Category: Concrete Cutting

In layman terms, concrete cutting is the process of creating openings in concrete surfaces, whether they are walls, floors or ceilings for the installation of utilities, creating doors and windows, or even for simplifying the process of dismantling a concrete structure, or removing any unwanted concrete from any site.

The cutting of concrete, drilling it, and sawing it are great challenges for engineers tasked with this chore, as concrete is a very hard material that keeps on getting stronger as it ages. It is a tough material to work with when it is in this advanced hardened state and requires special tools, that are constantly being developed.

Concrete has been around for construction for a very long time and in earlier days any need for creating openings was dealt with by the use of chisels and hammers, the wielding of which required great brute strength. The actual dismantling of large blocks of concrete and other hard construction material was often carried out by jackhammers that used compressed air. This again required a lot of brawn and created a lot of noise.

Present day construction personnel have the advantage of having access to a wide range of steel saws

These saws can carry out the concrete cutting in a more precise manner, with less of physical effort and disturbance to the concrete structure. A concrete saw is a tool of high quality that is used by the professionals in this business to cut or create openings in concrete and is also able to deal with any other hard material that is used in construction, like brick, stone or tile.

These tools can be handheld

These tools can be saws that you walk behind, or those that are mounted on tracks attached to vertical surfaces for cutting walls. The motive power for most of these tools is electric motors, though you can also find some saws that use gasoline engines for the purpose.

The cutting of concrete can create a lot of dust

Dry sawing is more commonly used only for outdoor projects like in roads and bridges. Blades used for dry sawing are made of blades that have diamonds impregnated on their cutting edges and are relatively immune to the heat that concrete cutting can produce.

These dry saws require very high power and are useful for dense concrete. A technique that is now more widely used for cutting concrete is wet sawing. This method of wet sawing is environmentally friendly as not only is the dust controlled, but the saw also remains cool and gives extended services that require lesser replacement of saw blades.

Wire sawing meets the needs in the construction industry for creating very accurate opening sizes and can be used for cutting steel or even reinforced concrete. They can cut in a wide variety of shapes and deal with almost any size of an opening that needs to be created. Wire saws are cables that have embedments of diamonds to give them a cutting edge. They give contractors engaged in this work, a lot of flexibility and can help to minimize wastage.

The use of wire saws produces very little vibration in concrete structures as conventional blades will do, and this reduces the chances of cracks developing in concrete. Ring saws are used in handheld concrete breakers and are useful for executing small sized projects for cutting of concrete. It is a smaller version of wire saws and can create openings in confined spaces, with a high degree of precision and accuracy.

The sawing of floors is the most commonly required operation in construction

This equipment uses circular saws with hardened edges or diamond coated teeth, mounted on equipment that an operator can walk behind so that the machine is guided on a correct path.

Most of these floor saws also use water cooling for the blade, with the water also being used for reducing dust nuisance. Floor sawing is used to cut into bridge decks, roads, pavements and floor slabs. Walls saws are mounted on tracks that help to guide the saws and can cut through walls to create openings for doors and windows, as well as to create space for utilities.

Cutting cores is another form of cutting concrete and is useful for creating openings in walls and slabs to allow pipes and ducts to pass through. Perfectly circular openings of the required diameter are created with the drilling bits being of the required size and having cutting edges at a right angle to the direction of rotation. Cores are also used at times for checking the strength of concrete.

The cutting of concrete using these modern and evolving techniques is more practical and efficient than the previously used traditional methods for removing concrete. They are less likely to cause any damage to concrete structures, as vibration is almost eliminated.

Concrete cutting has gone through several changes in the last few decades. From using the jackhammer to the use of heavy sawing machines, the evolution of the concrete cutting solutions has been amazing. These have helped different industries and been a part of many construction projects. Be it for creating a new entry to a building or paving a path for a better road, concrete cutting services have always been necessary. The construction industry has required these specialized services more than any other sector.

Let’s take a look at how these services have benefited various industries and different projects:

1) No sound or air pollution

Even a decade back, when the machines were not as developed as today, there was too much noise when the drills and saws cut through concrete. You could not be anywhere near the machines because of the searing noise. Everyone involved in the project would take a break when the saws were in full flow. In fact, most of the concrete cutting in the construction projects was done when the workers were away. And, let’s not even begin with the respirable dust that got emitted from those machines. However, with the modern machines, things have changed for the better.

The modern machines do not produce so much noise or dust. With minimal noise, it has become easier for construction projects to be completed quickly. Not only for construction projects, there are times when concrete cutting is required by homeowners. Neighbors would have been irritated with all the noise of the concrete machines but not anymore!

2) Precision and accuracy

This is another reason why road makers and construction companies require the services of a concrete cutting company. The construction industry needs accurate cutting for setting up doors and windows. This can only be done by experienced concrete cutters. They have gigantic sawing machines that are specially designed to cut down walls to make way for doors and windows. Diamond blades are used in the machines to cut through walls. There is no denying that these machines have been a boon to the construction companies. They can cut down the thickest of walls within the wink of an eye.

Before the walls are cut down, the expert will check the measurements where the cut has to be made. The diameter of the blade is set accordingly. After that, the machine is switched on the walls are cut. These machines can also cut walls according to specific designs. Sometimes, the rooms need special openings that are not used for doors and windows. These designs can also be cut by the concrete cutting machines.

3) Fast and efficient

Let’s face it; the days when the jackhammer and chisel were used, it was such a pain for the workers to work in the scorching heat and break concrete floors or walls. They would take hours to finish a particular job and that extended the project longer than usual. With the modern concrete cutting machines, things have become faster. The work of almost 3 workers can now be done by one single person. It has been possible because of the evolution of the machines. The machines used these days come with inbuilt water container so that the machines do not leave a lot of mess in the form of dust and dirt.

The chances of missing a deadline have gone down. Be it a big or small construction project, you can be assured that the quality of work will be maintained even when the work is being done faster than normal.

4) Efficient for working in smaller areas

One of the biggest advantages of opting for the services of concrete cutting is that they can work within a very small space. There have been cases when concrete walls have to be cut to get through to the plumbing system of a house. This requires the precision and accuracy of the cutter to work within a space that will not be more than a couple of feet. There are machines that can be used in such small spaces too. Handsaws that specialize in working in small areas are used in such projects.

At MEGASAW, you can expect to get the best concrete cutting service that will give you your money’s worth. We have a dedicated team of cutters who can take up any challenge you throw at us. They have been a part of numerous projects for some of the most eminent companies. We have come up with a combination of techniques that have helped to cut through concrete easily. Apart from our quality service, we charge the least and you are free to compare the fees with other companies. Give us a call at 1300 920 419 to discuss your project and we assure you that you will be totally satisfied.

Know the trends, different equipment and precautions needed in concrete cutting. In cutting concrete, the safety of workers should be your priority.

You may have a slab of concrete where specific cuts need to be made, and you need to find a business that can provide you with this type of service.

If you can’t find a concrete cutting service in your city, you should not lose hope. Through the internet, you can readily find contractors with special tools that can meet your concrete cutting needs.

 

If there are a couple that offers that services you need, here are some guidelines to help you choose. One, consider the company’s reputation and experience.

Almost all companies have websites that showcase its portfolio. With this, you can examine the quality of their work.

They should also have the latest tools that can cut concrete very quickly, examples are diamond-tipped saws and blades. These should be able to cut through any type of concrete, regardless of its thickness. And they should provide value for money with their services.

 

What Concrete Cutting Companies Do

Initially, they would come to the project site, take measurements, and provide you with an estimate on the cost. From this, you can choose which company will carry out the project.

 

Experience Versus Cost

Although cost plays a major role in your decision which company you’d want to work with, this should go hand-in-hand with the company’s experience. Apart from looking at its body of work, verify if there are any complaints against the company.

 

Plus, make sure that the business has the requisite licenses.

If the company that has tons of experience prove to be beyond your budget’s reach, find someone that has both enough experience and give you the low rates.

 

How To Find These Companies Quickly

You should find all of the businesses in your area through the Internet. On their website, check the services they offer, their previous projects. Almost every business that is in the construction industry has a website showcasing their services, their previous projects, and contact information.

This will make it much easier for you to get the project started.

Granted, you can choose to invest in the equipment and ask a few of your workers to do the concrete cutting for you. But be careful. A mistake can significantly increase the cost and delay project completion.

In contrast, when hiring a contractor, you can see from the estimates if they can do the job and how much you need to shell out.

You just need to do due diligence in terms of research and assessment of prospective concrete cutting companies. This will ultimately lead you to the best choice and have the output you want.

You usually need to cut concrete in floors, foundations, and walls to either modify the structure or create openings for running services and other utilities. These are necessary for heating, plumbing, and electrical work and vents.

For this, you need to do controlled sawing or drilling and special equipment that uses diamond impregnated blades.

The blades together with water produce smooth and attractive finishes in one go. The water prevents the dust from rising and the entire process makes less noise and remains environment-friendly.

This is different from the previous method wherein jackhammers were used. This often left irregular openings and created a lot of dust and noise. Plus, the constant hammering produced vibrations and could cause structural problems in weak structures.

In contrast, now we can produce perfectly round holes in concrete,  as big as 12 inches in diameter. Just be careful that the cutting does not affect the reinforcement. But if you need to cut the reinforcement, strengthen the opening so that structural stability will not be affected.

The concrete cutting of slabs is often done with diamond blades that may be 33 inches in diameter at the most.

These blades are mounted on machines. Companies which cut concrete use ground radar penetrating machines to know what’s inside the reinforcements so that they can avoid the same during cutting. These obstructions are marked on the surface.

Slab cutting can help you during demolition work as you cut large parts of concrete.

But in doing this,  you and your crew should put a premium on safety. Some concrete cutting machines can be handheld while others are floor mounted or operate on some framework. Each of these has a set of guidelines for safety and efficiency.

Water is essential in cutting concrete. It helps deter sound, reduce dust and more importantly keep the temperature of the blade under control. That’s why you need adequate water and drainage. Improper drainage or flooding of areas where concrete is being cut can lead to slips and falls and may even result in electrocution. Electrical connections must have adequate grounding and all wires must be well insulated.

Further, remember to have the machines properly anchored while cutting. This is necessary because concrete’s hard and the machine may get out of control when you’re cutting it. Blades may get broken and become hazardous to the machine operator.

Finally, make sure that the tools you’ll use are in the best condition and saw blades are sharp and have all their cutting edges in place. Operators need to be well experienced and have all the necessary safety equipment like gloves, goggles, shoes and helmets.

 

The right concrete cutting blade can spell the difference between a cost-effective and efficient job and one with lots of downtime and additional costs.

Thus, you must know what to look for in a blade for your next concrete cutting project.

There are various considerations to make as you seek to get your best blade. But first, get to know the types of diamond blades available in the market.

Here are the options to choose from:

Dry-cutting blades

These are used to cut dry, hard concrete.

Sintered diamond blades are routinely used for dry cutting. They are typically high density alloys of silver and diamond – made by sintering steel cores, diamonds and metal bond materials already put into molds.  

These diamond blades are in two types:

• Hot-pressed diamond blades

Well alloyed, with high density segments. They have a longer service life.

 

• Cold-pressed diamond blades

have low-density diamond segments with high porosity. This feature can improve the cooling condition when the blades are in use. They however have a shorter service life.

Sintered diamond blades can cut marble, granite, concrete, asphalt, ceramics and other dry building materials.

Note: Some sintered diamond blades such as the continuous rim diamond blades can only be used in wet cutting.  

 

RELATED ARTICLES:

• Tips on Safe and Efficient Concrete Cutting
• Using Power Tools for Cutting a Concrete Slab
• Advantages Of Diamond Concrete Cutting
• A Step By Step Approach in Concrete Cutting Leads to Greater Safety

 

Wet-cutting blades

Water must be used to cool the blades, in contrast to dry-cutting blades that need no cooling. These are used to cut green concrete.

Silver brazed diamond saw blades are typically used in wet concrete cutting. The diamond segment of a silver brazed diamond blade does not have a transition layer.

They are brazed directly to the steel cores using silver-based brazing films which normally contain 40 – 50 percent silver.

As such, silver brazed diamond blades cannot be used in dry cutting. This is because the high temperatures generated in the dry cutting can melt the silver solder, causing the diamond segments to fall off the blade.

 

Laser welded diamond blades

These can be used in both wet and dry cutting. They are made by fusing the diamond segments and steel core by laser welding.

The diamond segment-steel core junction is melted to form a connection that can withstand high temperatures produced in dry cutting.

It’s still however recommended that laser welded diamond blades be used with lots of water, (wet-cutting) because dry cutting can cause the diamond segment or steel core to wear off and break.

 

Things to consider when choosing concrete cutting blades

The blade components

Armed with an understanding of how a diamond blade works, it becomes easy to pick a blade with the right cutting quality and characteristics that suit your needs. Here are the basic blade components and what to look for in each component:

 

• The diamond crystals

Are the sharp cutting teeth that slice through concrete as the blade rotates. The diamonds at the surface become dull with time as you use them. The matrix gradually sheds away worn out diamond crystals to expose new, sharp diamonds embedded within it.

 

• The matrix

The metal bond that holds the sharp diamond crystals in place until they wear off. The harder the matrix the longer it takes for the blade to wear away.

 

• The metal core

A steel disc that was precision engineered with a segmented rim. This holds the diamonds.

 

• The weld

Attaches the diamond cutting segments to the core. Can be laser or solder weld.

For soft, abrasive materials like green concrete, use a blade with a hard metal bond so the diamonds exposed at the surface are fully utilised before they get shed off.

For hard, solid and non-abrasive concrete, use a blade with soft bonds to allow the matrix to get rid of worn out diamond particles and ensure that sharp new diamonds get exposed with ease.

 

Characteristics of the concrete

The choice of blade depends on  material you want to cut. Consider characteristics such as:

• The hardness of the aggregate
• The type of sand
• The compressive strength

Concrete with a compressive strength below 3,000 psi is considered soft. On the other hand, concrete with a strength of 6,000 psi and above is hard.

Be sure to use a blade with a hard bond to cut soft concrete. When cutting  concrete with high psi (hard) however, use a blade with a soft bond.

This is because high-psi compressive strength, hard aggregate and hard sand tend to dull the diamond particles quickly.  Thus, a softer bond will allow new diamonds on the blade to be exposed as quickly as needed for better work.

 

Timing of the cut

Green (freshly applied) concrete is softer. Use a blade with strong bonds on the matrix so you can maximise the use of the exposed diamond particles before they are eroded.

This would apply if you cut the concrete approximately 1 to 2 hours after finishing.

Beyond that time, the concrete would already be hard. You’d want to use a soft-bonded diamond blade to cut it.

 

Cost of the blade

Like any product, manufacturers offer diamond blades at various prices depending on the quality. Options range from basic economy to professional or top-of-the-range versions.

They differ primarily on the diamond content, the most important part of the blade. The higher the diamond concentration the better the quality and the higher the amount you’ll typically pay.

In considering the cost, look at what’s important to you. Is it the initial savings from buying an inexpensive blade or the value given by a more expensive blade in the long run?

For small cutting jobs that involve little run on the blade, you’ll likely save money by buying the economy blade. Jobs that involve frequent or long hours of use however make top-quality blade more cost effective in the long run.

 

Conclusion

If the quality-cost consideration of buying your own blade shows you would be paying more that you are willing to, it will be better to hire a professional concrete cutting contractor like MegaSaw. By this, you avoid the hassle and unexpected additional costs.

Put down the phone.

Do you know what factors to consider before you hire a professional concrete cutter? If you don’t, don’t make that call until you have read this.

Many homeowners make the mistake of calling the first guys in the local telephone directory or on the first page of Google.

Bad idea!

Haphazard Way of Hiring a Concrete Cutting Service

There are a thousand things that can go wrong with this haphazard way of hiring a concrete cutting service.

• The guys could be con artists posing as professional concrete cutters in Melbourne. Don’t just let anyone into your home/project;
• If they happen to be genuine, they are probably new in the industry, thus, don’t have the necessary equipment and tools;
• If they are not new in the market, they’ve probably been at this for far too long, made enough money, and do not look to satisfy customers anymore.

These are the reasons doing due diligence is important before hiring concrete cutting experts in Melbourne.

At Megasaw, we aim to set the standard in the industry. We believe in providing consumers (irrespective of whether they are our customers) with concrete information. Information that helps you makes a solid decision.

Factors in Hiring Concrete Cutting Expert

So, what are some of the factors to consider when hiring a concrete cutting expert?

1. Licensing and Physical Office

It is important to make sure the contractor is duly licensed.

But licensing does not cut it in most instances.

RELATED:  Why It’s Best to Hire a Professional

Do they have a physical location where you can contact them if somehow stuff hits the fan and you need to get in touch with them.

Don’t just hire a contractor because their website is an eye-candy. If they are not licensed and they do not have a physical presence in your area, it will be better to go with other contractors.

2.  Experience Matters

Given the choice between a newbie and a contractor who’s been in the market for 3-5 years, who would you hire?

This is where experience comes in. I have nothing against new concrete cutting experts, but are you willing to be their guinea pig?

The more experienced concrete cutting experts are, the more reliable they become. They’ve probably accomplished harder and trickier tasks.

They have seen it all, and they are able to borrow from that vast experience when dealing with different concrete cutting scenarios.

RELATED:  Pros and Cons That Have To Considered in Choosing A Contractor

3. Tech and Tools of Trade

Apart from experience, contractors need to be well-equipped.

What tools and technology do they use? Are their machines up to date?

Do they have any backup plans if a machine gets broken?

Don’t be afraid to ask these questions. They go a long way in ensuring your project gets done well.

4. Who Bears the Liability?

Construction projects can go awfully wrong, resulting in the loss or destruction of property worth thousands of dollars.

Ask yourself and your shortlisted concrete contractors, “Who bears the responsibility in case of losses?”

The best saw cutting experts in Melbourne will have insurance policies to cover against any untoward incidents. These insurance policies include workers’ liability and a clearly outlined property compensation policy.

Keep in mind that concrete cutting is a challenging task. It involves the use of heavy machinery, some of which are operated at very high power supply.

If something goes awry during the project, you surely do not want to be the one to shoulder the liabilities.

If a concrete cutting contractor is not insured, keep off.

5. What’s the Word in the Street?

What’s their reputation?

Don’t ignore recommendations and referrals in choosing professional concrete cutters. Look for people who might have hired concrete cutters recently, and ask about their experience with the experts.

In most cases, you’ll discover something that you missed when doing your research. What’s the best way to get referrals?

Identify at least 4-5 companies that look promising and ask them to send you references from projects they have recently completed.

Call these previous clients and ask their thoughts on the services rendered.

6. Only Hire Professionals

I hope you are going solo on this. If you are, I hope you’ll change your mind.

Any task that involves cutting concrete should not be entrusted to a helper who owns an old dust mask and an electric saw.

Instead, hire specialized concrete cutting contractors that will surely save you time and money.

Most of these contractors can handle cutting concrete of all sizes. They use special tools and other machinery that make the work easier.

Megasaw has some of the best concrete cutting experts in Melbourne. We’ll be happy to help you with your project.

RELATED: How to Choose your Professional Concrete Cutter

Does Megasaw Have What it takes?

We have been doing it for generations. And honestly, I don’t think there is any other concrete cutting expert in Melbourne who can match our level of experience and expertise.

We have been through thick and thin (pun intended) in our 40+ years of drilling and cutting through concrete.

How many projects have we handled?

Thousands!

Click here to see more of our work

Look through our online portfolio for an extended list of various projects we have successfully completed.

We are also willing to present you with a list of references that you can use to counter-check our work history.

What about our arsenal?

Click here to see more of our services

We use nothing but the best power tools and latest technology in the construction industry. Thus, you are assured of precise cuts in the shortest time possible.

We are here to serve you, and we aim for the best whatever task you give us. Give us a call today +61 1300 920 419 or use the online contact form to send us a quick email.

At MegaSaw we get the job done.