Core Drilling for Reinforced and Non-Reinforced Concrete Surfaces – An Overview

Reinforced and non-reinforced – both types of concrete surface are often encountered in highway drilling and construction applications. Both require unique drilling methods and also differ in drilling results.

For instance, drilling through steel bar produces a different sort of pressure and therefore, has a different wear on the cutting surface. Thus, it is important to determine the type of concrete surface first and then choose the right drilling equipment that will perform the job efficiently.

What is Core Drilling?

Core drilling is one of the most effective, non-vibratory ways of drilling through reinforced and non-reinforced concrete surface. It creates holes without causing aggressive demolition or too much strain.

The core drill is a highly efficient and powerful tool for boring holes through reinforced concrete, block, brick, masonry, and stone.

The typical core bits are made of hollow steel cylinders that are fitted with segmented diamond teeth. The teeth grind away the concrete surface for creating a hole of any desired size.

Usually, core bits vary in size from 3/8” to 14” in diameter. Most core bits are capable of drilling through 12” and even more. However, longer extensions, threaded barrels and bits are also available.

Diamond drilling is essentially preferred.This is how to get neat and clean holes through all types of reinforced and non-reinforced concrete, block work and bricks. The core drilling procedure is most effective in getting precise and accurate circular cuts through varied concrete surfaces.

Benefits of Core Drilling

The significance of core drilling is unparalleled. Unlike traditional drilling procedures, diamond drilling is more comprehensive in nature and environmentally sound. Discussed here are some of the key benefits of core drilling:

  • Core diamond drilling is most efficient where precise circular cut and neat holes are required
  • The drilling method can be equally used for reinforced as well as non-reinforced concrete surfaces
  • Drill holes of virtually any diameter to make openings for electrical, plumbing, and HVAC installation
  • Core drilling can also be used for studying and analyzing rock, structures, and strata
  • It produces less vibration and strain as compared to conventional methods, thus, causing minimal structural damage
  • Use core drilling procedure for increased accuracy and minimal labor cost

Drilling Reinforced Concrete Surface

Drilling through reinforced concrete surfaces can be difficult and takes longer than other concrete and allied material.

For this, the core drilling procedure is adopted.This is where the steel bar of reinforced concrete is drilled through by fine diamond crystals in a machining mode. However, it puts a high strain on the diamond core bit as steel is a relatively ductile and very tough material.

When the core bit rotates against the same section of drilling surface, it encounters concrete that’s more brittle than before. This facilitates loading and unloading of diamond crystals and bond materials.

Drilling Non-reinforced Concrete Surface

Drilling through plain concrete is relatively different from that of reinforced concrete. However, the core drilling method can also be used in cutting holes of any diameter through non-reinforced concrete surfaces.

Here, the concrete material is removed or drilled through the process of crack propagation. Diamond in the core bit generates stress on brittle non-reinforced concrete that creates a crack on the surface.

The cracks are caused when the concrete is broken away from base material, allowing the core bit to drill through the material efficiently.

Tips for Core Drilling

Core drilling can be used for both reinforced and non-reinforced concrete surfaces, delivering increased accuracy, precision, and efficiency. Here are some valuable tips for core drilling that will help you save time and money, and improve the drilling results.

1. Water – If you are using a wet diamond core bit, it is preferable that you use little water. This enables the diamond to grind away the concrete surface efficiently. Excessive water pressure can wash away concrete grit, preventing the diamonds from becoming exposed. To get effective results, apply little water only till the slurry resembles that of creamed coffee. Appropriate slurry helps in the grinding process and also keeps the core bit cool. The diamonds remain exposed all through and stay in contact with the slurry particles.

2. Vacuum Base – Base vacuum can be used while drilling through concrete surface that is smooth. However, make sure that the gasket is in good working condition. Also, do not use a vacuum base while drilling through ceiling or walls.That can be dangerous. Ensure that the vacuum filter bottle has no debris or water inside as it can harm the vacuum. Also make sure that the vacuum pressure is just adequate for the drilling purpose.

3. Diamond – To get best results and also save time and money, it is important to choose a diamond type that matches the application. For this, it is imperative to consider the material to be drilled and particular diamond bond specifications of the core bit. Too soft a bond may wear away the diamond prematurely; too hard a bond may increase drilling time. For reinforced concrete, choose a soft diamond matrix; for softer materials, choose a hard diamond matrix for effective results.

4. Pressure – For efficient drilling through reinforced and non-reinforced concrete surface, maintaining steady and even pressure is most important. The right amount of pressure ensures maximum life of the core bit. Too little pressure than required for the application can cause the diamond to glaze over, while inconsistent pressure can cause the drill to glaze over. On the other hand, too much pressure can overload the drill, causing significant damage to the drill motor and core bit.

5. Speed – To grind through surfaces efficiently and prevent glazing diamond segments, it is important to set the motor at the right Revolutions per Minute (RPM). It is only at ideal surface speed, which is dependent on core bit diameter that you can cut through efficiently. For instance, smaller diameter core bits require higher RPMs.

6. Power – To achieve the right drilling speed, it is imperative to have adequate power. If the drill is underpowered, it can cause overheating during drilling, thus, damaging the equipment. When the equipment receives too much power, it can also cause increased abrasion and glazing of diamond segments.

Concrete Recycling: Mega Saw’s Contribution for a Greener Environment

MegaSaw has been offering concrete drilling and cutting solutions for 40+ years now. They use cost effective and safe methods for masonry products and concrete related services. Aside from this, the company also contributes towards a greener environment through successful recycling of concrete, ensuring complete peace of mind for their clients.

With MegaSaw coming to the aid and ensuring proper disposal of on-site debris, making significant savings is not difficult.

Cost savings with MegaSaw concrete recycling:

  • Savings on transport to landfills, at the rate of $.25/ton per mile
  • Savings on disposal costs at $100/ton

As time passes, the costs of using landfills already overburdened with debris are becoming quite expensive. In such situations, the construction industry has no other option but to look for alternatives to deal with concrete debris successfully, so that they do not become an unnecessary burden.

Today, landfills remain heavily regulated, so naturally, the debris related to land clearing, construction and demolition has become a big headache for everybody related to the real estate industry.

MegaSaw understands the situation very well. They are always looking for ways to minimize the hassles for their clients.

The good news is they have developed a viable method of dealing with this problem, while doing something for the environment at the same time.

Recycling of concrete waste is how they managed the problem. This solution produced the best results for their customers.

Concrete Recycling Process

Do you think that recycling concrete is a complex and expensive process? With MegaSaw at the helm, everything becomes smooth, quick, and highly affordable. Their use of the latest technologies signifies fast solutions in keeping with specific project needs.

Over the years, the company has made a conscious effort toward incorporating state-of-the-art equipment and methodologies, with focus on environmental issues.

Naturally, they emphasized the use of a simple concrete recycling process, which is both time and budget friendly.

For example, when it comes to recycling pavement concrete debris, the process involves breaking the pavement, removal, and crushing of the concrete slabs.

The crushing process turns big slabs into materials of specific quality and size for ease of recycling. Now it becomes possible to reuse the crushed concrete as aggregate in concrete or other structural layers.

In general, people tend to use it in combination with virgin aggregate for new concrete use scenarios. However, it is important to remember that the maximal use of recycled concrete is in the form of sub-base layer aggregate. MegaSaw uses both formats based upon specific situations and client requirements.

Developments in modern technology have led to advancements in the recycling process. MegaSaw is quick to jump on the chance to use them as quickly as possible.

After all, it signifies an economical way to deal with various concrete pavement types. Some of the technology inputs available from the company include the following:

  • Concrete pavement breaking for continuously reinforced, mesh-and-dowel, or plain
  • Mechanized steel removal for minimizing hand labor
  • Crushing equipment application & use for accommodating steel reinforcement

Recycling of Concrete Pavement

Recycling of concrete pavement is MegaSaw’s forte. They offer the best solutions for all types of pavement recycling. This includes use of latest recycling technology for

  •   Plain Jointed Pavement
  • Continuously Reinforced Type
  • Reinforced Jointed Pavement
  • Airport Pavement

Use of high quality equipment ensures that the company is able to recycle concrete pavements of high thickness, including those that are 17 inches or more. Recycling involves transportation of concrete debris to a recycling plant. But many times, they also use portable machinery for on-site green disposal of concrete.

The MegaSaw Benefits

Do you know why concrete waste poses such a big threat to the environment? The simple reason for this is that concrete debris is never biodegradable, not in any shape, form, or way!

So, while over the years, it may gradually crumble pitiably, it still sits as it is in place or at landfills for times to come. Can you allow this to happen to your environment? What about the substantial costs involved in transportation to the landfills in the first place?

MegaSaw takes its concrete disposal responsibility seriously. They will never allow Mother Earth to clutter up unnecessarily.

Consequently, when you are dealing with this company, you will be able to reap all the benefits related to concrete recycling the successful way.

Concrete recycling is the energy saving endeavor when compared to various mining processes or transportation related to new aggregates. Use of recycled material in new constructions is another cost-saving proposition that the company wants their clients to benefit from thoroughly.

Remember, the responsibility of MegaSaw doesn’t end with construction project completions. It already contemplates the next step – that of recycling concrete successfully. Naturally, one cannot deny the company’s contributions towards a greener environment!