Band Saws

Portable band saws cut metal with a continuous blade running around two wheels, which produces a slow, quiet, sparkless cut and leaves an edge that usually needs no dressing. That is why they have largely replaced abrasive cutting for conduit, strut, threaded rod, cable tray, unistrut and pipe on occupied or fire-sensitive sites: no sparks, no hot slag, no abrasive dust, and a cut that is cool enough to handle. Deep cut saws take the larger capacities — heavy pipe, bar and section — and are the choice where the material dictates the tool. Compact saws cut a smaller capacity but can be used one-handed and in places a full-size saw cannot reach, which on electrical and mechanical work covers most of the day; dual-trigger designs keep both hands on the tool where that is the safer way to hold it. Blade speed and tooth pitch have to suit the wall thickness being cut — too coarse a blade on thin wall strips teeth immediately. Blades are consumables and worth stocking; they are in Accessories & Consumables.

Blade selection follows a simple rule: at least three teeth in contact with the material at all times. On thin-wall EMT or strut that means a fine 18 or 24 TPI blade, while solid bar and heavy pipe want 10 or 14 TPI to clear the chip. Break in a new blade by running the first few cuts at reduced feed pressure, which rounds the tooth edges slightly and roughly doubles blade life. Deep-cut saws take up to about five inches of capacity and suit shop and fabrication work; compact one-handed saws cut around two and a half inches and live in the field. Both beat an abrasive chop saw anywhere a hot work permit would otherwise be required, which is most occupied buildings, and neither leaves an edge that needs deburring before a fitting goes on.