Cut Concrete Without a Saw & With a Saw [Step by Step]

Cut Concrete

A. Overview of the importance of cutting concrete

Concrete is one of the strongest and most popular construction material in the world. Concrete structures are known to last for decades due to their resistance to weather and climate damage. There are various forms of concrete; the applications vary depending on suitability and one’s choice.

In-situ cast concrete structures are very popular; they involve pouring concrete into pre-established forms and letting it settle. Once concrete settles and solidifies, it becomes impossible to change the shape or form it has taken. Concrete cutting is a way of adjusting the shape of settle cast concrete by removing the unwanted parts. Various tools are used for concrete cutting; including saws and non-saw techniques which are further discussed in this article.

B. Common applications for cutting concrete

Cutting concrete is done for various reasons. The most common applications are in demolition and quality control practices. Concrete cutting, also known as line cutting or core boring,

Regular core boring is used for quality assessment of concrete structures, including concrete paved roads. The cut geometry is taken to laboratories where structural tests are conducted for approval of works.

Demolition in congested areas require procedural removal of concrete pieces to avoid accidents and pollution. Such processes require concrete elements such as slabs to be cut into small movable parts for disposal.

Other concrete cutting applications include MEP installation in constructed concrete buildings.

C. Safety precautions before starting the cutting process

Concrete cutting is one of the risky procedures in the construction industry. It is therefore important that certain safety measures be observed before starting the process. Workers must wear appropriate personal protective equipment (PPE), these include safety goggles, ear muffs, and masks to protect them from dust and debris.

Thorough site inspection ensures identification of potential hazards, such as buried utilities, and allows for proper planning. Ensuring operators have the right skills and knowledge to use equipment prevents accidents and low-quality work.

Cutting Concrete Without a Saw

A. Tools and materials needed

1. Chalk line or marker

Geometries to be cut from concrete are pre-determined as specified by technicians or engineers. These geometries are marked on the concrete to be cut using chalk or markers. A chalk line or marker guides the operator on lengths, angles, and depths needed.

2. Hammer and chisel

A hammer and chisel are used to chip away concrete along the marked lines. This is done by holding the chisel vertically over the marks and striking it on the head. The process is repeated until the right depth and width are attained.

3. Sledgehammer

Sledgehammers are used to break off larger portions of concrete. They require more effort and deliver a significant impact on targeted parts. After chiseling out the required geometry and depth of cut, you can use a sledge hammer to break off the targeted part.

4. Masonry drill

Masonry drills create weak points for a controlled breaking or cutting. To achieve this, drill holes at specified distances along the marker lines. You can use a chisel to complete the cutting process or a sledgehammer to break off the targeted part.

5. Angle grinder with a diamond blade

Angle grinders are used for precise concrete cutting and shaping already cut geometries. A diamond or abrasive blade is attached to the grinder which is then connected to power. The blade rotates to create a cut or filing effect on the surface it’s in contact with.

B. Step-by-step process

1. Marking the cutting line

Once the desired shape and depth of the cut has been established, it is drawn on the concrete surface to be cut. The drawing can be done by hand or printed on transparent material and traced on the concrete. Marking can be done using chalk or markers.

2. Creating a groove with a masonry drill

Once the outline has been drawn on the concrete, use a masonry drill to make holes at specified distances along the marker lines. The holes create weakness joints for controlled breaking of the concrete. Selecting the right drill bit helps minimize loses and speeds up the drilling process.

3. Using a hammer and chisel to break the concrete

Place the chisel on the concrete portions between the drilled holes and strike the head with a hammer. The anticipated breakage pattern determines how much force you should use on the chisel.

4. Finalizing the cut with an angle grinder

After cutting the desired geometry using a hammer and chisel, refine the edges with the angle grinder of am more aesthetic look.

Cutting Concrete with a Circular Saw

Cutting Concrete with a Circular Saw

A. Tools and materials needed

1. Circular saw with a diamond or abrasive blade

Circular saws are the most common concrete cutting equipment. They are available in different sizes depending on the application. Circular saw operates by the induction motor principle; a cutting disc rotates at a high-speed splitting the concrete surface. Diamond is a hard carbon metal; it used in the manufacture of cutting blades due to its resistance to wear and tear while cutting.

2. Safety gear (gloves, goggles, ear protection)

Safety gear protects the operator from physical injury while cutting concrete. Gloves improve the comfort when holding the cutting equipment. Some gloves are built with damping materials to reduce the vibration of the cutter on the operator.

Goggles protect the operator’s eyes from dust and debris generated while cutting. Friction between concrete and cutting blades generates a lot of noise. Ear protection prevents hearing damage caused by prolonged exposure to noise.

3. Chalk line or marker

Once the geometry to be cut has been established, it has to be marked out. Marks provide a guide to the operator for safety and avoiding damage to the concrete being cut. A chalk line or marker is used to mark directions for the cutting process.

4. Sawhorses or a stable work surface

Sawhorses are a pair of stands used to hold the concrete at the right height for easy cutting. For effective cutting, the sawhorses should be at the same level to ensure the surface is stable. The surface should be clamped onto the sawhorses to minimize vibrations.

A. Step-by-step process

1. Setting up the work area

Clear the area of any loose material or debris that can obstruct the cutting process. Ensure the sawhorses are well leveled, stable, and at the right height to prevent any accidents. The cutting surface should be strong to sustain the weight of concrete being cut.

2. Marking the cutting line

Measure and mark the intended cutting lines on the concrete using a marker or chalk. Ensure the lines are straight and visible to avoid irregular cuts.

3. Adjusting the circular saw for depth and angle

Set the depth of the circular saw blade to match the thickness of the concrete. Adjust the depth by loosening the blade adjustment lever and moving the base plate. If you need to make beveled cuts, adjust the angle of the saw blade accordingly.

4. Making the initial cut and following the line

Put on personal protective equipment and tart the circular saw. Position it at the edge of the marked cutting line and hold it with both hands for stability. Lower the saw onto the concrete and make an initial shallow cut along the marked line to establish the cutting path. Gradually follow the marked line with the saw, keeping a steady pace and applying even pressure. Allow the saw blade to do the cutting work without forcing it.

5. Preventing overheating and ensuring a clean cut

To prevent the saw blade from overheating, pause periodically during the cutting process to allow the blade to cool. Consider using a water supply system or a wet-cutting blade attachment to cool the blade and minimize dust. This also helps achieve a cleaner cut.

Tips and Best Practices

A. Safety reminders for both methods

There are several safety precautions to be observed when cutting concrete with or without a saw. The most important one is having the right PPEs. Clearing the working space of all debris and marking out the area to cut prevents damage to the tools and third-party accidents. Being well versed with the cutting tools and properly maintaining them ensures efficient cutting.

B. Choosing the right blade for the job

There are various types of concrete cutting blades; you should choose one that is best applicable to your needs. Abrasive blades are ideal for hard to medium concrete cutting while diamond blades are used for more tough cutting; including reinforced concrete. Other types of blades include Turbo-Rim blades which have serrated edges to facilitate cooling.

C. Maintaining and caring for your tools

Maintenance practices for tools vary. Chisels should be regularly sharpened after being used to cut concrete. Storing them in dry environments prevents rusting making them last longer.

Grinders and drills require regular checking of the moving parts and electricals. The cutting discs and bits should be replaced on time to maintain the cutting radius and boring effectiveness.

D. Common mistakes to avoid

The most common mistake in concrete cutting is having improper PPEs. Goggles and masks protect you from dust and debris produced while cutting concrete. Respiratory and eye complications might start after prolonged exposure to such environment.

Incorrect tool selection is another mistake many people make. Using a sledgehammer is areas that require a chisel and hammer to break causes more damage to the concrete. When using grinders and drills, they should be allowed enough time to cool down. Overheating due to friction can damage the electricals leading to unnecessary expenses.


Whether employing cutting concrete with or without a saw, the key steps for cutting concrete remain consistent. For cutting without a saw, establishing a stable work area, marking precise cutting lines, and employing tools like hammer and chisel or an angle grinder are pivotal.

On the other hand, when using a circular saw, careful setup, accurate line marking, and adjusting the saw for depth and angle are critical steps for success. Throughout these processes, you should prioritize safety by wearing proper protective gear, choosing the right blade, and ensuring adequate cooling.

Precision and caution in concrete cutting projects will help you achieve optimal results and create a secure working environment for operators and tools.