4.6: Tools for Cutting Pipes

 

Tools for Cutting Pipes in HVAC: Choosing the Right Tool for the Job

     Cutting pipes is a fundamental skill in HVAC installations, whether working with copper or plastic piping. A clean, precise cut ensures proper fitting, leak-free connections, and efficient system performance. Depending on the type of material, pipe size, and accessibility of the workspace, HVAC technicians rely on different cutting tools, including pipe cutters, tubing cutters, hacksaws, and plastic pipe shears. Each tool has specific advantages and limitations, making it essential to understand when and how to use them effectively.

---

 

Pipe Cutters: The Clean and Professional Choice for Copper and Metal Pipes

     Pipe cutters are the go-to tool for cutting copper and other metal pipes in HVAC applications. These tools use a rotating cutting wheel to score the pipe gradually, creating a clean, burr-free edge that is ideal for soldering, brazing, or compression fittings.

     The operation is straightforward: the technician places the pipe in the cutter's adjustable jaw, tightens the cutting wheel onto the pipe, and rotates the tool around the pipe while gradually tightening. This controlled cutting process minimizes pipe deformation, ensuring a round, uniform edge.

Pipe cutters come in two primary types:

• Standard Pipe Cutters: Used for rigid copper tubing and larger metal pipes, these tools provide precise, square cuts with minimal effort. They are ideal for on-site HVAC installations where reliability is crucial.
• Mini or Close-Quarters Pipe Cutters: Designed for tight spaces, these smaller versions of standard pipe cutters allow technicians to cut pipes in confined areas, such as inside walls or near obstructions. Their compact size makes them an essential tool for fieldwork and repairs in existing HVAC systems.

     One of the biggest advantages of pipe cutters is their ability to create smooth, even cuts without jagged edges, reducing the risk of leaks and poor-fitting connections. However, they are not ideal for plastic pipes, as the rotating motion tends to crack or deform softer materials.

---

 

Tubing Cutters: Precision Cutting for Small-Diameter Copper and Soft Metal Pipes

     Tubing cutters function similarly to pipe cutters but are specifically designed for smaller-diameter copper tubing used in HVAC refrigerant lines. They feature a sharp cutting wheel and a ratcheting or rotating mechanism, allowing technicians to make precise, clean cuts with minimal material loss.

     The process involves placing the tubing in the cutter, tightening the blade onto the pipe, and rotating it around the pipe while applying slight pressure. The cutting wheel gradually deepens into the tubing until the pipe is severed.

     Tubing cutters are ideal for soft copper, aluminum, and brass tubing, commonly used in HVAC refrigerant lines and small-diameter water lines. The precision of the cut ensures a proper seal, which is crucial for brazing, flaring, and compression fittings in high-pressure HVAC applications.

     While tubing cutters excel in precision cutting, they struggle with larger pipes and are not effective for cutting plastic materials. Additionally, their manual operation requires multiple rotations, making them slower than other cutting methods for thick-walled pipes.

 

  

Image: Close Quarters Tubing Cutter

Image 2: Tubing Cutter

---

 

Hacksaws: The Versatile but Labor-Intensive Option for Cutting Pipes

     A hacksaw is one of the most versatile cutting tools for HVAC piping, capable of cutting both metal and plastic pipes. Unlike specialized pipe cutters, a hacksaw uses a toothed blade to cut through material manually, making it a low-cost, all-purpose cutting solution.

     Hacksaws are particularly useful for cutting PVC, CPVC, and other plastic piping, where rotary-style cutters might crush or crack the material. However, they can also be used for copper and metal pipes, though they produce rougher cuts that require additional deburring before fittings can be applied.

     One of the biggest advantages of a hacksaw is its ability to cut through pipes of any size without the need for a specific pipe diameter range, as required by pipe cutters. However, hacksaws have several downsides:

• They require significant manual effort, especially for thicker metal pipes.
• Cuts are often uneven or jagged, requiring extra deburring with a file or reamer.
• Hacksaws create metal shavings, which can contaminate refrigerant lines if not properly cleaned.

     Despite these drawbacks, a hacksaw is an excellent backup tool for any HVAC technician, especially when specialty cutting tools are not available. For best results, using a fine-toothed blade and applying steady, controlled strokes can improve cut quality.

---

 

Plastic Pipe Shears: The Fastest and Cleanest Cut for PVC, CPVC, and PEX

     Plastic pipe shears are the best tool for cutting PVC, CPVC, and PEX piping in HVAC applications. Unlike rotary pipe cutters or hacksaws, shears use a sharp, scissor-like blade that slices through plastic piping with a single squeeze, providing a clean, burr-free cut in seconds.

     Shears are particularly useful for PEX tubing, which is soft, flexible, and prone to deformation when cut with a hacksaw or rotary cutter. The sharp blade of plastic shears prevents crushing, ensuring a round, uniform cut that allows proper fittings and connections.

     Some plastic pipe shears feature a ratcheting mechanism, which increases cutting force and reduces hand strain when working with thicker-walled PVC or CPVC pipes. This makes them a preferred choice for HVAC technicians installing condensate drains and hydronic piping systems.

     The main drawback of plastic pipe shears is their limited versatility. Unlike hacksaws, they cannot cut copper or metal pipes, meaning HVAC professionals must carry multiple cutting tools when working with both metal and plastic piping systems. Additionally, over time, the blades can dull, requiring periodic sharpening or replacement to maintain clean, effortless cuts.

---

 

Choosing the Right Cutting Tool for the Job

Selecting the appropriate cutting tool depends on pipe material, pipe diameter, and installation environment.

• For rigid copper pipes and refrigerant lines, a pipe cutter or tubing cutter is the best option for precise, smooth cuts that ensure proper sealing and brazing.
• For plastic pipes like PVC, CPVC, and PEX, plastic pipe shears provide the fastest, cleanest cut with minimal deformation.
• For general-purpose cutting, especially in tight spaces, a hacksaw offers versatility but requires additional finishing to smooth rough edges.

     Regardless of the tool used, proper technique and preparation—such as measuring accurately, using the right cutting speed, and deburring metal edges—are essential for ensuring a leak-free, professional installation in HVAC piping systems.