TRICKS OF THE TRADE

Cutting techniques for bullnose pavers and radius designs

So many times I am asked or I try to explain the technique to cutting bullnose pavers and radius paver designs. It is extremely difficult to verbally explain this process. So, to help illustrate the process, I've spent several hours cutting pavers to visually explain the steps.

Please excuse my photographic shortcomings. I am a much better paver installer then photographer. However, each picture will have an explanation which I hope will help everyone understand the process. Additional questions can be e-mailed to me at mark@woodburycement.com or feel free to call me at 800.325.7383. All photos are "thumbnails", just click to enlarge.

In order to create a 90° corner with original width bullnose pavers (3.56") use must miter 8 pavers into a 45° angle. The first step is to lay out four bullnose pavers side by side. Mark the pavers as shown in pictured 1. Note that the on pavernto the far left paver, the mark goes to the half way point. You will see why later. A total of eight (8) pavers must be cut, four right and four left. Mark as shown and take them to the saw and cut.
Once the pavers have been cut, butt them together and glue them down. You can now see why we only cut half way through the fourth paver. We've created a 90° angle for additional pavers on the "inside". This is a common situation when building a step platform or raised patio (picture 1). For a single step, note that width the two end mitered bullnose pavers are thinner, allowing for an even 12 inch tread (picture 2)
If you prefer a radius corner over a 90° corner, eight bullnose pavers are still needed. It is my experience that the easiest way to do this is to find the center point at the bottom of the paver. From there, measure 1/2 inch on either side of the center mark. From both the right and left mark, mark a line to the same side corner of the bullnose as shown in picture 1. Cut all eight pavers and put them together as shown in picture 2.
EP Henry also offers a six inch bullnose and the techniques are similar. For a platform or raised patio, use six pieces of six inch bullnose (3 right, 3 left - marked as shown in picture 1 and cut as shown in picture 2), and for a single step, four bullnose pavers are required (picture 3). *Special thanks to "Roy" from Think Pavers for his time showing me this "trick" cutting the 6 inch bullnose* (www.thinkpavers.com) DON'T LET THIS HAPPEN TO YOU follow below
A very popular (and my personal favorite) look for pavers are curves. Now keep in mind, pavers are made out of concrete. They do not literally curve. We create the appearance of curves through cutting. Step 1 - overlay the pattern. Continue to lay full pavers past where you anticipate the curve will be (picture 1) Step 2 - using a garden hose (or 1" PVC electrical conduit), lay out the radius you desire (picture 2) Step 3 - carefully mark the pavers (picture 3). These lines represent where you will cut the pavers. In this example I used soapstone so that you could see the lines better. normally I prefer either a carpenter pencil or a Sharpie® because when cutting with water, the soapstone tends to wash off. If cutting dry, any of the above works fine. Step 4 - put an "X" on the portion of the paver to be thrown away. This reduces any confusion about which portion of the paver is to be used in the pattern. This is especially important when multiple people (highly recommended) are working on this portion.
Cut the pavers as marked and return them to the pattern. You've now created a curved deign in your paver project. However...
More times then not, a radius curve is surrounded by a border paver. This insures that a larger and stronger piece is on the outside of the project, as opposed to an odd small piece as is the case with many radius cuts. But cutting a radius border presents its own set of challenges. Step 1 - layout your border paver (picture 1) Step 2 - lay (what I prefer) a one inch wide ruler between paver one and paver two (picture 2) Step 3 - mark both pavers accordingly. These will be your "cut lines" (picture 3)
Step 4 - cut both pavers, then slide them together. Repeat the process (picture 1). Notice that each paver gets cut TWICE Pictures 2 and 3 show the finished project There is no EASY way when it comes to bullnose 90's and/or radius corners or radius cuts on any shape paver. Cutting is a tiring and time consuming process, especially if you are a do-it-yourselfer and you're doing this project all alone. There are precious few shortcuts. However, keep this thought in mind. YOU have to look at the completed project EVERY day. Isn't it worth the extra effort to make it look really special. I think so. Good luck with your particular project. Call me before you pull all of your hair out.