27Sep 2023
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Rigid pavements often require concrete cuts. This is a laborious and tedious process that involves light construction equipment assistance to perform. These cuts are usually made with a road saw or a road cutter. In this article, BISON will discuss how a road saw works, types, purpose and how it cuts roads.
Road saws, known by various names such as road cutters, concrete saws, slab saws, cutting saws, floor saws, or quick cuts, are versatile tools capable of precisely cutting through a wide range of solid materials.
A road saw is a powerful abrasive blade attached to a motor that spins the blade. As the blade rotates, it cuts the surface or road beneath it. The motor can be powered by gasoline or batteries.
The electric version is, of course, quieter. Various controllers are connected to the motor to regulate the blade speed.
Using a road saw or road cutter in construction projects provides several advantages:
Increased Efficiency: Road saws enable faster cutting compared to manual methods. Utilizing potent blades and high cutting speeds, road saws can efficiently accomplish cutting tasks, reducing both labor requirements and project duration.
Accurate and Clean Cuts: Road saws are designed to deliver precise and clean cuts. The diamond blades ensure smooth and straight edges, making the resulting work of higher quality. The precision achieved minimizes the necessity for additional repairs or adjustments.
Cost-Effective: Despite the upfront costs, the utilization of road saws can prove to be cost-effective over time. They contribute to savings on labor expenses, as the need for fewer workers is required for cutting tasks. Moreover, their precise cutting ability minimizes material wastage, reducing overall project expenses.
There are small hand saws, chop saws, and large walk-behind saws or other models powered by hydraulic, gasoline, pneumatic pressure, or electric motors. According to the equipment used for sawing ranges from small to large. A typical classification is
Their power ranges from 6 kW to 13 kW, and it is most commonly used for dry sawing.
They are designed to be compact and lightweight, making them ideal for light tasks such as small repairs or residential projects. They are often used for projects such as sidewalks. Their maneuverability makes them ideal for projects with limited cutting needs.
Medium-duty road saws is a sturdier version capable of handling medium-sized cutting tasks, range in power from 15 to 28 kW. And often used on commercial and industrial projects such as car park construction, road maintenance or small infrastructure works.
Large road saws are heavy-duty machines equipped with powerful engines and larger blades, have a power range between 50 – 55 kW and are best for wet cutting. Specifically designed for major roadworks and extensive projects, they handle demanding cutting tasks on a larger scale, crucial for highway construction.
Most commonly used for wet sawing, heavy-duty road saws are available in the 50 – 150 kW power range, which are often used for high-volume applications, like major roadworks and extensive projects.
The most common use of road saws is to cut road sections, cutting concrete, floors, cement and stone pavements etc, designed to provide professional cutting for on-site operations such as municipal construction, road maintenance, construction, airport road cutting, communication engineering embedding, concrete floors, and driveways.
BISON road saw can also be equipped with a specific blade for cutting the asphalt layer of the road. Different saw blades can be replaced during use, effectively cutting old and new concrete and asphalt pavement and equipped with a water tank for motorized water-cutting operations.
Another everyday use is to cut controlled expansion incisions in raw concrete. Green concrete is freshly poured concrete, and expansion notches control the cracks that inevitably develop due to expansion and contraction. Road saws are very effective for making long, straight expansive cuts in concrete.
Using a road saw effectively and safely requires proper technical and equipment knowledge. Here are the general steps for using a road saw:
Inspection and Setup: Prior to commencing, carefully examine your road saw to identify any damaged or loosely fitted components. Set the desired depth of cut and position the road saw at the start of the cut.
Start the road saw: Start the engine according to the manufacturer's instructions. Lift the blade above the surface, start the engine and allow it to warm up. When ready, lower the blade and begin the cutting process.
Cutting Technique: Progress the road saw smoothly along the intended cut line, applying moderate pressure. Refrain from exerting excessive force on the blade or tilting the road saw excessively, as it may lead to inefficient cutting or blade damage. Maintain a consistent cutting speed.
Finishing: When the cut is complete, release the throttle and stop the blade. Carefully lift the blade away from the material. Turn off the engine and store the road saw safely.
If you use water-cutting equipment, check that the water flows to the blades.
After the blade reaches the desired depth, walk or move the equipment along the chalk mark.
The saw blade should not be twisted.
The blade should not rotate in the cut as this increases wear on the bond.
Use a soft metal tip blade when cutting concrete with heavy rebar.
Wear PPE and take precautions to protect yourself.
When cutting joints, it's vital to follow the general rule: aim for a depth between one-quarter and one-third of the board's thickness. For 12-inch slabs, the recommended cutting depth is 3 to 4 inches.Be sure to cut to the specified depth recommended by a structural engineer. The load will not be transferred efficiently if the joint is too deep. Shallow sawing may result in random cracks.
A more powerful engine on a road saw means more torque so the blade can cut through surfaces faster. Road saws and road cutters often come with tracking controls, which means cutting straight lines is quick and easy. Also, due to the size of the saw blade, deeper cuts can be made compared to regular hand-held concrete saws.
Road saws are usually controlled from a dashboard that handles all aspects of the cutting mechanism. The control panel contains the direction and depth of the cut, and the RPM, which is how fast the blade rotates. Many road saws also come with a belt tensioner, a water pump kit to disperse harmful concrete dust, and mounted lights for use on dimly lit construction sites or when working at night.
In concrete, sawing creates control joints, which help control where cracks will appear due to shrinkage.
Concrete should be cut at predetermined intervals and only after it has acquired sufficient strength but before internal cracking begins. Therefore, the timing of sawing is critical. Cutting is made based on many factors, including the type of admixtures and aggregates used, the surrounding air's temperature, and the concrete's mix design.
In addition to concrete mix and weather conditions, the type of cutting equipment, and the hardness of the concrete are other factors in determining when to saw concrete. If cut too early, the saw blade will pull the aggregate out of place, creating messy, fragile edges during the cut. Diamond concrete saw blades are also subject to this reduction wear. If cut too late, the concrete will shrink uncontrollably during curing, causing uncontrollable cracking.
In hot weather, sawing may begin within 4 hours of concrete placement. Before sawing in cold weather, it is best to make a trial cut to check for unraveling. After 12 hours of pouring, the slab is ready for sawing. Once the wrapping stops, the sawing should begin.
Contractors sometimes delay cutting to reduce blade wear and protect their equipment. Several types of saw blades are available depending on the kind of concrete and when you are cutting. Some other factors that can cause blades to unravel and wear excessively include:
Too much pressure on the blade
When cutting at high speed
When using a saw with a bent shaft
Improper choice of blade
In rigid pavements, it is often necessary to cut concrete. Concrete control joints are created by road sawing, which helps control cracking due to shrinkage. This is a laborious and tedious process that requires machine assistance. BISON Road saws and road cutters are often used for this task. There are small hand saws, chop saws and large walk-behind saws powered by gasoline, hydraulic, air or electric motors. The belt and blade determine the performance of the saw. If the belt slips, the cutting speed will be slower, and loose drive changes will affect the feed rate. Keep your road saw and road cutter well-maintained.
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