How to Cut Metal Studs Like a Pro: Detailed Walkthrough

What Are Metal Studs?

Builders use metal studs and joists to create steel frames for buildings. These building materials have been formed into shapes and sizes comparable to dimensional wood through a process called roll forming. 

To create the necessary bends in the metal stud, sheet steel is passed through a series of rollers that progressively form the shape of the stud’s web, flanges, and lips. The process is called cold-form because no heat is used during manufacturing, which makes the studs and joists stronger than the original sheet steel.

Metal studs are typically made from galvanized steel for corrosion resistance. The steel is coated with a thin layer of zinc to prevent rusting and deterioration from moisture exposure. 

Galvanized steel studs are suitable for interior and exterior wall applications. Some manufacturers also offer studs made from stainless steel, which is inherently corrosion-resistant without a coating.

Metal studs come in different thickness gauges. Thicker 20-gauge and 18-gauge studs are used for load-bearing walls. Thinner 25 gauge studs are common for non-load-bearing interior partitions. The flange width also varies, with wider 1 5/8-inch and 2-inch flanges able to support more weight.

Framing With Metal Studs

When constructing walls and structures with metal stud framing, you’ll work with cold-formed steel parts — mainly the studs and tracks. Thicker-gauge studs are used in load-bearing structures like exterior walls that support the weight of the building.

One advantage of steel studs is that they don’t have to fit perfectly like wood. You can take measurements on the wall and cut studs to the same size to save time. If you make a mistake, it’s easy to fix — just unscrew, adjust, and screw the stud back in.

The track fastens studs at the top and bottom. Tracks come in the same widths and thicknesses as studs. Choosing the right gauge track is important for proper load transfer. You can connect the studs to the tracks using self-tapping screws.

Metal stud walls require diagonal bracing because they lack the fastening and shear strength of wood walls. Diagonal steel straps in an X pattern or structural sheathing like plywood brace the walls.

Metal studs conduct heat and cold more readily than wood. Extra insulation is often needed in exterior walls to meet energy codes. Spray foam and fiberglass batts enclosed by rigid foam sheathing improve thermal performance.

The Best Way to Cut Metal Studs

You have the option to use either hand tools or power tools when cutting metal studs. While power tools are the easiest to use and allow you to cut bulk quantities, when you only have a few metal studs to cut, some simple tools can get the job done:

• Aviation Snips: Snips easily cut straight lines in metal studs. Mark both stud sides, bend it backward to crease and cut.
• Hacksaw: A low-cost, easy way to cut metal studs that anyone can use.
• Utility Knife: Use to cut creased sides or all three sides after initial snips.

How to Choose the Right Saw

You’ll find that most contractors keep a circular saw on hand for straight cuts, along with a miter saw for angled cuts. You might also have a chop saw, which is great for straight cuts, though it doesn’t handle angles like a miter saw. Each of these tools is effective for slicing through steel studs.

When working with miter and chop saws, opt for larger blades — 10-inch or 12-inch sizes are best to give you a broader cutting capacity. Make sure your saw is up to the task of cutting through 2×4 studs and is designed specifically for cutting steel structural shapes.

For added flexibility in your projects, consider a portable band saw. This tool is invaluable for making a variety of cuts, whether you’re cutting straight lines, curves, or more complex shapes in different metals.

You can cut studs individually or as a group. They’re normally sold in 10 packs, and you can cut all of them simultaneously. Make sure the blade always contacts the wide side first.

Blades for Cutting Metal Studs

For smooth, straight cuts you’ll need to use the right blade. If you’re working with metal, diamond-tipped blades are the best option for a precise job. For a cheaper option, abrasive grit blades are a solid, less expensive alternative.

Carbide-tipped blades are advantageous for their durability and longevity when cutting various construction metals. Abrasive blades, embedded with materials such as aluminum oxide, ceramic, or diamond, offer different levels of cutting efficiency, with diamond blades ensuring the smoothest cuts with minimal burring.

When cutting steel studs, it’s best to use blades with a density of 80 teeth per inch (TPI). The higher the TPI count, the finer the cuts will be. Remember, it’s important to cut slowly when using high TPI blades to avoid overheating.

Safety Tips

Cutting metal has risks, especially from sharp edges. You can minimize risks by following these precautions:

• Allow the blade to reach full speed before cutting. Feed metal slowly and steadily.
• Ensure blades are sharp and appropriate for the metal. Dull blades increase binding risk.
• For power saws, wear long sleeves, pants, leather gloves, and a face shield.
• Keep hands clear of the blade path. Don’t reach past until it stops spinning.
• Unplug when changing blades.
• Use clamps to secure the metal tightly. Don’t cut freehand.
• Wear heavy gloves and safety glasses for hand tools.

So, Is Cutting Metal Studs Difficult?

Cutting basic steel studs is not overly hard for ambitious DIYers. With sharp blades and a miter saw, the process is similar to cutting wood. Hand tools also work for small jobs.

Your main challenge will be securing the studs to prevent vibration and binding while cutting. Always clamp materials. Support long pieces along their length. Wear protective gear and keep your hands away from the blade.

With practice, cutting metal studs can become second nature. The lighter weight compared to wood makes maneuvering easier. Go slowly and use care for the best results.