Best Hole Saw for Cutting 20mm and 40mm Hole Through Brick Wall of 2026 for Clean Cuts

Wandering pilot bits and chipped exterior masonry ruin clean conduit runs and pipe penetrations in seconds. Drilling through solid clay or concrete block demands serious impact tolerance, stout carbide teeth, and deep flute clearance that will not choke on red brick dust. If you need clean 20mm holes for electrical conduits and 40mm bores for domestic waste pipes, picking the best hole saw for cutting 20mm and 40mm hole through brick wall saves your rotary hammer from motor burnout while preventing nasty wall blowouts. Working with masonry requires matching your drill shank to the right arbor, much like selecting specialized cutting tools for tough dense materials where standard bi-metal teeth would instantly strip.

Solid brick quickly destroys thin bi-metal hole cutters, which means tungsten carbide tipped (TCT) teeth and heavy-gauge core barrels are essential for penetrating exterior walls. Based on our detailed comparison of shank designs, ventilation slots, and verified user feedback across major brands like ZELCAN and METOTY, using dedicated masonry cores with SDS Plus or SDS Max arbors delivers far smoother cutting action than standard cutters. Reliable chip clearance ports prevent binding inside deep masonry, keeping the cutting perimeter cooler and extending the service life of your gear.

Frequently Asked Questions About Brick Hole Cutters

Can you use a standard bi-metal hole saw on a brick wall?

No, standard bi-metal hole saws will instantly dull and strip their teeth on masonry. Brick requires tungsten carbide tipped (TCT) teeth or diamond grit that can withstand abrasive masonry friction. Thin bi-metal teeth are designed for timber and sheet metal, meaning they quickly overheat and fail against kiln-fired brick.

Should you use hammer mode when drilling brick with a hole saw?

Yes, hammer action or rotary hammer mode is generally required for TCT masonry core bits to pulverize dense brick. However, for brittle engineering brick or when starting the pilot hole, rotary-only mode helps prevent surface spalling. Once the circular groove is established, switching to hammer action speeds up penetration.

How do you prevent blowout on the back side of an exterior brick wall?

Drilling a small pilot hole completely through the wall first and finishing the core cut from the outside inward prevents back-face blowout. Heavy hammer action can shatter the exterior face of soft facing brick as the bit exits. Relieving feed pressure right before breakthrough also keeps the brickwork neat, similar to careful backer techniques seen with proper cutting gear setups on delicate construction materials.

What drill shank type works best for 20mm and 40mm masonry hole saws?

SDS Plus shanks offer the most reliable torque transfer and hammer impact efficiency for masonry holes up to 40mm. Standard 3-jaw drill chucks often slip under high rotational resistance in masonry. SDS Plus rods lock firmly into rotary hammer drills, ensuring the best hole saw for cutting 20mm and 40mm hole through brick wall operates without arbor slipping.

How do you clear brick dust and debris from deep core cuts?

Backing the hole saw out of the cut every 10 to 15 seconds allows built-up dust and brick chips to escape. Ventilation flutes and body slots help eject debris, but packed brick powder will cause friction lock if not cleared frequently. Using a low rotational speed prevents excessive heat buildup while maintaining steady dust flow.

Why are 20mm and 40mm the standard sizes for wall penetrations?

A 20mm hole accommodates standard 16mm to 20mm electrical conduit and cabling, while a 40mm hole fits standard 1-1/4 inch to 1-1/2 inch domestic waste and condensate pipes. Having dedicated core bits for both dimensions ensures clean, airtight pipe runs without unnecessary patching. In 2026, multi-size SDS masonry kits provide these exact diameters for rapid utility rough-ins.

About the author