Asphalt Cutting: The Best Blades & Saw Selection Guide

Cutting asphalt requires the right tools and techniques to ensure clean and precise cuts. Whether you’re involved in road construction, utility trenching, or pavement repairs, using the correct cutting equipment is crucial to achieving optimal results and minimizing equipment wear. This guide is designed for contractors and construction wholesalers, providing expert advice on the best tools for cutting asphalt, as well as techniques to ensure efficient and professional outcomes.

In this article, we will cover:

• The best tools for cutting asphalt

• Choosing the right blade

• Step-by-step guide for cutting asphalt

• Johnson Tools' premium products for professional results

Essential Tools for Cutting Asphalt

Before starting any asphalt cutting project, it’s important to choose the right tools. The tools you need depend on the type of asphalt you’re working with, the project size, and the cutting requirements. Here’s a breakdown of the best tools for cutting asphalt, which are suitable for both large-scale projects and precision work.

Walk-Behind Road Cutter

A walk-behind road cutter, also known as a surface cutter, is ideal for cutting large areas or making deep cuts in asphalt. These machines are designed to provide straight, clean cuts and are excellent for trenching or cutting long strips in paved roads or driveways. The Diamond Products 16-Inch Walk-Behind Cutter is a reliable option, offering high performance and precision.

For professionals handling larger asphalt cutting jobs, a high-quality road cutter is essential for efficiency and precision.

Handheld Asphalt Cutter

A handheld asphalt cutter is suitable for cutting smaller areas or specific sections of asphalt, such as paving repairs or trenching for cables. It can be used for both shallow and deep cuts, depending on the type of saw blade used. The Makita 14-Inch Handheld Cutter is a popular choice, offering powerful cutting ability in a portable, compact design.

When working in tight spaces or for small-scale jobs, handheld cutters provide flexibility and maneuverability.

Angle Grinder with Diamond Blade

An angle grinder is a versatile tool used for making curved cuts or adjustments in asphalt around fixtures. When equipped with a diamond blade, an angle grinder provides a precise and efficient cutting solution. The DeWalt 4.5-Inch Angle Grinder is a highly recommended model, offering reliable performance for cutting through tough asphalt surfaces.

Angle grinders are also ideal for cutting along edges, allowing contractors to make detailed cuts in confined spaces.

Diamond Blades for Asphalt

Using the right diamond blade is crucial for efficient and clean asphalt cutting. The blade you choose directly affects the performance and quality of the cut. Let’s explore the most common types of diamond blades for asphalt cutting and when to use them.

Continuous Rim Diamond Blade

The continuous rim diamond blade is designed for smooth, chip-free cuts. It’s perfect for cutting ceramic, porcelain, and asphalt without causing cracks or damage to the material. A recommended blade is the DEWALT 7-Inch Continuous Rim Diamond Blade, known for its clean cutting performance and durability for asphalt applications.

Turbo Rim Diamond Blade

For faster cuts, the turbo rim diamond blade is the best option. While it might cause slight chipping, it provides excellent speed and performance. The Bosch 4.5-Inch Turbo Rim Blade is an excellent choice for larger projects where speed is more important than a perfectly smooth edge.

Segmented Diamond Blade

The segmented diamond blade is designed for rough cuts in tough materials like stone, concrete, and asphalt. It is ideal for heavy-duty use but may cause more chipping on softer materials. The Makita 7-Inch Segmented Diamond Blade is a great choice for general cutting tasks in asphalt and stone.

Johnson Tools offers a wide range of diamond blades designed for high-performance asphalt cutting, ensuring clean, efficient results every time. For heavy-duty projects, consider the Johnson Tools Diamond Asphalt Blades, which are engineered to deliver exceptional durability and precision.

Explore Johnson Tools Diamond Asphalt Blades

Step-by-Step Guide: How to Cut Asphalt Like a Pro

Cutting asphalt can seem daunting, but by following these steps, you can ensure a clean, professional cut every time. Here’s a detailed guide to help you navigate the asphalt cutting process:

Step 1: Gather Your Tools & Safety Gear

Before beginning, make sure you have the right equipment:

• Road cutters, handheld asphalt saws, angle grinders, and diamond blades

• Clamps, painter’s tape, and masking tape for securing and marking the asphalt

• Personal protective equipment (PPE): gloves, goggles, dust masks, and ear protection

• Water supply or dust extraction system for wet or dry cutting

Proper preparation ensures efficiency and safety throughout the project.

Step 2: Mark & Secure the Asphalt for Cutting

Use a chalk line or spray paint to mark the cutting lines on the asphalt. For straight cuts, a straightedge or laser line is recommended. Secure the area with masking tape to prevent the blade from causing rough edges or cracks. Make sure the asphalt is clean and free from debris before starting the cutting process.

Step 3: Cutting Methods Based on Tool Choice

How to Cut Asphalt with a Walk-Behind Cutter

• Align the cutter with the marked line and adjust the cutting depth.

• Start the cutter and slowly push it forward, following the marked line.

• Ensure the blade maintains a consistent cutting speed for smooth, uniform cuts.

Cutting Asphalt with a Handheld Cutter

• Install the appropriate diamond blade and adjust the depth of the cut.

• Hold the cutter firmly and make steady passes along the marked line.

• Use slow, controlled movements to avoid uneven cuts.

Cutting Asphalt with an Angle Grinder

• Attach the diamond blade and set the grinder to the proper speed.

• Cut along the line with steady, smooth pressure, ensuring the grinder doesn’t overheat.

Step 4: Finishing & Polishing the Cut

After completing the cut, use a grinding wheel or sanding pad to smooth the edges of the asphalt. This is especially important for curved cuts or when installing additional layers of asphalt. Clean the cut area thoroughly to remove dust and debris, ensuring a professional finish.

Asphalt Cutting vs. Concrete Cutting

While cutting asphalt is similar to cutting concrete, there are some key differences:

• Asphalt: Asphalt is softer and more flexible, requiring softer diamond blades and often wet cutting methods for clean, chip-free cuts. The Johnson Tools 14-Inch Diamond Asphalt Blade is specifically designed for this purpose, providing efficiency and longevity.

• Concrete: Concrete is much harder, requiring more durable blades and the use of high-speed saws for deep cuts. If cutting through both materials in the same project, be sure to use dedicated blades for each to achieve optimal results.

Common Problems and How to Avoid Them

Why is my asphalt cracking during cutting?
This is usually caused by cutting too quickly or using an inappropriate blade. Ensure you’re using the right diamond blade and maintaining a consistent, slow cutting pace.

Why are the edges of my cut rough?
Rough edges often result from using a harder blade or cutting too aggressively. Switch to a continuous rim diamond blade for smoother cuts, or use wet cutting to reduce friction and heat.

Can I use a concrete blade to cut asphalt?
It’s best to use a blade designed specifically for asphalt. Concrete blades are too hard and will wear out faster when cutting softer materials like asphalt.

How do I prevent overheating during cutting?
Use wet cutting whenever possible, and allow the blade to cool between cuts to avoid overheating. If dry cutting is necessary, ensure you have an industrial dust extraction system in place.

Recommended Asphalt Cutting Tools & Accessories

To ensure smooth and efficient asphalt cutting, using the right tools is essential. Here are some top-rated products and accessories to help:

• DEWALT D24000S Wet Tile Saw – A reliable option for precision asphalt cutting.

• Johnson Tools 14-Inch Diamond Asphalt Blade – Ideal for deep, fast cuts with excellent durability.

Cutting Accessories:

• Bosch Dust Extraction System – Keeps the worksite cleaner by removing dust during dry cutting.

• Diamond Polishing Pads – Ideal for smoothing the edges of asphalt cuts.

Conclusion

Mastering asphalt cutting is essential for professional contractors. With the right tools, blades, and techniques, you can achieve clean, precise cuts that ensure the durability and safety of your asphalt projects. Whether you're cutting for road repairs, utility trenches, or other asphalt applications, using high-quality equipment, like the Johnson Tools Diamond Asphalt Blade, ensures your work is efficient and meets industry standards.

Ready to take your asphalt cutting to the next level? Visit Johnson Tools Official Website to explore our premium diamond blades and cutting tools. Enhance your efficiency with our top-rated products designed for professionals like you. Contact us today for personalized solutions and to get the best tools for your projects!