Brick is a versatile and attractive building material used in everything from historic homes to modern architecture. However, there may come a time when you need to cut or remove brick from a structure. Knowing the proper techniques for cutting and removing brick safely and efficiently is crucial.

In this comprehensive guide, we will overview 5 key methods for cutting and removing brick, including both manual and power tools. With practice and the right approach, DIYers can gain the skills to take on brickwork projects. Read on to learn essential tips for success!

Gather the Proper Materials and Safety Equipment

Before you start any brick cutting or removal project, be sure you have gathered all the necessary materials and safety gear. Attempting brickwork without the proper equipment can be dangerous and will likely result in subpar results.

Here is a checklist of recommended materials and safety equipment:

• Hammer and Chisel – A manual hammer and chisel set allows for precision cutting of brick. Opt for a masonry chisel made for brick rather than a wood chisel. Wear safety goggles to protect your eyes from flying debris.
• Circular Saw with Diamond Blade – For straight cuts, a circular saw outfitted with a diamond masonry blade is ideal. Be sure to use a specialized blade designed for masonry, not wood. Wear eye protection, ear protection, gloves and a dust mask.
• Masonry Grinder – To smoothly shape brick edges, use an electric or pneumatic masonry grinder with a diamond wheel attachment. Wear a full face shield, gloves, ear protection and a dust mask when operating.
• Masonry Saw – A wet masonry saw is the go-to tool for making curved cuts in brick. The water prevents fine brick dust from becoming airborne. Use eye protection, gloves, ear protection and a dust mask.
• ** SDS Rotary Hammer Drill** – For drilling anchor holes in brick or demolishing brickwork, a heavy-duty SDS rotary hammer drill is a must. Wear eye and ear protection when using this high-powered tool.
• Dust Mask – Cutting or grinding brick produces clouds of thick dust containing crystalline silica. Wearing an N95 dust mask is essential to avoid inhaling this hazardous substance.
• Gloves – Durable work gloves protect hands from abrasions when handling rubble and sharp edges. Leather and rubber coated options offer the best grip and protection.
• Safety Glasses or Full Face Shield – Flying shards and debris are common hazards of brick cutting. Be sure to protect your eyes with ANSI-rated safety goggles or a full face shield.

Gathering the appropriate PPE and tools for working with brick reduces the safety risks involved. Always review tool manuals thoroughly and inspect equipment before use to prevent accidents. Now let’s explore 5 methods for cutting and removing brick!

Method 1: Hand Chiseling Brick

One of the most basic methods for cutting brick is by hand using a hammer and chisel. With practice, this manual technique allows for precision cuts. Follow these simple steps:

Materials Needed

• Hammer
• Masonry chisel
• Eye protection
• Work gloves

Steps

1. Mark your cut line on the brick using a pencil or permanent marker. Chiseling along a marked line helps ensure accuracy.
2. Position the chisel at the edge of the brick on one end of the cut mark. Hold it at a 45 degree angle to the brick face.
3. Firmly strike the head of the chisel using the hammer. Apply repeated forceful blows while moving the chisel along the cut line.
4. Occasionally stop to check your progress. Chip away any rough edges for a smoother cut.
5. Once finished, sweep away any residual dust and debris.

Hand chiseling is ideal for making small notches, holes or cleaning up edges. However, it requires physical strength and is not practical for making long cuts. Combining chiseling with other methods can improve results. Always wear eye protection when chiseling to avoid injury.

Method 2: Masonry Grinder

For smoothing edges and doing detail work on brick, a masonry grinder is the perfect power tool. Follow this process for expert results:

Materials Needed

• Masonry grinder
• Diamond wheel attachment
• Face shield
• Dust mask
• Work gloves

Steps

1. Mark your desired cut line on the brick with a permanent marker. Careful measurements ensure accuracy.
2. Fit the diamond wheel attachment on the grinder. Double check that it is securely mounted.
3. Position your body to avoid direct line of debris. Turn on grinder to recommended speed.
4. Holding grinder firmly with both hands, ease the spinning wheel onto the brick edge. Grind along cut line using steady, even pressure.
5. Periodically dip the wheel in water to prevent overheating and minimize dust.
6. Make repeated grinding passes until the cut is complete. Grind evenly for a smooth edge.
7. When finished, unplug the grinder. Rinse brick dust from the wheel attachment.

Masonry grinders generate clouds of hazardous silica dust. Always work outdoors or use wet cutting methods. Proper PPE is essential for respiratory safety. Grinding wheels become very hot during use – allow for cooling before handling.

Method 3: Circular Saw with Diamond Blade

A circular saw outfitted with a diamond masonry blade is the best option for straight cuts through brick. Here is a step-by-step guide:

Materials Needed

• Circular saw
• Diamond masonry blade
• Eye protection
• Ear protection
• Dust mask
• Gloves

Steps

1. Mark your cut line using a straight edge and permanent marker. Carefully measure and align.
2. Select an appropriate diamond masonry blade for your saw model and brick thickness. Install blade securely.
3. Set brick on a steady surface. Position circular saw aligned to cut line.
4. Wearing PPE, turn saw on, allowing blade to reach full speed.
5. Slowly lower spinning blade into brick, letting the diamond edges do the cutting. Apply gentle pressure.
6. Cut along marked line, keeping blade motion smooth and controlled. Support brick as needed.
7. Make multiple passes if necessary until cut is complete. Turn saw off and allow blade to stop spinning.
8. Check cut for straightness. Use a chisel to clean up any rough sections or corners.

Always use wet cutting methods when possible to reduce dangerous airborne dust. Work cautiously – circular saw blades spinning at high speeds can easily catch and bind.

Method 4: Masonry Saw

For curvy cuts and notches in brick, a masonry saw is the best power tool for the job. Follow these safe and effective steps:

Materials Needed

• Masonry saw
• Diamond masonry blade
• Water
• Eye protection
• Ear protection
• Dust mask
• Gloves

Steps

1. Mark the desired curved cut path on the brick using a pencil or marker.
2. Set up the masonry saw on a level surface and fill reservoir with water.
3. Fit the diamond masonry blade and ensure it is locked in place securely.
4. Position brick in saw bed. Align blade to start of cut mark.
5. Turn masonry saw on and allow blade to reach optimal speed before cutting.
6. Slowly lower the blade into the brick, allowing water to flow over cut point. Apply steady, even pressure.
7. Carefully guide the blade along the marked cut path. Use smooth motions to follow your line.
8. Make multiple passes along cut if needed, allowing water to flow over blade continually.
9. Turn masonry saw off once cut is complete. Rinse away residual slurry and debris.

The water from masonry saws helps suppress dangerous dust. Always wear a dust mask in addition to other PPE for optimal respiratory protection.

Method 5: SDS Rotary Hammer Drill

When time comes to demolish brickwork, the most efficient tool for the job is an SDS rotary hammer drill. Here are helpful tips:

Materials Needed

• SDS rotary hammer drill
• Masonry drill bit
• Ear protection
• Eye protection
• Dust mask
• Gloves

Steps

1. Select a carbide tip masonry drill bit recommended for use with SDS hammer drills.
2. Insert bit into chuck and tighten securely. Ensure bit locks into rotating and hammering modes.
3. Position drill perpendicular to brick surface. Keep body clear of potential debris.
4. Power on hammer drill, allowing it to reach full speed. Apply moderate pressure.
5. Drill holes in strategic locations to break apart mortar joints and weaken brick bonds. Space holes approximately 8-10 inches apart.
6. Continue drilling additional rows of holes as you work across the surface. Widen cracks with a chisel if needed.
7. Once brick and mortar is sufficiently weakened, full bricks or sections can be chiseled out manually.
8. Repeat process until all desired brickwork is removed. Use a pry bar as needed to leverage pieces out.

SDS hammer drills are immensely powerful. Maintain a firm two-handed grip and operate cautiously. Wear sturdy foot protection in case of dropped bricks. Never operate near flammable materials.

Tips for Successful Brick Cutting and Removal

Now that we’ve covered 5 go-to methods for cutting and removing brick, here are some additional tips to ensure your project goes smoothly:

Use Proper Safety Gear

Brickwork is inherently dusty and hazardous. At minimum, always wear eye protection and an N95 respirator mask when cutting or grinding. Use additional gear like ear protection and gloves as needed for your chosen tools.

Practice on Scrap Brick First

Don’t take tools directly to a project on day one. Master your technique by practicing on spare bricks first. Get a feel for how manually tools handle and how different power tools perform.

Cut Slowly and Check Lines Frequently

Rushing through cutting brick risks expensive mistakes and injury. Work slowly and recheck your marked cut line often. Pace yourself for accuracy.

Let Tools Cool Frequently

Masonry grinders, circular saws, and other powered cutting tools generate intense heat that can damage blades. Allow time for cool downs to prevent malfunctions.

Control Dust and Debris

Contain and control brick dust by working outdoors or using wet cutting methods. Sweep up debris frequently to prevent slips or falls. Properly dispose of dust and shards.

Work from Both Sides for Clean Cuts

For complete cuts, gradually penetrate the brick from both the face and back side. Taking turns allows waste material to fully detach.

Account for Brick Expansion

Brick tends to expand slightly when cut. Make cuts 1/8 inch smaller than measurements to compensate for this.

Replace Damaged Blades

Diamond masonry blades wear down over time. Replace blades that become chipped, dull or damaged. Using worn blades risks accidents and poor cuts.

By keeping these tips in mind, you can take on brick cutting and removal tasks with greater confidence. Always err on the side of caution and seek help if unsure how to operate power tools. Now let’s look at frequently asked questions.

FAQs about Cutting and Removing Brick

Cutting and removing brick on your own can seem intimidating for beginners. Here we answer some of the most commonly asked questions:

Can I use a wood chisel on brick instead of a masonry chisel?

It’s best avoid using a woodworking chisel on masonry materials. The steel in wood chisels is not hardened enough to stand up to the abrasiveness of brick. Opt for a chisel specifically designed for brick and concrete instead.

What PPE should I wear when using a masonry saw?

At minimum, always wear eye protection, ear protection, an N95 dust mask, and gloves when using a masonry saw. The water spray helps suppress some dust, but airborne particles are still present. Protect yourself fully.

How do I know which circular saw blade to choose?

Check your saw manual for recommended sizes and RPMs. Look for a diamond masonry blade rated for use with your specific saw model. Ensure the cutting depth is greater than the brick thickness.

Can I cut brick with a wood cutting circular saw blade?

Never attempt to cut brick with a wood blade – it will become damaged very quickly. The diamond edges of masonry blades are essential for cutting through the hardened surface.

What kind of bit works best for hammer drilling brick?

A masonry SDS bit with a carbide tip designed for hammer function is best. Carbide provides hardness and impact resistance when pounding through brick and mortar.

How deep should anchor holes be drilled into brick?

For secure anchoring, drill holes at least 1 inch deeper than the anchor length. This provides ample room for expansion as the anchor tightens.

Is a hammer and chisel able to split full bricks?

Hand chiseling can break apart a scored brick but takes immense effort. For splitting many bricks, use power tools like an SDS hammer drill instead. Work cautiously.

What does the diamond coating do on masonry blades?

The tiny diamond fragments on the blade edges help grind through the abrasive brick material. Diamond is one of the hardest substances and withstands high heat.

How often do diamond masonry blades need replaced?

Expect to replace diamond masonry blades after cutting 20-25 linear feet of 4-inch thick brick. Dull or damaged blades should be swapped out sooner.

Using the proper tools and techniques, nearly any DIYer can learn to cut and remove brick successfully. Always emphasize safety by wearing protective gear, working cautiously, and asking experts if unsure. With some practice and patience, you will gain skill and confidence taking on brickwork projects around your home.

Conclusion

From chiseling small notches to demolishing walls, this guide covers 5 go-to methods for cutting and removing brick. Hand chisels allow for precision and detail work. Masonry grinders smooth edges quickly. Circular saws outfitted with diamond blades make straight cuts a breeze. For curved cuts, masonry saws are ideal. SDS hammer drills efficiently break apart brick when removing entire sections.

Understanding the tools, techniques and safety precautions is key to success. Always wear protective gear like dust masks, eye protection and gloves when cutting or grinding brick. Work slowly and let tools rest to prevent overheating. With the right preparation and practices, DIYers can take on cutting and removing brick tasks confidently.

If a project requires extensive brickwork, don’t hesitate to seek guidance from experienced masonry professionals. For large demolition jobs or structural changes, it’s wise to consult an engineer as well. While meticulous DIYers can learn these skills, certain brick projects are best left to the experts.

For routine tasks like cutting a new opening or removing a damaged section, this overview gives you the essentials for tackling brickwork yourself. With the information learned here, you can choose the best method for your particular needs and impress with your newly acquired abilities. Just remember to emphasize safety, take it slow, and enjoy improving another home DIY skill.