Hacksaw Blades

About Hacksaw Blades

Hacksaw blades are essential cutting tools used across countless trades and DIY applications for cutting metal, plastic, and other hard materials with precision and control. Whether you're a plumber cutting through copper pipes, a mechanical engineer working with steel bar, or a home DIY enthusiast tackling renovation projects, choosing the right hacksaw blade can make the difference between clean, efficient cuts and frustrating, time-consuming work. Modern hacksaw blades come in various materials, tooth configurations, and lengths to suit different materials and cutting requirements.

Our comprehensive range includes bi-metal hacksaw blades offering exceptional durability and flexibility, high-speed steel (HSS) blades for industrial applications, and flexible carbon steel options for general purpose use. We stock standard full-size hacksaw blades (typically 300mm in length) as well as junior hacksaw blades for smaller frames and more intricate work. Leading brands such as Bahco, Irwin, Stanley, DeWalt, and Draper Expert ensure you're getting professional-quality cutting performance that tradespeople rely on daily.

From general-purpose blades suitable for mild steel and aluminium to specialised wood-cutting junior blades and aggressive tooth patterns for rapid material removal, our hacksaw blade selection covers every cutting scenario. Many of our blades feature shatter-resistant construction and precision-ground teeth that maintain their cutting edge through extended use, delivering excellent value for both professional contractors and serious DIY enthusiasts.

Jargon Buster

TPI (Teeth Per Inch)

The number of teeth along one inch of blade length. Higher TPI (24-32) provides finer, smoother cuts ideal for thin materials and precision work, whilst lower TPI (14-18) removes material faster and suits thicker stock and softer metals.

Bi-Metal Construction

Blades manufactured with a high-speed steel cutting edge electron-beam welded to a flexible spring steel backing. This combination delivers both cutting performance and blade flexibility, significantly reducing breakage and extending blade life.

Set

The outward angle of alternating teeth that creates a cutting kerf wider than the blade thickness. Proper set prevents binding and allows efficient chip removal during cutting operations.

Sandflex

Bahco's proprietary bi-metal blade technology featuring hardened teeth and a flexible back, offering exceptional durability and precision for professional applications.

HSS (High-Speed Steel)

A tool steel alloy that maintains hardness at high temperatures, making it ideal for cutting tough materials and maintaining sharpness through extended use in industrial settings.

Kerf

The width of material removed by the blade during cutting. A wider kerf provides better chip clearance but requires more cutting effort, whilst narrower kerfs offer more precise cuts with less waste.

Who Uses Hacksaw Blades?

Hacksaw blades are indispensable tools across a wide range of trades and applications:

• Plumbers and heating engineers – cutting copper pipe, steel tube, and plastic waste systems
• Mechanical engineers and fitters – precision cutting of metal bar, rod, and plate materials
• Electricians – cutting conduit, trunking, and cable tray installations
• Motor mechanics and vehicle technicians – exhaust work, bracket fabrication, and component modification
• Maintenance and facilities engineers – general metalwork, repairs, and fabrication tasks
• Fabricators and welders – preparing materials for welding and assembly work
• HVAC installers – cutting ductwork supports and fixings
• General builders and contractors – cutting metal fixings, brackets, and building materials
• DIY enthusiasts and home improvers – general cutting tasks around the home and workshop
• Model makers and hobbyists – precision cutting for detailed projects

How to Choose the Right Hacksaw Blades

Material You're Cutting: Match your blade to your workpiece material. Bi-metal blades from brands like Bahco Sandflex or Draper Expert offer versatility across most metals. For thick steel sections, choose lower TPI (14-18); for thin sheet metal, tube, or conduit, opt for higher TPI (24-32) to prevent tooth stripping and ensure at least three teeth are in contact with the material.

Blade Length: Standard hacksaws accommodate 300mm (12-inch) blades, whilst junior hacksaws use shorter blades typically around 150mm. Ensure you're purchasing the correct length for your frame – most modern adjustable frames accept standard 300mm blades with hole spacing of approximately 25mm.

Blade Material: Bi-metal construction, as featured in Irwin and Eclipse blades, offers the best combination of cutting performance and durability for professional use. These blades resist shattering and maintain sharpness significantly longer than standard carbon steel options. HSS blades suit industrial power hacksaw applications, whilst flexible carbon steel blades like those from Roughneck provide economical solutions for light-duty work.

Tooth Configuration: Regular set teeth suit general purpose cutting, whilst wavy set patterns on blades like the DeWalt mixed sets provide smoother cuts in thin materials. Consider multi-packs offering different TPI options if you work with varied materials regularly – this gives you flexibility without maintaining extensive stock.

Application Intensity: Professional tradespeople benefit from premium bi-metal blades from Bahco, Irwin, or Stanley that withstand daily site work. Weekend DIY users may find good value in quality mid-range options from Faithfull or Sealey that balance performance with economy.

Specialist Requirements: Wood-cutting junior hacksaw blades feature coarser teeth optimised for timber and composite materials, whilst flexible hacksaw blades allow flush cutting against surfaces where standard rigid blades cannot reach.

Popular Accessories

• Hacksaws and frames – adjustable frames from Stanley, Bahco, and Draper to hold your blades securely
• Junior hacksaws – compact frames for detailed work and confined spaces
• Cutting fluid and lubricants – extend blade life and improve cut quality in metals
• Workbenches and vices – secure workholding for safe, accurate cutting
• Measuring and marking tools – tape measures, squares, and markers for precise cutting lines
• Files and deburring tools – finishing cut edges for professional results
• Safety glasses and gloves – essential PPE for metalworking operations
• Blade storage cases – protect unused blades and keep them organised

Safety Information

Always wear appropriate personal protective equipment when using hacksaw blades, including safety glasses or goggles to protect against metal chips and particles, and work gloves to prevent hand injuries from sharp edges and burrs. Ensure your workpiece is securely clamped in a suitable vice or workbench before cutting – never attempt to cut materials held by hand or in unstable positions.

Inspect blades before use for damage, cracks, or missing teeth. Damaged blades should be disposed of immediately as they can shatter during use, causing serious injury. Install blades with teeth pointing forward (away from the handle) and ensure proper tension – loose blades can twist and break, whilst over-tightened blades may snap under load.

Allow freshly cut metal to cool before handling, as friction can generate significant heat. Be aware that newly cut edges are extremely sharp and require deburring before further handling. When cutting, use smooth, steady strokes and avoid excessive pressure which can cause blade binding or breakage. Follow HSE guidelines for manual handling and maintain good posture to prevent repetitive strain injuries during extended cutting operations.

Dispose of worn or broken blades safely by wrapping them in thick paper or cardboard and clearly marking them as sharp waste. Never leave used blades loose in toolboxes where they present a cutting hazard.

Frequently Asked Questions

What TPI hacksaw blade should I use for cutting steel tube?

For steel tube and pipe, a 24 TPI blade provides the best balance of cutting speed and finish quality. This ensures at least three teeth are in contact with the tube wall at any time, preventing tooth damage and producing clean cuts. For very thin-walled tube (under 2mm), consider a 32 TPI blade to prevent snagging.

How long should a quality hacksaw blade last?

A professional bi-metal blade from brands like Bahco or Irwin should deliver 30-50 cuts or more in mild steel depending on material thickness and cutting technique. Proper blade tension, appropriate cutting speed, and occasional lubrication significantly extend blade life. When cutting becomes noticeably slower or requires excessive pressure, it's time to replace the blade.

Can I use hacksaw blades to cut wood or plastic?

Whilst standard metal-cutting blades can cut plastic and some woods, they're not optimised for these materials. For plastic, use a blade with 24-32 TPI and cut slowly to prevent melting from friction. For wood, specialist wood-cutting junior hacksaw blades with coarser teeth and wider set remove material more efficiently. Standard metal blades used on wood quickly clog with sawdust and lose effectiveness.

Why do my hacksaw blades keep breaking?

Blade breakage typically results from excessive tension, incorrect TPI for the material thickness, twisted or bent blades, or forcing cuts rather than allowing the blade to cut at its natural pace. Ensure your blade is correctly tensioned (firm but not over-tight), select appropriate TPI, maintain straight cutting strokes, and use steady, moderate pressure. Bi-metal blades are significantly more resistant to breakage than carbon steel alternatives.

What's the difference between standard and bi-metal hacksaw blades?

Standard carbon steel blades are economical but relatively brittle and lose sharpness quickly. Bi-metal blades feature high-speed steel cutting teeth welded to a flexible spring steel backing, combining superior cutting performance with flexibility that resists shattering. Whilst initially more expensive, bi-metal blades from Bahco, Irwin, and Stanley last significantly longer and maintain cutting performance, making them more cost-effective for regular use and essential for professional applications.