The tool for cutting concrete without dust

Diamond cutting of reinforced concrete: like a knife through butter

Equipment for concrete cutting may be needed when performing a variety of works in the case when you need to make a hole or an opening in the concrete, cut a piece of monolith, saw a concrete product, or perform any other task. The most efficient and productive method of cutting concrete is considered to be diamond technology. in the process there is less garbage and noise, the cut is smooth, the work is done quickly.

A few years ago concrete and reinforced concrete was cut with torches, demolition hammers, sledgehammers. The process of creating even a small hole was time-consuming, labor-intensive, and created noise and mountains of debris. Modern diamond cutting of reinforced concrete involves faster and more efficient cutting. Tools of all sizes and capacities. from handheld cutters to production machines. can be used for these applications.

For what purposes diamond cutting of concrete and reinforced concrete is used:

• When dismantling various building structures.
• For sawing reinforced concrete blocks. to create wall extensions or to make transportation more comfortable.
• For creating openings, gaps and cavities in simple and solid partition walls.
• Creating expansion and contraction joints in concrete screed.
• Increasing the height and width of existing openings.
• Drilling holes in foundations.
• Creating a niche in the wall to install a safe.
• When there is a need to correct construction defects.

What is diamond cutting in concrete

Diamond cutting of concrete is a highly effective method of making openings in constructions made of concrete or reinforced concrete. With this method, a perfectly even cut is obtained without any chips or cracks. Its speed is several times faster than works performed with a jackhammer or a torch. over, the equipment in use operates without vibration, excessive noise and dust.

Diamond tools are very hard, and that is why they are good for processing concrete and stone

The main advantages of cutting concrete with diamond tools:

• smooth, even cut. This feature helps to significantly reduce costs required for additional finishing of openings. No other modern processing method can provide such a precise contouring dismantling;
• high speed of cutting concrete and other materials;
• Relatively low noise background;
• no vibration. This is a very important advantage that allows you to carry out repairs even in old buildings, because it has no destructive effects on their load-bearing elements;
• little dust. Diamond cutting of openings in concrete is carried out by two methods. dry and wet. When using the dry method a special vacuum cleaner works together with wall saw equipment. When the wet method is used, dust is mixed with water, which is used to cool the cutting tool.

Where diamond cutting is used

It should be said that diamond cutting of reinforced concrete has a wide range of applications. Here are some varieties of construction work, where you need to use a diamond tool:

• Dismantling, demolition of building structures.
• Cutting of reinforced concrete blocks, for example to make them easier to transport.
• Construction of openings and apertures in solid and simple interior walls.
• Increasing the width or height of existing openings.
• Construction of expansion joints in concrete floor screeds.
• Construction of holes in foundations.
• Building recesses in the wall to install safes.
• When correcting faults made during construction.

How reinforced concrete is cut

With all its simplicity, the diamond cutting of reinforced concrete walls does not tolerate amateurish approach, that is, the process should conduct the master, with appropriate tolerances.

Do not forget that the professionalism and experience of the working depends not only on the quality of cutting, but also the safety of people who will then live or work in the building where the work was done.

If you need to divide reinforced concrete into parts, diamond cutting is performed in several stages. For example, a popular service is the division of large blocks into parts that are convenient for transportation.

• The blocks to be cut are marked out. This requires filigree precision, otherwise the quality of work will suffer.
• The concrete is cut along the marked line. first the diamond cuts through on one side.
• Next, holes are drilled along the cutting line, this allows you to move the line for the trimmer on the opposite side of the block.
• Now the cutting of the block from the back side is carried out.
• The result is the block segments of given parameters.

Diamond cutting of reinforced concrete walls is carried out approximately by the same algorithm. However, if the opening is made in a load-bearing wall, it is necessary to install metal structures at the place of the cut. Their task is to compensate for the loads carried by the removed part of the wall.

Tip! It is strictly forbidden to arrange openings or completely demolish load-bearing reinforced concrete walls. diamond cutting in this case, is carried out in accordance with a specially developed and approved project.

Types of cutting discs

There are three standard types. Each of them has a number of characteristics related to the scope of application.

• solid (used for wet treatment of the material);
• Segmented (used in dry sawing);
• ground (there are grooves for dust extraction).

In addition, it is customary to divide them into categories according to geometric dimensions. Usually these values are in accordance with GOST:

• disc diameter from 100 to 600 mm;
• cutting width does not exceed 3,5 mm and cannot be less than 0,45 mm;
• bore diameter from 15 mm.

The most common sizes on the market are universal discs. their diameters are 230 and 350 mm. They allow you to make channels and passages according to standard communications.

These specifications can be seen on the product label. It comes after the manufacturer’s name in the form of a numerical code, e.g. 230/3,5/30 (diameter, cutting width, insertion depth respectively).

The table shows the possible parameters of disks.

Diameter in mm	100	125	150	175	200	250	З00	З50	400	450	500
Width of cutting part min./max., in mm	0.451	0.451	0.451	0.601	0.802	1.52	1.52	1.52	1.92	2.4	2.4

discs are subdivided according to material type and density. soft and hard. The first are used when you need to cut reinforced concrete, natural stone, granite, marble surface. The second one is more often used when working with bricks, foam blocks, composites, since their density is much lower.

Another division: according to the method of cutting. There are two types: wet and dry cutting.

Discs for dry cutting

Their effectiveness is due to the segmentation of the cutting part. Each single tooth is powdered with diamond coating. Gaps in the segments allow for free cooling of the wheel as it rotates, as well as dust extraction.

Standard dimensions of the disc in diameter are 230 mm. Depth of cut is 22 mm or more. Convenient for laying cables.

How to make a cover for a vacuum cleaner with your own hands

Chopper with integrated vacuum cleaner allows you to get rid of small particles of material generated during cutting with the “grinder. But what if you need to cut concrete with conventional tools without additional options? The most common solution would be to buy a cover for a vacuum cleaner separately or without the help of others to make the device. You can get an assistant to pick up the particles generated during sawing with a vacuum cleaner.

Make a comfortable attachment from an ordinary plastic canister, which is often used to implement the car “anti-freeze” is simple. To work for you will need a construction cutter and a container of the appropriate size, the nozzle which fits into the cross section of the hose vacuum cleaner.

• The holes are trimmed on 2 sides so that you can simply reverse the direction of rotation of the disc.
• Under the circles is made a gap of appropriate size.
• To attach the cutter “grinder” cut another hole.
• The hose is attached to the canister neck and secured by an adapter ring with a clamp.
• “Grinder” is placed in the casing and all elements are connected.
• Cover the unused hole with the lid.

An ordinary five-liter plastic bottle also makes a good dust collector. It is attached with a standard protective cover, and the vacuum cleaner nozzle to the throat. This design is suitable for all work other than chasing.

Last final tip: to make the cut straight, first make a marking. Then the wood blocks are fastened along the mowing line. After that a shallow cut of up to one cm is made, the stops are removed and the work continues. During the whole process a coolant is applied to the blade of the disc. All manipulations must be performed with goggles, a respirator and gloves.

Concrete cutting with wall saws

Wall saws are used for cutting concrete in large and complex jobs. It gives less dust than a grinder, the productivity and efficiency is much higher.

Features of cutting concrete monolith with a wall saw:

• Diamond cutting of this type is characterized by great depth of cutting, so it is used for industrial cutting of hatches / holes, other parts with a volume of reinforcement in the walls, walls, floor slabs. Work can be done in the shortest time.
• Free single-sided access of 30-35 cm is required to complete the job.
• A lot of water is required for cooling (up to fifteen liters). per minute), so it should be possible to restore.
• Waste water can be collected with a normal vacuum cleaner.
• To operate the equipment requires AC power of 32A and 380V.

Professional wheels

Professional diamond wheels with diameters ranging from 125 to 350 millimeters are used for production purposes. Their cost is much higher than similar household cutting tools, but their very high wear resistance, excellent quality of the abrasive coating ultimately makes them more profitable with regular use.

Large

Classification of professional diamond discs by purpose:

It is very important to understand that the mismatch between the purpose of professional tools for use occurs very quickly their wear and tear, eventually increasing the cost of the work.

How to cut shallow concrete?

An angle grinder (angle grinder) with a diamond disc mounted is excellent for creating shallow cuts. The grinding media may be segment grinding discs, endless discs (wet cutting discs) or turbo-diamond discs.

Diagram of a wire cutting machine for concrete.

In segmented grinding wheels, the blades are arranged in sectors, between which a series of technological grooves are cut. They reduce stress on the cutting edge and improve heat dissipation.

Endless wheels are designed as a single piece. In order to evenly distribute the tension that occurs when cutting concrete, special radius holes can be made in them.

When operating such equipment, it is imperative that the disc is cooled with water, which is fed into the area of the kerf.

Turbo-diamond wheels are used to perform work with heavy loads (for example, when you want to saw reinforced concrete construction). They are characterized by an increased thickness of the body and a large m of diamond substance. The only disadvantage of this tool is the high cost, so it is used only in extreme cases where no other cutting methods are suitable.

To reduce dust formation and reduce the temperature of the cutting element, you can periodically spray water on the diamond wheel and the area of the kerf. If for safety reasons you do not have the ability to use water, you can use air to cool the disc. For this purpose, the diamond wheel is removed from the kerf at regular intervals and it is rotated freely without switching off the angle grinder for a few minutes, after which the cut can be continued.

Diamond cutting applications

This technology is used for various purposes:

• expansion of existing openings;
• the device of niches in the walls;
• To create technological holes;
• Wet and dry diamond cutting is used for dismantling concrete structures, floor slabs;
• Installation of openings in supporting walls and partitions.

This technology is realized by means of any equipment equipped with diamond cutting edge. A tool with the right specifications is particularly versatile, i.e. it can be fitted on all sides of the opening. к. it makes it possible to cut any type and configuration of material: basic concrete, artificial marble of concrete with additives, weakly reinforced material, reinforced concrete structures.

Reinforcing the opening

When cutting a wall, it is important to compensate for the partial loss of bearing capacity and to apply reinforcement. Diamond cutting and drilling. this ensures that the element can be installed at the top of the opening, which will take up a substantial part of the load and help distribute it further to the sides of the rectangular cut-out in the wall. Reinforcement is realized in different ways: by means of a concrete or metal beam.

Depending on how solid the wall is cut, the technology is chosen to strengthen the opening. A prefabricated or homemade concrete beam is used. The second option is realized by shaping the formwork and installing the reinforcement in it. Both sides of the element must rest on the supporting surface. Reinforcing the opening is carried out before a section of wall is dismantled.

Coordinating openings in load-bearing walls

When a hole is made in the structure, it partially loses its properties. Such a wall becomes less strong and can be destroyed. At the same time the entire building is endangered. Even at the stage of selecting construction materials and before the cutting process begins, the project documentation concerning the remodeling is drawn up. When deciding where to locate the door or window opening, a number of requirements must be taken into account.

Remodeling actions must be coordinated with the organization that designed the facility. It is necessary to prepare a technical passport of the room and invite a specialist to assess the condition of the structures. Probability of obtaining redevelopment permits increases if the apartment is located on a higher floor, then the load on the walls is lower. Year of construction, wall condition and width of opening are important factors in making a decision. If the project is approved, a diamond disc can be used to cut the concrete.

Openings in monolithic concrete walls

Such structures are much stronger than panel buildings, t. к. they are built by forming a reinforcement framework, formwork with further pouring of the walls over the entire height. When cutting holes in concrete with a diamond cutting edge it is necessary to choose the tool carefully. Reinforcement of openings in load-bearing walls on such objects is made by means of high-strength material of great thickness.

In cases where an opening is made in a partition, there is no need to reinforce the structure. If you use a diamond disk to cut soft material, it will wear out faster, but the opening will be ready earlier. If you use a cutting edge made of hard material, you should be prepared that the work will take longer, but you won’t have to change the disk frequently.

How to make a hood for a vacuum cleaner with your own hands

Get rid of formed during the cutting “angle grinder” of small particles of material can angle grinder with a built-in vacuum cleaner. But what to do if you need to saw concrete with an ordinary tool without additional options? The easiest solution would be to buy a cover for the vacuum cleaner separately, or make a device with their own hands. You can involve an assistant, who will collect particles formed during the sawing process with a vacuum cleaner.

It is easy to make a convenient nozzle from a simple plastic canister, which is often sold as auto “antifreeze”. To work you will need a construction cutter and a container of the appropriate size, the nozzle which fits the diameter of the hose with the vacuum cleaner.

The sequence of manufacturing is as follows:

• Seating holes are cut on both sides so that the direction of rotation of the disc is reversed easily.
• A cut of suitable size is made under the wheel.
• To fix the cutter of the “angle grinder” another hole is cut.
• Hose dock with the canister mouth and fasten the adapter ring with a clamp.
• The “angle grinder” is placed in the cover and all elements are connected.
• The unused hole is closed with a cover.

A simple five-litre polyethylene bottle also makes a good dust canister. It is fastened by means of a standard protective cap, and the vacuum cleaner nozzle to the throat. Such a construction is suitable for any kind of work, with the exception of potholing.

One last tip: In order to make the cut evenly, you must first draw a line. Then wooden blocks are fastened along the line. After that a shallow cut of up to 1 cm is made, the stops are removed and the work is continued. Throughout the process, coolant is applied to the disc blade. All manipulations must be performed in safety glasses, respirator and gloves.

The second method is to connect a vacuum cleaner

This method consists in connecting a construction vacuum cleaner to the angle grinder with improvised means.

Polypropylene drainage outlet diameter of 50mm, 45 degrees;

Reinforced adhesive tape (for greater reliability);

The described components for this method can be replaced by any suitable analogues.

Step by step instruction

1) Place the angle grinder on the floor, table or other place on the table. so that it lies with the disk upwards, parallel to the plane of the base.

NOTE:

The angle grinder must be positioned fairly steadily.

2) Use pliers or a clamp to take the tap.

3) We turn on the angle grinder and literally saw the pipe along the body, under the hood of the angle grinder, about 3 cm.

4) We take reinforced adhesive tape, and tightly, under tension, attach the tap to the body of the angle grinder, with a small setback (a couple of centimeters) in the saw blade.

Important!

The socket must be fixed firmly so that it stands absolutely still.

5) Take the masking tape, and glue the open side of the cover with it, connecting it to the outlet.

This design allows you to easily connect a vacuum cleaner and saw with an angle grinder without dust.

NOTE:

You can only use a construction vacuum cleaner for this kind of work.

When sawing, guide the blade into the material on the engine side of the sawmill, closer to the nozzle.

That way all dust is ducted to the vacuum cleaner.

Important!

Always saw objects with the motor facing forwards.

Dust-free concrete cutting with your own hands

Dust-free concrete cutting is nearly impossible, because when sawing and sanding stone, a lot of dust is generated anyway, the amount of which can only be reduced. But it is also desirable to do, as too much dust in the course of work carries a lot of trouble: it spoils the tool and blunt parts, settles in the lungs and on all surfaces in the room.

With the use of modern equipment it has become easier to cut concrete. there are special tools for cutting, consumables for them. The devices can be hand-held or stationary, powered by electricity or other sources. As a rule, all concrete cutting tools are equipped with diamond parts. chains, discs, bits, tips, etc.д.

Is there a technology for cutting concrete without noise and dust?

When thinking about what to cut the concrete with, one should also take care of reducing the amount of dust, which inevitably appears during the process of execution of works. In certain cases it is impossible to do anything and you have to work in difficult conditions, but in others it is quite realistic to remove the dust. The main thing is not to violate safety requirements and use proven methods.

Cutting concrete is a targeted mechanical impact on the monolith by rotating parts of the tool. Cutting is not accompanied by impact noise, but always involves noise from the electric motor of the tool drive and the operation of its moving parts, which cut a groove in the stone or cut the rebar, cut into pieces, etc.д.

Different methods are used for cutting concrete. manual, machine, wet and dry. The first two are determined by the type of tool chosen, the wet method involves the impact of water on the cutting part and on the concrete surface itself, the dry method of water supply does not use. Regardless of the chosen cutting method, the amount of dust that accompanies the process is always quite high.

The most common methods of cutting concrete:

• Diamond cutting of walls and partitions with hand tools (angle grinder and others).
• Diamond cutting with the use of a stationary-type wall cutter.
• Diamond cutting with wire cutters.
• Using for wire cutting.

When using a hand-held tool (most often it is an angle grinder) you can connect to it a construction vacuum cleaner, which will suck up almost all the dust that appears in the process of cutting. If you can’t connect the tool to a vacuum cleaner, you can do it all with your own hands.

What will be needed to create an adapter for the construction vacuum cleaner:

• Drainage branch from polypropylene with a diameter of 50 millimeters, under 45 degrees.
• Reinforced tape (it is more reliable).
• Painting tape of high quality.

The process of creating a vacuum cleaner nozzle for dust extraction:

• Place the angle grinder as steadily as possible on the table or floor so that it lies up with the disc parallel to the plane of the base.
• Take the branch with pliers or a clip, switch on the angle grinder and “saw” the branch pipe along the body, 3 centimeters under the cover of the tool.
• Reinforced scotch tape very tightly to the body of the angle grinder outlet, a little going into the saw blade (a few centimeters). The socket must be fixed firmly so that it is fixed in a fixed position.
• Put masking tape on the open side of the casing to connect it to the branch pipe. Then you can plug in a construction vacuum cleaner and remove the dust while you are working.

Such a system of design changes in the tool does not involve, but before its application, it is desirable to consult with a representative of the manufacturing company about the possibility of making modifications.

Cutting concrete with hand tools

Not all hand tools are suitable for work with this material due to its durability. Most often for these purposes use an angle grinder (aka angle grinder). For cutting concrete a special nozzle is used in the form of a diamond wheel, which can be solid, segmental, combined.

Types of diamond wheels for angle grinder with which you can cut concrete:

• Solid. is made with a continuous diamond cutting edge, so there are no chips in the work. The nozzle occasionally heats up, so it requires constant cooling with a jet of water.
• Segmented disc. the base is solid, the edge is segmented. The wheel is inexpensive, but it wears out quickly on tough materials. Only suitable for dry cutting.
• Combination (aka turbo-diamond) disc is considered a universal disc that can withstand maximum loads, even reinforced concrete can be cut with it.

Nozzles are selected in accordance with the material to be sawn, as well as taking into account the type of work, conditions, etc. Concrete with over 10 centimetres pits can only be cut with discs of higher strength (turbine discs). All disc segments are attached to the blade by laser welding or silver soldering. The former can only be used for dry cutting, the latter for wet cutting.

The inside diameter of the disc must correspond to the diameter of the angle grinder. The speed of the disc is also important. preferably it should be higher than that of the angle grinder. Depending on the type of cutting and proper selection of tool, the amount of dust created in the process may be different.

So if you spend a lot of time sawing concrete with a tool and nozzle that isn’t strong enough and doesn’t cut enough, you end up with a lot of dust and very little result. You can reduce the amount of dust by using the wet cutting method. water keeps the tool from overheating and prevents dust. This speeds up the work and increases the life of the diamond tip.

The water supply can be arranged in different ways. from spraying the concrete with a sprayer periodically during work to attaching a hose to the tool so that the liquid flows in a continuous stream to the disc.

A handy nozzle is made of an ordinary plastic canister. You will also need a cutter, a container of the right size, the throat of which by its diameter docked with a hose cleaner.

Next, you need to make seating holes on both sides to be able to easily change the direction of rotation of the disk. A suitably sized slot is made under the wheel, and another hole is cut to mount the torch. Carefully connect the hose to the neck of the canister, then fasten with an adapter ring with a clamp. Angle grinder is sent to the hood, all elements are securely connected. Cover the opening that is not in use.

Dust-free concrete cutting with your own hands

Cutting concrete without dust is almost impossible, because in the process of sawing and processing the stone in one way or another a lot of dust appears, the volume of which can only be reduced. But it is also desirable to do, as too much dust in the process of work carries a lot of trouble: it spoils the tool and blunt details, settles in the lungs and on all surfaces in the room.

With the use of modern equipment sawing concrete has become easier. there are special tools for cutting, consumables for them. The devices can be manual or stationary, powered by electricity or other sources. As a rule, all concrete cutting tools are equipped with diamond tools. chains, discs, bits, pads, etc.д.

Is there a technology for cutting concrete without noise and dust?

Thinking about what to cut the concrete, you need to take care and to reduce the volume of dust, which inevitably appears in the process of execution of works. In some cases it is impossible to do anything and you have to work in difficult conditions, but in others it is quite realistic to remove the dust. The most important thing is to stay safety-conscious and use proven methods.

Concrete cutting is the deliberate application of rotating tool parts to the monolith. Cutting is not accompanied by impact noise, but always involves noise from the electric motor of the tool drive and the work of its moving parts that cut a groove in the stone or cut the reinforcement, cut into pieces, etc.д.

There are different processes for cutting concrete. manual, mechanical, wet and dry cutting. The first two are determined by the type of tool chosen, the wet method involves the impact of water on the cutting part and on the concrete surface itself, the dry method does not use the water supply. Regardless of the chosen method of cutting, the amount of dust that accompanies the process is always quite large.

The most common methods of cutting concrete:

• Diamond cutting of partitions and walls with hand tools (angle grinder and others).
• Diamond cutting with a stationary wall saw.
• Diamond cutting with floor saws.
• Using to cut the rope.

When using a hand-held tool (most often an angle grinder), you can connect a construction vacuum cleaner, which will suck up almost all the dust that appears during the cutting process. If it is not possible to connect the tool to a vacuum cleaner, everything can be done with your own hands.

What you will need to create an adapter for the construction vacuum cleaner:

• A polypropylene drainpipe, 50 millimeters in diameter, 45 degrees.
• Reinforced tape (it is more reliable).
• High quality masking tape.

The process of creating a vacuum cleaner nozzle for dust extraction:

• Set the angle grinder as steadily as possible on the table or the floor so that it would lie with the disc upside down, parallel to the plane of the base.
• Take the branch with pliers or a clamp, turn on the angle grinder and “saw” the branch pipe along the case, 3 centimeters under the tool cover.
• Screw the bend to the angle grinder body with reinforced tape very tightly to the saw blade (a few centimeters). The fixation of the nozzle must be secure, so that it is fixed in a fixed position.
• Put masking tape on the open side of the guard, so that it is connected to the outlet. Then you can connect a vacuum cleaner and remove dust during work.

This system does not involve changes in the design of the tool, but before its use, it is desirable to consult with a representative of the manufacturer for the possibility of making improvements.

Concrete cutting with a hand tool

Because of the strength of the material to work with it is not suitable for any hand tool. Most often for these purposes use an angle grinder (aka UGS, angle grinder). To cut concrete, a special nozzle is used in the form of a diamond wheel, which can be solid, segmental, combined.

Types of diamond wheels for angle grinder with which you can cut concrete:

• Solid. made with a continuous diamond cutting edge, so there are no splinters in the work. The tool blade heats up from time to time and therefore requires constant cooling with a water jet.
• Segmented disc. the base is solid, the edge is segmented. The wheel is inexpensive, but it quickly wears away from durable materials. Suitable only for dry cutting.
• Combined (aka turbo-diamond) disk. is considered a universal, can withstand maximum loads, it can even cut reinforced concrete.

Attachments are selected in accordance with the material to be sawn, the type of work and the conditions of work. Reinforced concrete with indentations of more than 10 cm can only be cut with high-strength (turbocharged) discs. All disc segments are attached to the blade by laser welding or silver soldering. The first can only be used for dry cutting, the second for wet cutting.

The wheel must be made with an inner diameter that corresponds to the diameter of the angle grinder. The disc speed is also important. it is desirable that it is higher than that of the angle grinder. Depending on the type of cutting you do and whether you use the right tool, the amount of dust that can be created will vary.

So, if you cut long enough concrete with an insufficiently strong and ineffective tool with nozzles, there will be a lot of dust, but the result is minimal. You can reduce the amount of dust by using the wet cutting method. water keeps the tool from overheating and prevents dust. This speeds up the work and increases the life of the diamond bit.

The water supply can be arranged in different ways. from spraying concrete with a spray gun periodically during the work to fixing a hose to the tool so that the liquid flows continuously on the disk.

A handy nozzle is made from an ordinary plastic can. A cutting torch and a container with a sizeable nozzle that matches the diameter of a vacuum cleaner hose are also needed.

Next, the seating holes on both sides must be made to enable the easy change of direction of the disc rotation. Cut a suitable size for the wheel, and another hole is made to fit the cutter. Carefully connect the hose to the neck of the canister, then fasten the adapter ring with a clamp. the angle grinder is sent into the casing, all elements are securely connected. Cover the hole that is not in use.