How to Cut Asphalt Using a Circular Saw

You can cut asphalt with a regular circular saw if you fit it with a diamond blade rated for asphalt. Set the depth, mark your line, let the saw reach full speed, and feed it slowly without forcing it. The big limit is depth. DeWalt, for example, lists a 2-9/16-inch maximum depth of cut for its DWE575SB 7 1/4-inch saw, so a typical saw of that size gets you roughly 2 1/2 inches, which may not get through a thicker driveway. It's fine for short patch and edge cuts; rent a bigger saw for long or deep ones.

Removing an old driveway → DIY driveway repair →

Can You Cut Asphalt With Circular Saw Blades Meant for Wood?

No. Wood blades and ordinary abrasive discs won't last. You need a diamond blade, and the right kind of diamond blade.

ShunTool, a tool information site, explains that because asphalt is soft, it calls for a diamond blade with a hard bond, and that soft-bond blades don't work well on asphalt pavement. Concrete Cutting Pro goes further, warning never to use a standard concrete blade on asphalt, because soft, abrasive asphalt wears it out two to three times faster.

A few blade pointers:

• Pick an asphalt-rated blade. The packaging should say asphalt or "green concrete/asphalt."
• Segmented rim blades have gaps that let air cool the blade, which suits dry cutting, according to SawsHub.
• Continuous rim blades cut cleaner but need water to stay cool.
• Check the arbor size and maximum RPM so the blade matches your saw.

What You'll Need

• Circular saw (ShunTool recommends a worm drive because it puts less strain on the motor)
• Asphalt-rated diamond blade
• Chalk or marking paint and a straightedge
• Broom
• Safety glasses, hearing protection, a dust respirator, gloves, and sturdy boots
• A long enough extension cord plugged into a GFCI outlet

Steps

1. Check what's underneath. A saw cut this shallow rarely reaches utilities, but if you plan to dig after cutting, contact 811 first.
2. Sweep the area. Clear grit and loose stone.
3. Mark the cut. Snap a chalk line or paint a straight line. For a patch, mark a square or rectangle a few inches outside the damaged area.
4. Set the depth. ShunTool says to set the cut no deeper than the asphalt is thick, because a blade that hits rock or concrete below can crack or skip. It suggests digging at the pavement edge to measure how thick the asphalt is.
5. Let the blade reach full speed before it touches the surface.
6. Feed slowly. Guide the saw along the line with steady pressure. Don't push hard or twist the blade. If it slows or smokes, back off.
7. Make several shallow passes on thick asphalt rather than one deep cut.
8. Finish the cut. If the saw can't reach full depth, score the line as deep as possible, then break the rest free with a chisel or pry bar.

Cutting an opening for a hoop footing is one common reason to do this; see installing a basketball hoop on an asphalt driveway.

Keep the Blade Guard Working

Let the lower guard retract on its own; never tie or wedge it open. Keep both hands on the saw, stand to the side of the blade's path, and keep the cord behind you.

Wet vs. Dry Cutting

Concrete Cutting Pro recommends cutting wet whenever possible, saying it gives 2 to 3 times the blade life along with cleaner cuts. But water and a standard corded circular saw don't mix. Only wet-cut with a saw designed for it, such as a gas cut-off saw with a water attachment.

OSHA's construction silica standard, 29 CFR 1926.1153, covers employers whose workers are exposed to respirable crystalline silica. It sets a permissible exposure limit of 50 micrograms per cubic meter of air over an 8-hour average, and it doesn't apply where exposure will stay below 25 micrograms under any foreseeable conditions. For handheld power saws of any blade diameter, the standard's Table 1 method is a saw with an integrated water system that continuously feeds the blade. Outdoors, that setup needs no respirator for up to 4 hours a shift and an APF 10 respirator beyond that. Employers who don't follow Table 1 have to measure and limit exposure in other ways.

The standard doesn't cover homeowners, but it's a useful benchmark: dry cutting with a handheld saw isn't a Table 1 method, so keep dry cuts short.

Dust and Safety

The stone in asphalt can contain crystalline silica. Wear a well-fitting respirator rated for fine dust, keep the wind at your back, keep kids and pets away, and wear hearing protection.

When to Rent a Bigger Saw

A circular saw is best for short, shallow cuts. Consider renting:

• A gas cut-off saw (often 12 or 14 inches) for deeper cuts
• A walk-behind saw for long, straight cuts across a driveway

Why Clean Cuts Matter

Squaring up a damaged area or trimming a broken edge back to solid pavement leaves clean vertical walls, and those help a patch bond and hold. If you're hiring out a hot mix repair, the crew will make these cuts. Our guide on hot patch repairs shows how cut edges fit into that job. For crumbling sides, our crumbling-edge fixes page shows when trimming makes sense.

Once the patch material is in, compact it properly; see plate compactor vs roller for asphalt patches.

Bottom Line on Cutting Asphalt with a Circular Saw

To cut asphalt with circular saw equipment, use an asphalt-rated diamond blade, set the depth, and feed slowly at full speed. Expect about 2 1/2 inches of depth, control dust, and rent a bigger saw for long or deep cuts.