Hole Saw Size Chart: Complete Guide to Hole Saw Sizes and Applications

Hole saws are widely used for cutting clean and accurate holes in wood, metal, plastic, drywall, and concrete. Choosing the correct hole saw size is essential for achieving precise results and avoiding material damage.

This guide provides a practical hole saw size chart and explains how to select the right hole saw for different drilling applications.

What Is a Hole Saw?

A hole saw is a circular cutting tool designed to create large-diameter holes while removing only a ring of material. Compared with conventional drill bits, hole saws require less power and allow larger holes to be drilled efficiently.

Hole saws are commonly used in:

• Electrical installations
• Plumbing projects
• HVAC systems
• Construction work
• Metal fabrication
• Industrial manufacturing

For a complete overview of available hole saw types, visit our Hole Saws collection.

Standard Hole Saw Size Chart

Hole Saw Diameter	Common Application
14 mm	Cable routing
16 mm	Small electrical conduits
20 mm	Pipe installation
22 mm	Electrical boxes
25 mm	Conduit fittings
29 mm	Cable entry holes
32 mm	PVC pipe installation
35 mm	Electrical work
38 mm	General-purpose drilling
44 mm	Plumbing and conduit installation
51 mm	Pipe openings
57 mm	Ventilation systems
64 mm	Large conduit openings
76 mm	Drain pipes
89 mm	HVAC applications
102 mm	Large ventilation holes
127 mm	Industrial installations

Looking for professional hole saw solutions? Explore our TCT Hole Saw and Metal Hole Saw products for industrial drilling applications.

How to Choose the Right Hole Saw Size

When selecting a hole saw, consider the following factors:

Material Type

Different materials require different hole saw designs.

• Wood: Bi-metal hole saws
• Metal: TCT hole saws
• Stainless steel: Carbide-tipped hole saws
• Concrete and masonry: Core drill hole saws

Required Hole Diameter

Measure the outside diameter of the pipe, conduit, or fitting before selecting the hole saw size.

Always allow sufficient clearance for installation.

Cutting Depth

Standard hole saws are suitable for shallow cutting applications.

Deep-cut hole saws are recommended for thicker materials.

TCT Hole Saw vs Bi-Metal Hole Saw

TCT (Tungsten Carbide Tipped) hole saws are designed for harder materials such as steel, stainless steel, and metal sheets.

Bi-metal hole saws are commonly used for wood, plastic, and light metal applications.

For industrial drilling projects, TCT hole saws generally offer longer service life and faster cutting performance.

Common Hole Saw Applications

Metal Drilling

Hole saws are widely used for drilling holes in steel panels, stainless steel sheets, and metal structures.

For steel and metal cutting applications, Metal Hole Saws are commonly used because of their durability and cutting performance.

Woodworking

Ideal for door hardware installation, cable routing, and furniture production.

Concrete and Masonry

Specialized core drill hole saws are used for wall openings, pipe installation, and construction projects.

Hole Saw Safety Tips

• Use the correct arbor for the hole saw size.
• Start drilling at low speed.
• Apply consistent pressure.
• Use cutting fluid when drilling metal.
• Wear appropriate eye protection.

Frequently Asked Questions

What is the most common hole saw size?

The most commonly used sizes range from 22 mm to 64 mm depending on the application.

Can I use a hole saw on stainless steel?

Yes. TCT hole saws are recommended for stainless steel because of their superior wear resistance.

How deep can a hole saw cut?

Cutting depth depends on the hole saw design. Standard models typically cut between 25 mm and 50 mm, while deep-cut models can exceed 100 mm.

Conclusion

Selecting the correct hole saw size improves drilling efficiency, hole quality, and tool life. By understanding hole saw diameters, material compatibility, and application requirements, users can choose the most suitable hole saw for their projects.

For industrial and wholesale hole saw solutions, selecting the appropriate TCT, metal-cutting, or concrete drilling hole saw is critical for achieving reliable performance and long service life.