Cut Aluminum Deck Railings

How To Cut Aluminum Deck Railings?

Aluminum deck railings can be a great choice in terms of style, durability and cost. But if you’re not used to working with metal, cutting aluminum can present some challenges that aren’t found when dealing with other materials. Cutting aluminum deck railings requires special tools and techniques to ensure both safeties while working and accuracy while cutting your desired shape or size.

In this blog post, we’ll walk you through the necessary steps for properly measuring and then safely cutting aluminum deck railings so you can customize them to fit your needs!

Things to Consider While Cutting Aluminum Deck Railings

Tools and Equipment Needed

Here is a list of the tools and equipment you will need to get started on cutting aluminum deck railings:

  1. Metal saw: A metal saw is the best tool for cutting aluminum deck railings since it is specifically designed to cut metal. It will help you make precise cuts and ensure you are cutting at the correct angle.
  2. Safety goggles and gloves: Safety should always be your number one priority when working with sharp tools like a metal saw. Wearing safety goggles and gloves will protect your eyes and hands from any flying pieces of aluminum while cutting.
  3. Tape measure: Using a tape measure is essential to ensure that you are measuring the correct dimensions for your cut. Taking accurate measurements will also help you make more precise cuts, resulting in a better finished product.
  4. Measuring tape: Measuring the area where you are going to be cutting your aluminum deck railing is important for ensuring accuracy. A regular measuring tape will suffice, but a laser measuring tool can also be used.
  5. Pencil: A pencil is needed for marking the area where you are going to be cutting.
  6. Level: A level will help you ensure accuracy when cutting your aluminum deck railings. It is used to check that the railing is slanted in the right direction.
  7. Clamps and or vice grips: Clamps and/or vice grips can be used to hold the railing in place while you cut it.

Now that you have all the necessary tools and equipment, you can start cutting your aluminum deck railings!

Safety Equipment

  • Hard hat
  • Ear protection (earplugs, earmuffs, etc.)
  • Dust mask
  • Goggles and face shield
  • Work gloves
  • Steel-toed work boots

Preparation of Tools and Equipment

  • Check the saw blade for any signs of damage.
  • Make sure the saw is properly lubricated.
  • Make sure all clamps and vice grips are securely in place to avoid accidents while cutting.
  • Ensure that safety goggles, gloves and other protective gear are worn at all times.
  • Measure the area to be cut accurately with a tape measure or laser measuring tool.
  • Mark the area with a pencil so you know exactly where to cut.
  • Set your level on top of the railing to make sure it is slanted in the right direction

Steps for Cutting Aluminum Deck Railings

Here are the steps for cutting aluminum deck railings

  1. Measuring and Marking the Cutting Line
  2. Measure your desired length or shape with a tape measure or laser measuring tool.
  3. Mark the area with a pencil to indicate where you’ll be cutting.

Setting Up the Work Area

  1. Set up a work area on a flat and stable surface.
  2. Make sure your clamps and vice grips are securely in place to hold the railing.
  3. Put on your safety goggles and gloves before proceeding.

Cutting the Railing

  • Start the metal saw and slowly guide it along the marked line.
  • Make sure to keep your hands away from the saw blade at all times.
  • Cut slowly and steadily, making sure to keep the saw blade at a perpendicular angle.

Finishing The Cut Edge

  • Once the cut is complete, use a hand file to smooth out any rough edges.
  • Sand down any sharp edges with a piece of sandpaper for a smooth finish.
  • Use a rag to remove any metal shavings or debris from the work area.

And that’s it! With these steps, you should now be able to cut your aluminum deck railings with confidence. Remember to take all necessary safety precautions while operating any power tools.

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Tips for Cutting Aluminum Deck Railings

1) Proper Cutting Technique

  • Cut slowly and steadily, ensuring that your saw blade is at a perpendicular angle.
  • Make sure to stay focused while cutting and keep your hands away from the saw blade.

2) Maintenance of Tools and Equipment

  • Make sure to check the saw blade for any signs of damage before each use.
  • Properly lubricate the saw with oil or grease to ensure optimal performance and minimize wear and tear.

3) Safety Measures

  • Always wear the necessary safety gear such as a hard hat, ear protection, dust mask, goggles and face shield, work gloves and steel-toed work boots.
  • Make sure to keep the area free of debris and remove any metal shavings after cutting.
  • Disconnect the power source from the saw before performing any maintenance work.


Aluminum is a popular material for deck railings because it’s durable and low-maintenance. If you’re looking to cut your aluminum deck railings, there are a few things you need to keep in mind.

  • First, make sure you have the right tools.
  • Second, take your time and measure twice before cutting once.
  • And finally, use a good quality saw blade designed for cutting aluminum.

Following these tips will help you get clean, precise cuts on your aluminum deck railings – giving you the perfect finished product.

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