How to Cut Galvanized Steel

August 25, 2020 by Crossroads Galvanizing

Galvanized steel has been around since roughly 1870 and can still be found in many homes that were constructed around the 1950s. Galvanized steel is a great choice for various personal and professional projects. If you are thinking about cutting galvanized steel, there are some things that you should know. 

It can be a challenge to get a perfect smooth edge… However, with the proper tools and steps, you can cut both galvanized sheets and pipes with accuracy. 

Cutting Galvanized Sheets 

  1. Start by clamping the sheet of the galvanized steel securely by using a bench vice with guidelines facing upwards. 
  2. Take a circular saw that is fitted with a 7 ¼ inch fiber blade to cut the galvanized sheet, still following the guidelines. 
  3. Go over any edges that aren’t clean-cut to smooth them down with a steel reamer. 

Cutting Galvanized Pipe 

  1. Secure the galvanized pipe in either a pipe vise or solid bench vise. 
  2. Place the rotary pipe cutter on the galvanized pipe. Make sure you are centering the line you need to cut with the blade. 
  3. Take your cutting oil and apply it while tightening the handle of the pipe cutter. Keep doing so until the blade touches the pipe. 
  4. Turn the cutter in a circular motion, tighten the knurled handle as needed with each revolution until the pipe is cut. You may need to add cutting oil as needed throughout the process. 
  5. Go over any edges that aren’t clean-cut to smooth them down with a steel reamer. 

Cutting Wires or Cables 

  1. Make sure that you’re working with your galvanized wire in a flat, secure area. 
  2. Check that the wire is level, or position it in a table wise to ensure that it’s secure.
  3. Arrange the teeth of the wire to be lined up with where you want to cut. Apply a heavy amount of pressure till the wire is cut. 
  4. Sand down the rough edge of the wire with a single-cut steel file.

Our Tips 

Make sure that when you are measuring and marking your steel you are doing it on a flat surface to get the best precision. Throughout the process, it is highly encouraged that you wear proper protective equipment such as thick leather gloves and safety glasses. Also, if you plan on sanding down any part of the galvanized metal, wear a breathing mask as you don’t want to breathe in any metal dust.

Before starting the project, have a list of the specific tools and protective equipment you will need for a successful cutting process. 

Final Thoughts

While it is always best to consult a professional or expert in galvanized steel projects and renovations, you can easily cut galvanized metal. You can achieve cutting galvanized wires, sheets, pipes, and cables with some specialized tools and a little bit of elbow grease.

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