Wire Saw Operation With Cleaning and Maintenance After Sawing

In our previous blog post “Preparing Your Wire Saw”, we explained a step by step procedure for preparing your wire saw for operation. This post explains the next procedure involved in utilising a wire saw efficiently for successful concrete cutting.

For operating a wire saw, you need to assemble it first. Once this is achieved, you can start with the cutting process. Following, are the steps involved in the wire saw operation.

Step 1:

Effective starting of the wire saw is important if you want to ensure the success of your operations. For starters, close the valve on reduction pressure block by counter-clockwise rotation of the knob. When it stops, go for 2 turns back. Now you can start your hydraulic unit. Set to maximum, the feeding flow related to the unit. In order to achieve this you need to turn the controls present on the related remote control in the clockwise direction.

Now you need to create wire tension through careful knob turning on the reduction pressure block in the clockwise direction. Continue with it until you find that the tension in the wire is sufficient. Seating of the wire should be correct on every individual wheel for ensuring an effective operational start to the wire sawing process.

Step 2:

Now the next step is starting the rotation of the motor and for this, you need to turn controls associated with motor rotation present on the remote control in the clockwise direction. Gradually increase the speed of the motor by turning associated controls for generating motor rotation. You should be quite careful regarding the process because this is one of the crucial factors determining smooth wire saw operations.

An effective working pressure is generated when cutting pressure falls between 100 bar to 130 bar. This depends upon a number of wheel sets used in the magazine coupled with the amount of wire used along with the hardness of the material you want to cut with the wire saw. However, during this process it is important to heed a special WARNING! For effective cooling of the wire during cutting, it is important to consider the best cooling water position via adjustment in relation to the material ready to be cut. It is important to stop the machine whenever excessive heat is generated.

Step 3:

Effective cutting occurs when the working pressure goes down. You can visualise the pressure drop on the display and it is important to generate tension in the magazine. For this, you need to turn the reduction pressure block knob in the clockwise direction. The machine indicator displays the magazine output tension and during full tension it is important to stop the machine and wind the wire around a new set of wheels. Now you can continue the cutting process as described above.

Wire Saw Cleaning

Once cutting is over, it is time to clean the wire saw. Clean up all the related equipment and the best way to do this will be to remove the hose from its pivot and then use this water source for cleaning. Cleaning brushes can also be used for doing this effectively. Washers working with high pressure are not appropriate for such processes.


Daily maintenance can keep your wire saw working effectively for a long time. You need to consider regular cleaning with lubrication and servicing. Ideally, you should use professional services after 50 hours of operation.

How To Prepare A Wire Saw For Concrete Cutting

Wire saws, which are usually complimented with a high-performance hydraulic unit, are exceptionally powerful and easy to use, which can handle bulk jobs efficiently. Simultaneously, it comes in a compact and portable design, which is easier to transport from one place to another. Top-notch wire saws can be used for a wide spectrum of applications, both on the ground and mounted on walls. Here is a quick guide on how to prepare a wire saw for operation:

Preparing The Saw:

  1. Determine your cutting needs comprehensively before you assemble the wire saw. This is important to ensure that the saw can be operated with ease.
  2. The key feature of many top-quality wire saws is that they can be assembled for making either vertical or horizontal cuts. If you are looking to make vertical cuts, assemble the saw in standing position. When the cut is to be made on the floor or at floor height, it can be assembled horizontally. Often, it might be necessary to drill holes to allow the wire to go through the material that is to be cut.
  3. In front of the planned cut position, place the saw appropriately. Make small adjustments in the position and then secure it by screwing the anchor bolt down. When you have anchored the saw onto the floor, the adjuster feet needs to be screwed down so that it stands firmly. If the wire saw is not properly secured, it can overturn when the material, which supports the adjuster feet pair, is cut through.

Fit Idler Wheels

wire_sawingWire saws often come with idler wheels, which can be fitted to the machine to assist the precision cutting process. Use of these wheels reduces the number of sharp corners that the wire needs to be pulled around, thus, resulting in less wear and tear on the wire. It also makes the cutting process easier. The wheels also enable the operator to guide the wire in different directions without the need of actually moving the saw unit. Once you have finished the cut, the idler wheels can be used in capturing the wire. Make sure that you position the saw appropriately so that you can stand and operate on the cutter, without the risk of being hit by a broken wire.

Connect the Power Pack

Once you have assembled the saw appropriately, connect it to the hydraulic unit. Here are some tips on how to connect the power pack to the saw:

  1. First, connect the incoming power cable.
  2. Next, connect the incoming water hose of the wire saw to the water coupling located at the bottom of the motor front on the hydraulic unit.
  3. Using the cable provided, connect the remote control and tighten the cable connector screws appropriately.
  4. If the machine comes with a radio, connect the radio antenna instead of the cable, by inserting it into the same socket as that of the cable.
  5. Check if the emergency stop power on the hydraulic unit and the remote control have been triggered or not; simply by moving them in the direction of the arrow.
  6. Confirm what the display shows by pressing the membrane key ‘OK’.
  7. As provided in the instructions, set the pressure reduction block on the power pack
  8. Next, set the hydraulic hoses and water on the power pack and lock the couplings by turning the sleeve so that the slot moves away from the ball
  9. Now connect the hydraulic hoses on the wire saw in the same manner as on the power pack
  10. Connect the water hose to the water coupling located on the saw unit
  11. Confirm that the hoses are connected appropriately

Thread the Wire

Next, thread the wire by following the instructions as provided by the wire saw and hydraulic unit.

Place Cooling Water

Attach the water spears to the outlets provided in the wire saw. The thread wire takes the water into the cut, facilitating concrete dust binding and ensuring that the wire is cooled more efficiently.