How To Cut Aluminium Copings

As a leading supplier of roofline products, we know that Aluminium copings are an integral part of many building and landscaping projects, providing a flexible, protective finish for walls, roofs and parapets.

Whether you are a professional tradesman or a DIY enthusiast, knowing how to properly cut aluminium copings is essential for a polished and professional look to your property.

Example of an aluminium coping used on a UK property.

Tools You’ll Need for Cutting Aluminium Coping

Before you start cutting aluminium copings, such as the 362mm wall coping, it’s essential to gather the right tools for the job. Using the correct equipment not only makes the task easier but also helps you achieve a clean, accurate cut without damaging the material.

• Angle Grinder: The go-to tool for many professionals, an angle grinder equipped with a thin metal cutting blade is perfect for cutting aluminium coping. The small, rotating blade allows for precise cuts and easy handling.
• Skill Saw: Ideal for making straight cuts, skill saws are robust and versatile. When fitted with a metal cutting blade, they can handle larger sections of coping effortlessly.
• Jig Saw: For more intricate or curved cuts, a jig saw is an excellent choice. Its small, reciprocating blade allows for greater control and flexibility when working with complex profiles.
• Mitre Saw: Known for precision, mitre saws are best for angled or detailed cuts. When equipped with a fine-tooth metal blade, they make quick work of aluminium coping, providing smooth and consistent edges.

 

Recommended Method: Using an Angle Grinder

The angle grinder with a diamond disk is widely recommended for cutting aluminium coping due to its versatility and ease of use.

When used with the correct blade and proper technique, it provides a smooth and precise cut that minimises waste and reduces the risk of damaging the material.

Here are some tips to use an angle grinder effectively.

Steps to Cutting Aluminium Coping with an Angle Grinder:

1. Select the Right Blade:

   • Use a 1mm wide metal cutting blade specifically designed for aluminium. A thin blade provides more precise cuts and reduces heat build-up.

2. Lubricate the Blade:

   • Before cutting, dip the blade in tallow or a suitable lubricant. This step is crucial as it helps reduce friction, keeps the blade cool, and prevents burrs from forming on the cut edges.
     
     

3. Position and Secure the Coping:

   • Place the aluminium coping on a stable surface and secure it with clamps. This ensures that the material won’t shift during the cutting process, allowing for a straight and controlled cut.
     
     

4. Begin Cutting:

   • Slowly guide the angle grinder along your marked line, letting the blade do the work. Avoid forcing the blade through the material as this can cause uneven cuts or damage the coping.
     
     

5. Finish the Cut:

   • Once the cut is complete, inspect the edges. Any slight burrs can be removed with a metal file to ensure a smooth, professional finish.

Key Takeaway: 🔆 Using an angle grinder with the correct blade and lubrication technique ensures precise, clean cuts in aluminium coping, making it a reliable choice for both simple and complex projects.

Alternative Cutting Tools and Techniques

While the angle grinder is highly recommended, there are other tools available that can effectively cut aluminium copings, depending on your project needs.

Each tool offers its own advantages and can be used to achieve different types of cuts. 

Other Tools for Cutting Aluminium Copings:

Skill Saw:

• Best For: Straight cuts on larger pieces of coping.
• How to Use: Mark your cutting line clearly, secure the coping, and use a metal cutting blade designed for aluminium. Skill saws offer stability and power, making them great for handling thicker profiles.

Jig Saw:

• Best For: Intricate, curved, or detailed cuts.
• How to Use: Equip the jig saw with a fine-tooth metal blade. Move the saw slowly and steadily along the marked line, allowing for controlled and precise shaping of the coping.

Mitre Saw:

• Best For: Precision angled cuts, ideal for coping that needs to join at corners.
• How to Use: Secure the coping in the mitre saw, adjust the blade to the desired angle, and cut slowly to maintain accuracy. A mitre saw is especially useful for achieving perfect 45-degree cuts needed for neat joins.

Key Takeaway: 🔆 Alternative tools like skill saws, jig saws, and mitre saws offer versatile options for cutting aluminium coping, each suited to specific types of cuts and project requirements.

Safety Tips

Safety should always be a top priority when cutting. The sharp blades and flying debris can pose serious risks if proper precautions are not taken.

Here’s a guide to staying safe while achieving professional results.

Wear Protective Gear:

• Always wear safety goggles to protect your eyes from flying metal shards.
• Use gloves to protect your hands from sharp edges and hot metal.
• Hearing protection is recommended as cutting metal can be loud and damaging to your ears.

Secure Your Workpiece:

• Use clamps or a sturdy vise to hold the aluminium coping securely in place while cutting. This prevents movement and ensures a precise cut.

Keep the Workspace Clean:

• Clear away any unnecessary tools and debris from your workspace. A tidy area reduces the risk of accidents and makes it easier to focus on the task.

Always Check Your Tools:

• Inspect your tools before use. Ensure the blades are sharp, clean, and free of damage. Blunt or damaged blades can lead to poor cuts and increased risk of accidents.

Key Takeaway: 🔆 Prioritising safety by using the correct protective gear, securing your work, and maintaining a clean workspace ensures a smooth and accident-free cutting process.

Finishing Touches

After successfully cutting your aluminium coping, a few finishing touches can make all the difference in achieving a professional-looking result.

Properly finished edges not only enhance the appearance but also improve the safety and functionality of the coping.

Finishing Steps for Aluminium Coping:

Filing Burrs:

• Use a metal file to smooth out any rough edges or burrs left after cutting. Filing the edges creates a safer, smoother finish that looks clean and polished.

Inspect and Test Fit:

• Before final installation, check that the coping pieces fit together properly. Make any necessary adjustments with a file or saw to ensure a snug, seamless fit.

Cleaning the Coping:

• Wipe down the coping with a clean cloth to remove any dust, metal shavings, or lubricant residue. This step ensures the coping is ready for installation or further finishing, such as painting or sealing.

Key Takeaway: 🔆 Finishing touches like filing and cleaning are crucial for a neat and professional appearance, ensuring your aluminium coping is ready for a perfect installation.

Conclusion

Cutting aluminium copings require the right tools, careful preparation, and a focus on safety to achieve a high-quality finish. Whether using an angle grinder, skill saw, jig saw, or mitre saw, each tool has its strengths and can be tailored to fit the specific needs of your project.

By following the recommended techniques, lubricating blades, and taking the time for proper finishing, you can ensure your aluminium coping is cut cleanly and accurately, enhancing the overall look and longevity of your installation.