Drywall is an inexpensive way to finish your home.
However, drywall isn’t the most durable material on the market.
If you need walls that can hold up against dents and scratches, then you may be considering blueboard instead.
Blueboard is a durable plaster that acts like drywall.
It can even be helpful for hiding joints and seams.
One of the hardest things about blueboard is cutting it.
We’ll provide eight methods to cut blueboard safely.
How To Cut Blueboard (Step-By-Step Guide)
Method 1: Use A Scorer
The least expensive way to cut blueboard is to score it.
The scorer digs deep enough into the blueboard for you to break it apart with your hands.
You can make it easier by using a tool that’s specifically made for scoring, but anything that cuts will work.
This method won’t work as well on thicker pieces of blueboard.
It’s possible, but it will take more time and effort.
The best thickness for this method is a quarter of an inch thick.
The cut will leave jagged edges.
Follow these steps to use a scorer to cut your blueboard.
Step 1: Gather The Materials
There are two main tools you’ll need for this method.
The first is a scorer.
This is a sharp blade that can pierce through most materials.
The goal isn’t to completely slice through it.
Instead, a scorer digs into the surface and creates a deep cut.
You can also use a utility knife if that’s all you have on hand.
In addition to a scorer, you’ll need clamps.
You can perform this method on the ground, but it’s easier if you can clamp the board to a table.
Step 2: Attach Blueboard To Clamps
Place the blueboard on the table and clamp it in place.
Use a 2×4 or another block of wood as your cutting guide and clamp that in place, too.
Step 3: Score The Blueboard
Mark the line that you want to cut using the wooden beam as your guide.
Then take your scorer and follow the marked line.
You can run it along the edge of the guide to ensure you cut it straight.
Because fiber cement is tough to cut through, you’ll need to score along the same line a few times.
Apply enough pressure to dig deeper and deeper into the board with every cut.
Step 4: Push Down On The Blueboard And Break It Off
Once the score is deep enough, around halfway through the board, you can break it off.
If your board is on a table, then you can use gravity to your advantage.
Push down on the board until it breaks off cleanly.
If you’re cutting the board on the ground, then grip the edges of the board and pull it up toward you.
The scoring weakens the spine which allows you to break it off yourself.
The result is a cut piece of blueboard with a jagged edge.
This method is ideal for those who want to create a minimal amount of dust.
Step 5: Sand As Necessary
Removing the jagged edge is easy.
Take some sandpaper or a sander and run it along the edge.
In no time, the edges will be smooth, and the board will be ready for installation.
Method 2: Use A Circular Saw
A circular saw is also effective at cutting blueboard.
The problem with this is that it generates a lot of dust.
Blueboard dust contains silica, which is known to cause cancer.
If you intend to use this method, then you need to wear protection.
You can also lay down tarps to make cleaning up easier.
Otherwise, this method is ideal for thick pieces of blueboard.
Follow these steps to use a circular saw to cut the blueboard.
Step 1: Gather The Materials
You’ll need a circular saw for this method.
The blade you use is important, too.
You’ll want to find a fiber cement blade at your local hardware store for your circular saw.
Attach the blade to the saw.
It’s a good idea to have a few extra blades because cutting the blueboard will dull the blade fast.
Aside from the saw, you’ll also need protective equipment like a mask and gloves.
Step 2: Attach Blueboard To Cutting Frame With Clamps
Like the scorer, you’ll want to clamp down the board to keep it from moving.
Clamp down a metal or wooden beam to act as a cutting guide as well.
Step 3: Mark And Cut Line
Mark where you need to cut the blueboard.
Then take the circular saw and cut along that line.
Move slow to ensure you control the saw and direction of the cut.
Once you cut the board, it will fall away from the rest of it.
Step 4: Clean Up The Dust
Don’t remove your protective gear while there is dust around.
Dispose of the dust, then you can remove your mask and gloves.
The edge of the board may need light sanding, but this will be a cleaner cut than with the scorer.
Method 3: Use A Grinder
A grinder is also an effective way to cut blueboard.
In some ways, it’s more effective than a scorer or a circular saw because certain brands of those tools cause the blueboard to crumble instead of cutting in a clean line.
The problem with the grinder is that it also produces a lot of dust like the circular saw method.
It can also be difficult to use if you’re new to using grinders.
Follow these steps to use a grinder to cut blueboard.
Step 1: Gather The Materials
Besides clamps, you’ll need the right kind of grinding disc.
You’ll need a four-inch grinder with a masonry disc.
This type of disc cuts through fiber cement well.
Buy a few because the disc will dull with use.
Step 2: Attach Blueboard To Cutting Frame
You’ll need to clamp the board to a table or cutting frame.
Then mark the line that you need to cut.
Adding a metal guide can help you cut in a straight line.
Step 3: Slowly Grind Down The Line
Follow the line that you made and move your grinder slowly along it.
The blade will start to cut through the fiber cement, but it will generate a lot of dust in the process.
You shouldn’t use this method without wearing protection.
You also need to grind your blueboard outside.
Once you run the grinder along the line once, go back over it a few times.
It’s similar to scoring except you’re using a power tool.
Step 4: Grind The Edge
After you cut the board, you can use the grinder to smooth the edges of the cut.
A few places may crumble depending on the quality of blueboard you bought.
Keep running the grinding wheel along the edge until it’s smooth.
Method 4: Use A Jigsaw
One of the best ways to cut blueboard is with a jigsaw.
It allows you to cut straight lines and curves with ease.
It also creates minimal dust although you should still wear protection.
Follow these steps to cut blueboard with a jigsaw.
Step 1: Gather The Materials
You’ll need a jigsaw if you don’t have one already.
The blade is the most important item to buy.
There are two blades that can cut through fiber cement.
The first is a specialty blade specifically made for cutting through fiber cement.
Because it’s a special blade, it will be expensive.
The other option is to use a coarse wood blade.
The blade can cut through fiber cement, but it will dull faster in the process.
It’s more affordable than the specialty blade.
Choose the option that works for your needs, but if you are going to use the wood blade, then you should buy a few.
Step 2: Set Jigsaw To Orbital Direction
Most people use jigsaws in the vertical direction.
It drives the blade up and down.
This is effective in cutting most materials, but it isn’t that efficient for fiber cement.
Instead, use the orbital direction.
This will make the blade cut in a circular shape.
It orbits the blueboard.
The direction makes it easier for the blade to cut through the fiber cement.
Step 3: Line Up Jigsaw With Mark And Cut Slowly
Mark the line that you want to cut.
Then line the jigsaw up with the mark and start to cut it.
The way to cut cleanly and accurately is to go slowly.
Take your time running down the line with the jigsaw.
The jigsaw will cut through the blueboard without any problem.
Step 4: Clean Up Dust As Necessary
Although jigsaws don’t produce that much dust, you will notice a bit that collects on the surface.
Simply brush it off as necessary and keep cutting.
Step 5: Sand Edge As Needed
Jigsaws already give a pretty smooth edge.
However, it may not be as smooth as you would like.
Use either sandpaper or a grinder to smooth it.
Be aware that this will produce more dust.
Method 5: Use A Dedicated Shear For Fiber Cement
The fifth method is to use a dedicated tool to cut blueboard.
A shear is one of the dedicated tools that you may want to use.
It’s specifically designed to cut the fiber cement.
Since it’s a dedicated tool, it is going to be an expensive option.
However, it’s easy to use, cuts the line smoothly, and generates minimal dust.
The shear is great for straight lines, but it isn’t as effective at cutting curves.
Follow these steps to use dedicated shears to cut blueboard.
Step 1: Gather The Materials
The average price on a dedicated shear for blueboard runs between $100 and $250.
You’ll be able to find a few different brands that make them at your local hardware store.
Find a brand you trust or do some research and look at reviews to determine which tool will work the best for you.
Step 2: Line The Shoe Of The Blade With The Board
A shear has a shoe that the blade runs along.
If you want to cut clean lines and avoid jagged edges, then you need to apply the right pressure to the blade.
Start by pressing the shoe of the blade along the line you intend to cut.
Double-check that there aren’t any gaps between the shoe and board.
Then apply downward pressure to keep the shoe pressed to the board as you cut.
Step 3: Cut The Line Slowly
Turn the shear on and slowly move it up the marked line to cut.
You’ll notice that it produces minimal dust.
Keep applying pressure downwards on the blade to keep gaps from forming.
Step 4: Sand Edge
Once you’re done cutting, check the edge.
It’s possible that you may have lost pressure on the shoe during your cut.
A few edges may need sanding with either sandpaper or a grinder.
Otherwise, you can expect the edge of the cut to be smooth.
Method 6: Wet Saw
Another great method to cut blueboard is to use a wet saw.
You can use water on fiber cement because it helps prevent mold growth and water damage.
A wet saw is a great solution because it creates virtually no dust.
Instead, the water captures the dust as it’s produced.
It sticks to the saw or the board instead of floating through the air.
The water also softens the blueboard just enough to make cutting it easier.
The wet saw isn’t ideal for cutting curves, but it is possible.
Follow these steps to use a wet saw to cut blueboard.
Step 1: Gather The Materials
Any type of wet saw will do the job.
It’s the blades that are important.
Check your local hardware store for fiber cement blades or something similar.
You’ll also want to stock up on blades since cutting the blueboard will dull them.
Step 2: Mark The Line
Mark the area that you need to cut.
Step 3: Feed The Board Through The Wet Saw
Turn on the wet saw and feed the board through the saw.
Use a guide if you can’t run the board through the saw in a straight line.
The water will spray at the board before the saw cuts it.
Step 4: Sand As Needed
You should expect a clean cut, but there’s always a chance that it needs some sanding.
Use either sandpaper or a grinder to smooth the edges.
Method 7: Table Saw
A table saw can cut through thick pieces of blueboard.
It also generates a lot of dust.
If you want to use this method, then you’ll want to wear protection and cut the board outside.
It’s most effective at cutting straight lines.
Follow these steps to cut blueboard with a table saw.
Step 1: Gather The Materials
Any table saw is fine to cut blueboard.
You’ll need extra blades, like the other methods, to replace them as they dull.
Step 2: Mark Line And Clamp Guide
Mark the line on the board to cut and clamp a guide in place.
Step 3: Move The Blueboard Through The Saw Slow
Line the mark up with the side of your guide, then slowly push the board towards the table saw.
The table saw will cut deeply and give you a clean edge.
Step 4: Clean Up The Dust
You should expect a lot of dust.
Clean up the area before you remove your protection.
Method 8: Fiber Cement Guillotine
This is another specialized tool made specifically for cutting fiber cement.
It isn’t a power tool, and instead, it relies on your own strength to cut the board.
The blades are sharp enough to cut through blueboard.
It produces minimal dust.
Since it isn’t a power tool, it’s cheaper.
However, you make up for the price in the amount of labor that you need to use.
Follow these steps to use a fiber cement guillotine to cut blueboard.
Step 1: Gather The Materials
You’ll need a fiber cement guillotine.
You’ll find them at your local hardware store.
The most important aspect of your guillotine is its thickness.
Each guillotine can only cut a certain thickness.
Ensure that the one you buy can handle the thickness of the board.
Most of the guillotines allow you to cut up to 10 mm of thickness.
Step 2: Mark The Line
Mark the line of where you need to cut.
Step 3: Slot The Board In The Cutting Space
The guillotine has a slot where you line up the board.
Your lined area needs to be in that slot.
Step 4: Push Handles Together
Push the two handles towards one another to cut the board.
Go slowly while you’re cutting and line up your mark in the slot each time.
The result is a clean line and minimal dust.
Conclusion
There are several methods to cut blueboard.
Some rely on power tools while others use manual labor.
Consider the methods above and choose one that fits your budget and comfort level.
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