. Start saw and allow blade to reach maximum RPMs.

6. Begin cutting using light pressure to start abrasive disc cutting.

7. Slowly advance blade through steel wall using steady, even pressure.

8. Support pipe near cut as it finishes to prevent binding.

9. Allow blade to stop fully before removing saw. File away any burrs.

Reciprocating Saw

Reciprocating saws with bi-metal blades can cut steel pipes up to around 6 inches in diameter:

Steps:

1. Secure pipe horizontally in a vice or clamp at comfortable working height.

2. Mark cut line fully around pipe circumference.

3. Install suitable bi-metal reciprocating blade at least 1 inch longer than pipe diameter.

4. Align blade on cut mark keeping it perpendicular to pipe.

5. Start saw and allow it to reach full speed before engaging pipe.

6. Begin cut using firm pressure but don’t force blade. Let it cut at its own rate.

7. Cut slowly and steadily completely through steel wall.

8. Allow blade to stop fully before removing from cut.

9. Carefully file any burrs left on cut ends.

Ratchet Pipe Cutter

Ratchet-style pipe cutters can cut steel pipe up to 6 inches in diameter with patience and effort:

Steps:

1. Mark cut line around pipe circumference.

2. Open cutter handles fully and place cutting wheel on mark.

3. Begin tightening handle enough so wheel contacts pipe surface.

4. Rotate cutter one full revolution tightening handle slightly more.

5. Repeat steps slowly increasing pressure each rotation.

6. Cut steadily through wall thickness without loosening handle.

7. It may take 15-20 revolutions to cut through thick steel.

8. Loosen handle fully once cut finishes and remove cutter.

9. Carefully deburr and file cut edges.

Cutting Thick Pipe Safely

Cutting pipes with power tools can be dangerous. Here are important safety tips when cutting thick steel or plastic pipes:

– Wear eye protection to prevent eye injuries from sparks and debris.

– Use proper hearing protection like ear muffs or plugs to prevent hearing loss from loud noise.

– Wear leather gloves to protect hands from sharp burrs and hot metal shards.

– Keep flammable liquids away from cutting operations to avoid fire risk.

– Ensure adequate workpiece support so it can’t twist or fall while cutting.

– Don’t wear loose clothing that can catch in spinning blades or accessories.

– Make sure cutting area is free of slip, trip, and fall hazards.

– Take care when handling and disposing of sharp cut-off scraps.

– Ensure saw blades or discs are designed for the specific material being cut.

– Unplug tools before changing accessories to prevent accidental startup.

– Maintain concentration and avoid distractions like phones or music.

Following proper safety practices helps prevent serious lacerations, amputations, burns, eye injuries and other accidents when cutting thick pipes.

Frequently Asked Questions

What are some signs I need to replace my pipe cutting blade?

Signs that a blade needs replacing when cutting thick steel or plastic pipe include:

– Excessive cutting time needed

– Increased saw/tool vibration

– Blade stopping or binding in cut

– Rougher cut edge finish

– Visible wear or damage on blade

– Overheating blade or motor

– Increased sparks when cutting

– Loud, high-pitched blade sounds

Can I cut a thick pipe with a reciprocating saw?

Yes, a heavy duty reciprocating saw with an appropriate bi-metal blade can cut steel and plastic pipes up to around 6 inches in diameter. Use a long blade, steady pressure, and slow feed rate for clean cuts.

What rpm should I run an abrasive saw when cutting thick pipe?

Chop saw rpm varies by blade size but typically 4000-6000 rpm for a 14 inch steel abrasive blade. Always follow manufacturer instructions and use the proper blade for the material and thickness. Too slow can bind and too fast can wear excessively or overheat.

How thick of a pipe can I cut with a ratchet style pipe cutter?

Manual ratchet cutters can usually cut steel and plastic pipe up to around 6 inches diameter depending on the tool’s size and leverage. Larger power-assisted cutters can cut much thicker pipes.

Should I use cutting fluid when cutting plastic pipe?

Cutting fluid is not necessary for plastic pipes. It’s more important when cutting steel to lubricate, cool and remove material. For plastic you mainly want to ensure adequate blade speed and feed rate.

What personal protective equipment should be used when cutting pipe?

At a minimum wear safety glasses, ear protection, leather gloves, long sleeve shirt, long pants, and sturdy shoes when cutting pipes. For operations with high heat or sparks, use a flame-resistant jacket, apron and face shield.

Conclusion

Cutting thick steel and plastic pipes requires specialized power cutting tools to handle the large diameters and thick walls. With the proper blade and technique, abrasive chop saws, reciprocating saws, circular saws, and pipe cutters can all be used to successfully cut thick pipes. Critical factors are using the right blade, maintaining proper feed rate, and rigidly securing the workpiece. Always wear appropriate protective gear and follow safe practices to prevent accidents when cutting. With preparation and care, even novice DIYers can cut thick pipes quickly and safely.