SDS Plus vs. SDS Max: Breaking Down the Differences

Picking the right tools is half the battle when it comes to concrete jobs. This is where the differences between SDS Plus and SDS Max begin to matter. Both types of tools are needed for drilling and demolition jobs, but they perform differently. Several brands offer both SDS Plus and SDS Max options, but understanding which one to grab for the job can make a world of difference.

SDS Plus tools have a smaller shank, at 10mm, compared to SDS Max , which is 18mm. The SDS Plus is made to fit into rotary hammers for tasks that are lighter than SDS Max projects, though SDS Plus can still put off some power.

You’ll often see SDS Plus tools used in jobs like drilling holes for anchors or screws, or in any kind of lighter-duty concrete work. If you’re an electrician or general contractor working on residential or light commercial projects, this would be the tool to go with.

Pros:

1. Lightweight and easy to handle: These tools are designed to reduce operator fatigue, especially when working overhead or in tight spaces.
2. Affordable: SDS Plus tools are typically less expensive than their SDS Max counterparts, making them an attractive option for those who don’t need the additional heavy-duty capabilities that SDS Max tools provide.

Cons:

1. Limited drilling capacity: If you’re working with thicker materials or need to drill large holes, SDS Plus might not cut it. They’re typically limited to drilling holes up to 1 inch in diameter.

2. Less impact energy: These tools aren’t designed for heavy-duty demolition or deep drilling. If you’re facing tough concrete, you might find them a bit lacking.

SDS Plus tools have many different applications for each trade. Electricians, for example, often use SDS Plus tools to drill holes for conduit through concrete walls. This is because they don’t require demolition-type power but still need the speed and durability to break through easily enough. Need to install pipe hangers or brackets for a plumbing job? These tools will do that, too. If you’re on a job that doesn’t require a lot of brute force or heavy applications, the SDS Plus would be the way to go.

SDS Max tools offer more power. With a larger shank—18mm—they’re built for heavier-duty tasks. These SDS Max tools provide much higher impact energy, which makes them ideal for demolition jobs, breaking up concrete, or even deep drilling for tasks like rebar installation.

Pros:

1. Superior impact energy: SDS Max tools can deliver powerful impact energy, making them perfect for breaking through tough materials like concrete or stone.

2. Handles larger bit sizes: These tools can accommodate bits ranging from 3/8 inch to over 2 inches in diameter, giving you the power to tackle large-scale projects.

Cons:

1. Heavier and more expensive: The power and durability of SDS Max tools come at a greater cost, both in terms of weight and price. SDS Max tools can be than SDS Plus, which can lead to operator fatigue during extended use.

Power and Impact Energy:

1. SDS Plus tools typically deliver impact energy that is sufficient for lighter-duty tasks some heavy-duty. They’re perfect when precision and ease of use are more important than raw power.

2. SDS Max tools, on the other hand, can deliver advanced impact energy because they have longer lengths. This makes them the go-to choice for heavy-duty demolition and deep drilling.

Bit Size and Capacity:

1. SDS Plus bits generally range from 5/32 inch to 1 inch in diameter. This is more than enough for most residential and light commercial tasks.

2. SDS Max bits, however, can range from 3/8 inch to over 2 inches. If you’re dealing with thick concrete or stone, the larger capacity of SDS Max is essential.

Shank Design:

1. SDS Plus shanks are smaller, which makes bit changes quick and easy. They’re designed for versatility and ease of use.

2. SDS Max shanks are larger and more robust, designed to handle the increased power and torque of heavy-duty work.

Tool Compatibility:

1. SDS Plus tools are generally smaller and lighter, making them easier to handle, especially in tight spaces or when working in overhead scenarios.

2. SDS Max tools tend to be larger and heavier, which requires more power to operate but offers far greater impact energy and drilling capacity.

Weight and Ergonomics:

1. SDS Plus tools are often more lightweight, making them easier to control and less fatiguing to use over long periods, especially on your hands or shoulders. They’re ideal for jobs where precision and ease of handling are needed.

2. SDS Max tools, while powerful, are also heavier and can be tiring to use for extended periods of time. They’re better suited for jobs where power is more important in the long run.

DeWalt has made a name for itself with its rugged and reliable tools, including its SDS Plus and SDS Max rotary hammers, which are no exception. 

The DeWalt DCH273B, for example, is a standout SDS Plus tool. This 20V Max XR brushless rotary hammer is ideal for professionals who are often drilling into concrete, brick, and masonry. Its compact size and lightweight design make it perfect for overhead work, while the brushless motor ensures that you have a long runtime with continued durability.

On the other end of the spectrum, the DeWalt D25773K SDS Max rotary hammer is meant for heavy-duty applications. With a 15-amp motor and 19.4 joules of impact energy, this particular tool is built for serious demolition projects and large-hole drilling in concrete. It also features DeWalt's E-Clutch and SHOCKS Active Vibration Control, providing enhanced user safety and comfort during extended periods of use.

Bosch, the original creator of the SDS system, continues to lead the market with its innovative designs. The Bosch GBH18V-26D is a versatile SDS Plus rotary hammer that operates on an 18V battery platform. It’s compact yet powerful, offering 1.9 ft-lbs of impact energy, making it suitable for a wide range of drilling and chiseling tasks. This tool also features KickBack Control to reduce the risk of sudden tool reactions during bind-up situations.

For those needing something more robust, the Bosch RH1255VC SDS Max rotary hammer is a go-to choice. With its 2-inch drilling capacity and 14.1 ft-lbs of impact energy, this tool is engineered for demanding jobs like drilling large holes or chiseling concrete. The vibration control in the hammer mechanism and grip area significantly reduces user fatigue, making it a solid option for extended use.

Makita is known for its high-performance tools, and its SDS Plus and SDS Max rotary hammers are no different. The Makita XRH04Z is an 18V LXT SDS Plus rotary hammer that’s perfect for professionals who need portability without sacrificing power. It delivers 0-1,200 RPM and 0-4,000 BPM for fast drilling, and with its three-mode operation, you can easily switch between rotation, hammering with rotation, and hammering only.

For more heavy-duty work, the Makita HR4013C SDS Max rotary hammer stands out. This corded tool provides 11 amps of power and up to 9.2 joules of impact energy. The Anti-Vibration Technology (AVT) and a soft start feature enhance user control and comfort, making it a reliable choice for tough applications.

Milwaukee’s reputation for durable, high-performing tools is well represented in their SDS Plus and SDS Max offerings. The Milwaukee 2912-20 is an M18 Fuel SDS Plus rotary hammer perfect for concrete drilling. It features Milwaukee’s POWERSTATE brushless motor and REDLINK PLUS intelligence, providing up to 2.1 ft-lbs of impact energy and a longer tool life. The tool's ergonomic design and anti-vibration handle make it comfortable for extended periods.

For heavy-duty needs, the Milwaukee 5546-21 SDS Max rotary hammer is a powerhouse. With its 10.5-amp motor delivering 5.5 ft-lbs of impact energy, it’s designed to handle the toughest drilling and chiseling tasks. The AVS (Anti-Vibration System) minimizes vibration, making it easier to manage during lengthy jobs.

The history of SDS Plus and SDS Max is a story of innovation driven by the demands of heavy-duty drilling. SDS, which stands for "Slotted Drive System," was originally developed by Bosch in the mid-1970s to meet the need for a more reliable and efficient system in rotary hammer drills.

Before SDS, most drills relied on round shank bits held in place by a standard three-jaw chuck, which often struggled to maintain grip under the intense forces of hammer drilling in concrete and masonry.

The SDS system changed that. By milling a special slot into the bit, Bosch created a system that provided much greater holding power. The design allows the bit to slide back and forth like a piston within the chuck, meaning the hammering force is directed straight into the bit, not wasted on moving the chuck. This made SDS bits much more effective for heavy-duty applications.

The name "SDS" is an acronym derived from the German words "Steck – Dreh – Sitz," which translates to "Insert – Drill – Attachment." In German-speaking countries, the back-formation "Spannen durch System" ("Clamping System") is sometimes used, though Bosch adopted the term "Special Direct System" for international markets.

As the system evolved, different sizes of SDS shanks were developed to accommodate varying levels of drilling power. The SDS Plus, with its 10 mm shank, became the most popular for medium-duty work, offering a good balance between size and strength. For larger, more demanding jobs, the SDS Max was introduced with an 18 mm shank, providing even greater power and durability. Other variations like the SDS Quick and the now largely obsolete SDS Top were designed for specific needs.

Bosch's SDS system wasn't the first of its kind, though. It built on the earlier TE system introduced by Hilti in 1960. While Hilti's original shanks could be used in SDS chucks, Bosch's design improvements made SDS the go-to choice for professionals working in stone and concrete.

Since the patents on the SDS system expired, it's become widely available and affordable, with manufacturers around the world producing SDS tools. Today, whether you're drilling small holes for anchors or taking on large demolition projects, there's an SDS bit and chuck system that can handle the job. 

When to Choose SDS Plus:

1. If you’re tackling smaller, frequent tasks that don’t require heavy-duty power, SDS Plus is your best bet. It’s perfect for residential jobs, overhead drilling, or any situation where ease of use and portability are more important than brute force. Plus, if you’re on a budget, SDS Plus tools offer great performance without the high price tag.

When to Choose SDS Max:

1. For large-scale demolition or deep drilling, SDS Max is the way to go. Whether you’re breaking up concrete slabs, drilling deep holes for rebar, or working on infrastructure projects, the extra power and bit capacity of SDS Max tools will save you time and effort. They’re a long-term investment, built to handle the toughest jobs, and worth every penny if you need that level of performance.

When it comes to drilling and demolition, the right tool makes all the difference. SDS Plus and SDS Max each have their strengths, and choosing the right one depends on the job at hand. For light-duty, everyday tasks, SDS Plus offers the perfect balance of power, portability, and price. But when you’re up against tough materials and large-scale projects, SDS Max is the heavy hitter you need. Milwaukee’s lineup in both categories ensures you’re equipped with top-tier tools, no matter what the job demands.