Circular Saws

About Circular Saws

Circular saws are essential power tools for any professional tradesperson or serious DIY enthusiast, offering versatility and efficiency for a wide range of cutting applications. Whether you're working on site framing timber structures, cutting sheet materials in a workshop, or tackling home improvement projects, a quality circular saw delivers fast, accurate straight cuts with minimal effort. At TooledUp, we stock an extensive selection of circular saws from leading manufacturers including DeWalt, Bosch Professional, Festool, and Einhell, ensuring you'll find the perfect tool for your specific needs and budget.

Modern circular saws come in various configurations to suit different applications and working environments. Traditional corded models provide consistent power for demanding jobsite work, whilst cordless circular saws offer unparalleled portability and convenience, particularly for work in locations without mains power. Blade diameters typically range from compact 85mm models for lightweight materials up to full-size 190mm saws capable of cutting through thick timber and engineered wood products. Most circular saws are optimised for wood cutting, though specialised metal cutting circular saws are also available, running at lower speeds specifically calibrated for ferrous and non-ferrous metals.

When selecting a circular saw, you'll encounter both standard handheld models and more sophisticated plunge saws. Standard circular saws excel at general-purpose cutting tasks and represent excellent value, whilst plunge saws offer enhanced precision and superior dust extraction, making them ideal for finish carpentry and fitted joinery work. Understanding the differences between these tools and matching their capabilities to your requirements will ensure you invest in equipment that enhances productivity and delivers professional results.

Jargon Buster

• Blade Diameter: The size of the circular saw blade, typically measured in millimetres (85mm to 190mm). Larger diameter blades allow for greater maximum depth of cut but result in heavier, more cumbersome tools.
• Depth of Cut: The maximum thickness of material a circular saw can cut through in a single pass. This varies depending on the blade angle – cuts at 90 degrees achieve maximum depth, whilst bevel cuts at 45 degrees have reduced capacity.
• Bevel Capacity: The ability to tilt the saw blade to cut angles, typically from 0 to 45 degrees, though some professional models offer up to 50 or 56 degrees for specialised applications.
• Brushless Motor: Modern motor technology that eliminates carbon brushes, resulting in improved efficiency, longer runtime on cordless models, reduced maintenance requirements, and extended tool lifespan.
• Guide Rail Compatible: Circular saws designed to run along precision guide rails (also called plunge tracks) for perfectly straight, splinter-free cuts over longer distances. Essential for cutting large sheet materials accurately.
• Rip Fence: An adjustable guide that attaches parallel to the blade, enabling you to make consistent cuts at a set distance from the material edge – particularly useful for ripping down timber or sheet goods.

Who Uses Circular Saws?

Circular saws are indispensable tools across numerous trades and applications:

• Carpenters and Joiners: For cutting timber frames, floor joists, roof rafters, and general construction carpentry work on site
• Shop Fitters: Breaking down sheet materials, cutting worktops, and fabricating bespoke retail installations
• Roofers: Cutting roof timbers, fascias, and decking materials at height or on scaffolding
• Kitchen Fitters: Trimming worktops, cutting plinths, and preparing materials for fitted kitchen installations
• Groundworkers and Landscapers: Cutting decking boards, fence panels, and formwork for concrete pours
• General Builders: All-round cutting requirements on construction sites, from first fix to finishing work
• Flooring Specialists: Cutting laminate, engineered wood, and solid timber flooring materials
• Shopfitters and Exhibition Stand Builders: Fabricating display units and temporary structures from plywood and MDF
• DIY Enthusiasts and Home Improvers: Garden projects, home renovations, furniture building, and general property maintenance

How to Choose the Right Circular Saws

Power Source: Decide between corded and cordless operation based on your working environment. Corded circular saws provide unlimited runtime and consistent power for intensive applications, making them ideal for workshop use or sites with established power supplies. Cordless models offer superior portability and eliminate trip hazards, with modern 18V platforms from DeWalt, Bosch, and Makita delivering impressive performance. For professional tradespeople already invested in a battery platform, choosing a compatible circular saw maximises value by sharing existing batteries and chargers.

Blade Size and Cutting Capacity: Match the blade diameter to your typical workload. Compact 85mm to 140mm saws suit lighter materials and overhead work where reduced weight minimises fatigue. Mid-size 165mm models represent the sweet spot for general-purpose work, comfortably cutting through standard 50mm timber whilst remaining manageable. Full-size 190mm circular saws deliver maximum cutting depth for heavy structural work, though their increased weight requires more physical effort to control accurately.

Motor Power and Performance: Corded models typically range from 1200W for DIY-grade tools up to 1800W for professional applications. Look for brushless motor technology in cordless models, which delivers superior efficiency and extended battery runtime. Professional-grade saws from manufacturers like Festool and Bosch Professional incorporate electronic motor management systems that maintain blade speed under load, ensuring consistent cutting performance in demanding materials.

Build Quality and Features: Professional tradespeople should prioritise durability with metal base plates, robust blade guards, and quality depth adjustment mechanisms that maintain accuracy over time. Useful features include LED work lights for improved visibility, electric brakes for enhanced safety, dust extraction ports compatible with 35mm vacuum hoses, and tool-free blade changes for increased productivity. Guide rail compatibility is essential if you regularly work with sheet materials requiring precision cuts.

Ergonomics and Handling: A well-balanced circular saw with comfortable grip positions reduces fatigue during extended use. Consider trigger position, handle design, and overall weight distribution. If possible, handle different models before purchasing – what feels comfortable varies between users. Check sight line visibility to the blade and ensure depth and angle adjustment controls are easily accessible whilst wearing work gloves.

Popular Accessories

• Circular Saw Blades: TCT (tungsten carbide tipped) blades in various tooth configurations for different materials – rip blades for cutting with the grain, cross-cut blades for cleaner cuts across the grain, and fine-tooth blades for laminated materials
• Guide Rails and Tracks: Precision aluminium extrusions that ensure perfectly straight cuts, particularly valuable when dimensioning sheet materials like plywood and MDF
• Rip Fences and Parallel Guides: Adjustable guides for making consistent parallel cuts at fixed distances from material edges
• Dust Extraction Adapters: Connectors enabling attachment to workshop vacuums or site dust extractors, essential for maintaining HSE compliance and protecting respiratory health
• Angle and Depth Setting Gauges: Precision measurement tools ensuring accurate setup for bevel cuts and consistent depth settings
• Spare Batteries and Chargers: Additional power packs to maintain productivity throughout the working day, particularly important for cordless models
• Protective Carrying Cases: Durable storage solutions that protect your investment during transport and on-site storage
• Blade Changing Wrenches: Often supplied with the tool, having spares prevents downtime if the original goes missing

Safety Information

Circular saws are powerful cutting tools capable of causing severe injuries if used improperly. Always read and understand the manufacturer's instructions before operating any circular saw, and never bypass or disable safety guards. The rotating blade presents serious risks including deep lacerations, severed fingers, and kickback incidents where the saw is violently thrown backwards towards the operator.

Personal Protective Equipment: Always wear appropriate PPE including safety glasses or a full face shield to protect against flying debris, hearing protection as circular saws typically exceed 85dB, and respiratory protection when cutting materials that produce harmful dust. Steel toe-capped boots provide essential protection if you drop the tool, whilst close-fitting clothing prevents entanglement with the blade. Never wear gloves when operating a circular saw as they can catch on the blade.

Safe Operating Practices: Ensure materials are properly secured before cutting – never hold workpieces by hand. Check for hidden nails, screws, or other obstructions that could cause blade binding and kickback. Maintain a firm two-handed grip with proper stance and footing. Allow the blade to reach full speed before entering the cut, and never force the saw – let the blade do the work. Always wait for the blade to stop completely before setting the tool down.

Electrical Safety and Maintenance: Inspect power cables for damage before each use, and ensure corded models are properly earthed and protected by RCD devices on construction sites. For cordless models, only use manufacturer-approved batteries and chargers. Keep blades sharp and properly tensioned – dull blades require excessive force and increase accident risk. Regularly check that all guards and safety features operate correctly, and never use a saw with damaged or missing guards. Comply with HSE guidance and COSHH regulations regarding dust control, particularly when cutting treated timber or engineered wood products containing formaldehyde.

Frequently Asked Questions

What's the difference between a circular saw and a plunge saw?

Standard circular saws have a fixed blade guard that retracts as you push the saw forward, with cutting typically started from the material edge. Plunge saws feature a spring-loaded mechanism allowing you to lower the spinning blade vertically into the material at any point, making them ideal for cutting internal openings and providing superior dust extraction. Plunge saws generally deliver cleaner, more precise cuts but cost considerably more than standard circular saws. For general construction work, a standard circular saw offers better value, whilst finish carpenters and kitchen fitters benefit from the precision of plunge saws.

What size circular saw do I need for cutting 50mm timber?

A 165mm circular saw comfortably handles 50mm timber with a typical maximum depth of cut around 55-60mm at 90 degrees. This blade size represents the most versatile option for general building work. Whilst a 190mm saw offers greater cutting capacity, the additional weight becomes tiring during extended use. Smaller 140mm cordless models may struggle with 50mm material at full depth, particularly in hardwoods or when batteries run low, though they excel at lighter duties and overhead work.

Are cordless circular saws powerful enough for professional use?

Modern 18V cordless circular saws from professional manufacturers like DeWalt, Bosch, and Milwaukee now rival corded models for most applications, thanks to brushless motor technology and high-capacity lithium-ion batteries. They're perfectly adequate for site work, especially first fix carpentry and general construction tasks. However, for sustained heavy-duty applications like ripping down large quantities of hardwood or cutting thick engineered timber all day, corded models still offer advantages in consistent power and unlimited runtime. Many professionals maintain both types – cordless for portability and convenience, corded for workshop-based production work.

Can I use a wood cutting circular saw to cut metal?

No – standard wood cutting circular saws operate at speeds (typically 4500-6000 RPM) far too high for safely cutting metal. The blade would overheat, teeth would break off, and serious injury could result. Metal cutting circular saws run at much lower speeds (around 1300-1800 RPM) specifically optimised for ferrous and non-ferrous metals. If you need to cut both materials, purchase purpose-specific tools or invest in a multi-material saw explicitly designed for both applications. Never fit a metal cutting blade to a standard wood saw – the speed differential creates dangerous conditions.

How do I prevent splintering when cutting laminated materials?

Splintering occurs primarily on the upper surface where blade teeth exit the material. Use a fine-tooth blade with 40+ teeth specifically designed for laminated materials. Score the cut line with a sharp knife to sever surface fibres before sawing. Apply masking tape along the cut line to support surface laminate. Most effectively, use a guide rail system with an anti-splinter strip that the blade cuts into, providing zero-clearance support right at the cutting edge. Position the material with the good face downward when using standard circular saws, as most splintering occurs on the top surface, or face upward with plunge saws where splintering is predominantly on the underside.