Durock is a durable and robust material. It is a multipurpose product used in tiling, flooring, and countertops. Cheap, easy to install, and comfortable to use, the Durock has captured the market with its extraordinary qualities. With a high demand for Durock, it is now becoming the new favorite of the workmen. So, in this article, we are going to discuss how to cut durock with some of the easy and effective methods.
Contents
How To Cut Durock – Different Methods
Method 1: Manual Process
As the name is already indicating, in this process, we use simple tools and human strength to cut Durock. It is a simple process with significant results. However, it has its limitations. It applies only to the Durock sheets, which are thinner.
Total Time: 1 Hour
Step 1
First of all, keep the Durock board at a flat leveled surface. Keep in mind to lay it down on a workstation. Now since it is the manual process, you will be using strength to cut the Durock sheet. So, practically it will be impossible to cut a very thick sheet by this method. So the sheet should not be more than 1⁄4 inch (0.64 cm) to 1⁄2 inch (1.3 cm) thick.
Step 2
Now that you have the Durock sheet spread evenly on the flat surface of the workstation, it is time to move forward. In this step, you need to mark the sheet. Take a carpenter’s pencil. Draw the line at the exact spot where you want to cut the board. If you are not sure about the orientation of the line and are not confident with freehand drawing, you can use a ruler. Ensure that the line is straight and visible.
Step 3
Now it is time to use the knife. Take a utility knife. It will help you to cut along the marked line. You must keep the board on a flat surface to ensure an even and clean cut. Now, put the utility knife on the line that you have marked with the pencil on the Durock sheet. Retrace the line with the knife. Apply an appropriate amount of pressure on the knife.
Make sure that the knife does not waver from the line drawn earlier. You can put the ruler on the marked line and trace the knife against it for a straight cut. Repeat the process 2 to 3 times. Make sure that the knife penetrates halfway through the sheet. If you make more in-depth cuts, it will be easy for you to break the board manually.
Step 4
Now pick up the board carefully in a vertical fashion. Place it on your knee. You must keep in mind to put your knee on the backside of the board. Now apply pressure along with the cuts and split the board.
Step 5
Now that the board is split into two parts, it is time for some finishing tasks. There might be some fiberglass mesh or wire inside the board. So, take the utility knife.
Method 2: Circular Saw
Durock boards like Durock are very hard, and so it is not easy to cut them with bare hands. The manual method works but only on boards with less thickness. But when it comes to cutting heavy thick boards of Durock, one has to resort to power tools.
So, in this method, we will use a circular saw to cut the Durock.
Step 1
First of all, take a circular saw with a wood cutting blade tipped with carbide. These blades are best suited for cutting Durock because these have fewer teeth as compared to other blades available for the circular saw. If you choose a blade with more teeth, it might damage the board.
Step 2
You must be familiar with this step as you have already done this in the manual method. Take a carpenter’s pencil and draw straight lines on the board from where you want to cut the Durock. You can use a ruler. This line needs to be straight because this line will aid you while cutting the board. Make sure that the line is visible.
Step 3
Now it is time to adjust the depth of the blade. You should set the blade’s depth to extend up to 1⁄2 inch or 1.3 cm below the board. Make sure that the circular saw is unplugged while you are adjusting it.
Step 4
Now keep the board upside down on the workbench. Align the saw blade with the cutting line drawn by you earlier on the Durock board. It is essential to keep the board upside down so that the blade of the circular saw should cut it from the back, and the front side can have a smooth edge. Another vital point to keep in mind is to make sure that the board is firm and steady and should not shake while cutting.
Step 5
Plug the saw and switch it on. Now put it on it’s maximum speed before letting it touch the board. This is essential because if the saw blades are not at their maximum speed beforehand, it might not be able to cut through the board. Moreover, due to its slow speed, it could break, and you could get injured.
Step 6
Now that the saw is at its highest speed start cutting the board. Slowly and steadily push the saw through the Durock board along the line drawn by you earlier. Do not lose control of the saw while cutting. Try to have a firm hold on the saw. Be patient and do not rush the process as if you hurry, the saw could be jammed because of Durock and stop working.
your blade gets jammed, take the saw out and let it spin for a while. Let the saw reach its maximum speed and then start cutting again. Also, ensure that there is enough space on the workbench so that the halves of the Durock board does not fall or break.
Method 3: JigSaw
In this method, we will use a jigsaw to cut the Durock. As most of you know, the jigsaw is generally used to make round cuts in any material. It is also known as a power scroll. It is perfectly capable of cutting a material straight and round. So, let us start the work!
Step 1
First of all, you should fit a metal cutting blade in the jigsaw. Durock is a tough material to cut through, so you need to choose the blade wisely. Either use a metal cutting blade or a carbide grit blade.
Step 2
Now keep the Durock on a sawhorse or workbench. In this method, we will keep the Durock with the front-facing up. Then again, start the marking process with the help of a ruler and a carpenter’s pencil. It is an essential step because the marks guide you while cutting. One of the advantages of using a jigsaw is that it gives a customizable cut. However, if you want, you can use a stencil to cut irregular or round shapes.
Step 3
You should now drill a hole for the jigsaw to fit into the board. The hole will help in the straightforward motion of the jigsaw. It is necessary to let the jigsaw turn freely while cutting; otherwise, the blade can break.
Step 4
Now, after fitting the jigsaw into the hole perfectly, move on to the next job. Turn the jigsaw on and put it on its maximum speed before it touches the Durock board. If the saw blade is not at its maximum speed, there are chances that it will bend or break while cutting the Durock.
Step 5
Now keep pushing the jigsaw at a slow pace through the board. It is necessary to apply steady pressure on the jigsaw to ensure a smooth cut. Make sure that you cut along the guiding lines. If there is any problem while cutting, turn the saw off and check for it. Once all is set, resume cutting. After finishing, keep the halves separately and properly to avoid any damage.
Things You Need To Cut Durock
- Ruler
- Carpenter’s Pencil
- Safety Glasses
- Protective Face Mask
- Work Station
- Utility Knife
- Jigsaw
- Circular Saw
FAQs
1. I want to cut the Durock sheet for the countertop. I need the edges of my Durock to be rounded. Which tool should I use?
You should use a jigsaw. Jigsaws are best for cutting round edges. As we discussed earlier, jigsaws provide more shape options according to your requirement. You can also use a stencil to help you while cutting with a jigsaw.
Final Thoughts
Cutting Durock may seem to be a problematic job, apparently because of the toughness of the material, but it is easy. If you have the right tools and a little skill, you can easily follow any of the processes listed above and do it on your own.
Just make sure that you are using all the protective gear and taking all safety measures while working with power tools.
Leave a Reply