Metal deck is often used during large commercial construction projects, but sometimes, contractors will use it for smaller-scale projects. If a contractor does choose to use metal deck for a smaller project, they may need to cut the metal deck to fit the smaller space. If you aren’t sure how to cut metal deck, we have you covered.
In this article, we will talk about how to cut deck to meet your specific needs, and the safety precautions that you should take when cutting metal deck.
Safety Precautions for Cutting Metal Deck
Cutting metal deck can be dangerous, so it is important to take proper precautions to ensure your safety and the safety of anyone who may be assisting you. Here are the steps we recommend you take when cutting metal deck:
- Wear both safety goggles or glasses and a face shield. Wearing only one or the other will not provide the same protection from the metal deck.
- Use safety gloves when cutting the deck. When metal deck is cut, small metal burrs are exposed along the edges. These sharp edges can easily cut you if you do not use safety gloves.
- Wear some form of ear protection, such as safety earmuffs. Cutting metal deck is a loud process, and prolonged period can negatively effect your hearing.
- Wear a respiratory mask to protect you from breathing in any debris.
- Use a blade guard for your saw. When you cut through metal deck, you may have some blades explode, especially if you are cutting a large amount of metal deck. A blade guard will protect you from any blowback if a blade does explode while you’re working.
- Cutting metal deck will create flammable sparks. Have a fire extinguisher nearby in case of fire. Additionally, perform a short cutting test to see which way the sparks move so that you can direct them away from yourself and others.
It is very important to follow safety these measures so that you do not injure yourself or someone else, and do not cause any damage to your workspace or surrounding property.
How to Cut Metal Deck
The way that you cut metal deck will depend on whether you are cutting the deck to a shorter length or shorter width.
Cutting Metal Deck to Length
When you need to cut metal deck from its original length to a shorter length, follow these steps:
- Gather your supplies. You will need a saw, saw oil, and a small gas container.
- Lay your sheets of metal deck out. Make sure that you are working in an area where it is safe to cut the deck.
- On the far left side of the sheet, use a tape measure to measure the new length you want, and mark the measurement on the metal deck with a medium point permanent marker. Repeat the same process on the far right side of the sheet.
- If you are planning to cut more than one sheet at a time, bundle the sheets together so that one end is square. Put tape on the square end as measurement.
- Keep in mind that a saw blade is typically 1/8 of an inch thick, and the blade will often wobble when it’s used at a high RPM. This means that you will lose approximately 3/16 of an inch when you cut metal deck, so you need to account for that loss when you are measuring, marking, and cutting sheets of deck.
- Draw a line between the two points on the left and right ends of the sheet of metal deck.
- Use a sturdy material to support both sides of the cut at the ends of the sheet of metal deck. One option is wood dunnage, which is inexpensive, reusable, and typically readily available. You will need two 4X4 inch pieces of wood dunnage for each cut.
- Stand with your legs spread wide. You want to ensure that the sparks from the metal deck don’t hit your legs or feet, as they can injure you or catch your clothing on fire.
- Hold your saw blade straight at a 90 degree angle.
- Cut the sheet of metal deck along the line that you marked. Make sure you are moving the saw in a forward motion along the deck.
Once you have cut your metal deck to your specifications, it can be installed on your project.
Cutting Metal Deck to Width
A sheet of metal deck is typically 36 inches wide. When you come to smaller areas of a project, the deck is usually wider than the area that needs to be covered.
Because metal decking has ribs, there are different approaches to cutting the highs and lows of a sheet of metal deck to width.
To cut the highs of a sheet of metal decking to width, follow these steps:
- Measure the metal deck, and use a medium point permanent marker to mark where you will cut the metal deck.
- Using a cut-off saw or electric shears, follow the mark that you have made along the metal deck.
- Ensure that you are directing any sparks away from yourself and others so that you do not injure yourself, others, or your workspace.
Once you are satisfied with the cut of the highs, you can begin to cut the low point of the ribs.
To cut the lows on a sheet of metal deck, follow these steps:
- Flip the deck upside down so that the low points are now the highs.
- Measure the metal deck, and use a medium point permanent marker to mark where you will cut the metal deck.
- Using a cut-off saw or electric shears, follow the mark that you have made along the metal deck.
- Ensure that you are directing any sparks away from yourself and others so that you do not injure yourself, others, or your workspace.
When you have cut the low and high points to your specifications, you can use the metal deck in your project.
Customized Metal Deck from CSM
While it is possible to cut metal deck yourself, we highly recommend working with a metal deck manufacturer to save time and money.
At CSM Products & Solutions, our manufacturing team has the necessary knowledge and tools to create metal deck that meets the needs of your small-scale construction project. We can also ship metal deck directly to your project site, cutting out the need for a third-party delivery company.
Want to get started on your order of metal deck? Contact us today – we are happy to help you with your next project.
