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Unistrut, also known as strut channel, is a versatile framing system used in electrical, plumbing, HVAC, and solar installations. Whether you're building a support rack, running conduit, or securing equipment, cutting unistrut accurately and efficiently is critical. While traditional methods like reciprocating saws or angle grinders get the job done, they often leave rough edges, produce sparks, and require significant cleanup. Enter the strut shear: a specialized tool designed to make clean, burr-free cuts in unistrut with minimal effort. In this step-by-step guide, we'll cover everything you need to know about how to use a strut shear, from setup to technique, and why it's a game-changer for your jobsite.

What Is a Strut Shear?

A strut shear is a manual or powered cutting tool specifically engineered to cut unistrut channels. It operates like a giant pair of scissors, using a guillotine-style blade that slices through the metal without creating heat, sparks, or jagged edges. This makes it ideal for work in sensitive environments like data centers, hospitals, or residential buildings where fire safety and debris control are paramount. Manual strut shears are portable and require no power, while powered versions—such as those compatible with the Milwaukee M18 system—offer rapid, repeatable cuts with less physical strain.

Why Use a Strut Shear Over Other Cutting Methods?

Let's compare strut shears to common alternatives:

Cutting Method	Advantages	Disadvantages
Strut Shear	Clean, burr-free cuts; no sparks; quiet; minimal cleanup	Limited to unistrut; may not cut thicker metals
Reciprocating Saw	Versatile; cuts many materials	Rough edges; sparks; vibration; debris
Angle Grinder	Fast cuts; portable	Loud; sparks; dangerous kickback; messy
Bandsaw	Precise; good for volume	Bulky; requires setup; not portable

For most jobsite applications, a strut shear strikes the perfect balance between speed, safety, and cleanliness. It's especially valuable when cutting multiple pieces of strut, as you can work quickly without stopping to deburr edges.

Tools You'll Need for Strut Cutting

Before you begin, gather these essentials:

• Strut shear – Manual or powered (e.g., Milwaukee M18 strut shear)
• Measuring tape – A reliable one, like the 25 ft. x 1-5/16 in. Wide Blade Magnetic Tape Measure with 17 ft. Reach, which offers a magnetic hook for easy single-person measurement
• Marker or scribe – For marking cut lines
• Safety gear – Gloves, safety glasses, and ear protection (if using powered shears)
• Unistrut channel – Standard 1-5/8 in. or 2-3/8 in. sizes

Step-by-Step Guide to Using a Strut Shear

Step 1: Measure and Mark Your Cut

Accurate measurement is the foundation of a good cut. Use a high-quality tape measure to determine the required length of unistrut. For example, the 25 ft. x 1-5/16 in. Wide Blade Magnetic Tape Measure with 17 ft. Reach provides a wide, easy-to-read blade and a magnetic tip that clings to the strut, making solo measurements a breeze. Mark the cut line clearly with a permanent marker or a metal scribe. For multiple cuts, consider using a stop block or a tape measure stop for repeatable lengths.

Step 2: Position the Unistrut in the Shear

Place the unistrut channel into the shear's jaws, aligning the cut line with the blade guide. Most strut shears have a built-in alignment mark or laser guide (on powered models) to ensure precision. Make sure the strut is seated fully against the shear's backstop to prevent crooked cuts. If you're using a manual shear, clamp the strut in place if possible; for powered shears, the tool's clamping mechanism will hold it securely.

Step 3: Activate the Shear

For manual shears, pull the lever or handle down firmly and steadily. The blade will descend and slice through the metal. Avoid jerky motions, as they can cause the strut to shift. For powered shears, such as those in the Milwaukee M18 lineup, squeeze the trigger and allow the hydraulic or mechanical system to complete the cut. The M18 18V Lithium-Ion REDLITHIUM FORGE XC 8.0 Ah Battery Pack is an excellent power source for these tools, providing extended runtime and consistent power delivery for multiple cuts on a single charge.

Step 4: Release and Remove

Once the cut is complete, release the lever or trigger. The blade will retract. Remove the cut piece from the shear. Inspect the cut edge for burrs; with a strut shear, you'll typically find a clean, smooth edge that requires no additional finishing. If you do notice minor burrs, a quick pass with a file will smooth them out.

Step 5: Repeat for Multiple Cuts

For production work, you can set up a stop block on the shear to cut identical lengths without measuring each time. This dramatically speeds up your workflow when installing long runs of strut channel. Just make sure to check the first few cuts for accuracy before committing to a batch.

Tips for Clean and Fast Strut Cutting

• Keep blades sharp – Dull blades cause rough cuts and require more force. Replace or sharpen blades as needed.
• Lubricate moving parts – A little WD-40 or light oil on the shear's pivot points reduces friction and extends tool life.
• Cut in a well-lit area – Good visibility helps you align the blade with your mark accurately.
• Use a deburring tool if necessary – Although strut shears produce clean cuts, a deburring tool can quickly smooth any sharp corners for safety.
• Plan your cuts – Cut longer pieces first, then trim down to size, to reduce waste and handling.

Safety Considerations

While strut shears are safer than many power tools, they still require caution. Always wear gloves to protect against sharp metal edges, and safety glasses to guard against flying debris. When using powered shears, ear protection is advisable. Never place fingers near the blade area when the shear is activated. Keep the work area clean to avoid tripping hazards, and dispose of cut-off pieces promptly.

Common Mistakes to Avoid

• Not measuring twice – The old adage holds true; a miscut piece of strut is difficult to reuse.
• Forcing the cut – If the blade binds or the tool struggles, stop and check alignment. Forcing it can damage the shear or create a dangerous kickback.
• Cutting the wrong strut size – Ensure your shear is rated for the strut profile you're using (e.g., 1-5/8 in. vs. 2-3/8 in.).
• Ignoring maintenance – A well-maintained shear is a reliable shear. Clean it after each use and store it in a dry place.

Frequently Asked Questions

Can I use a strut shear on other materials? No, strut shears are designed exclusively for unistrut channel. Using them on other metals can damage the blades or the tool.

How many cuts can I expect per battery charge? With a high-capacity battery like the M18 18V Lithium-Ion REDLITHIUM FORGE XC 8.0 Ah Battery Pack, you can get hundreds of cuts in standard 1-5/8 in. strut before needing to recharge.

Do I need to deburr after using a strut shear? In most cases, no. The guillotine action leaves a clean edge. However, if the cut edge is sharp to the touch, a quick deburring will improve safety.

Conclusion

Using a strut shear is one of the fastest, cleanest, and safest ways to cut unistrut. Whether you're a seasoned electrician or a DIY enthusiast, mastering this tool will save you time and frustration on your next project. Start with accurate measurements, follow the steps outlined above, and always prioritize safety. For best results, pair your shear with reliable accessories like a magnetic tape measure and high-capacity batteries to keep your workflow smooth.

Ready to upgrade your jobsite efficiency? Check out the M18 18V Lithium-Ion REDLITHIUM FORGE XC 8.0 Ah Battery Pack to power your strut shear for hours of uninterrupted cutting. Visit Acmetoolsdiscount today for the best deals on professional-grade tools!