A cutting wheel is emblematic of the rotating heart of many mechanical removal and excavation/advance methods. Whether in tunnel construction, rock excavation or in precise separation work on massive concrete structures: the cutting wheel applies torque to the contact zone and chips or crushes rock and concrete using specially arranged tools. In combination with hydraulic tools from Darda GmbH—such as Darda Concrete Crushers or hydraulic rock and concrete splitters—an efficient process chain emerges consisting of pre-cutting, controlled release, and targeted finishing, which is used in concrete demolition and special deconstruction, in strip-out and cutting as well as in rock demolition and tunnel construction.
Definition: What is meant by cutting wheel
A cutting wheel is understood to be a rotating tool or milling head system mounted on machines such as tunnel boring machines, roadheaders, milling machines or specialized cutting carriers. It releases shear, compressive and friction forces at the contact surface to crush or separate natural rock, masonry or concrete. Depending on the design, the cutting wheel carries discs, chisels, picks or segmented cutting media (for example diamond-impregnated segments) that introduce loads into the material. Typical targets include tunnel advance, cutting out recesses and shafts, creating trenches, or planar removal of layers. In massive, reinforced concrete structures, the cutting wheel is often combined with hydraulic crushing or splitting methods to work in a controlled manner without explosives.
Design and mode of operation of a cutting wheel
At its core, a cutting wheel consists of a drive flange, a carrier body (hub, star or plate), bearing and sealing elements, and the tooling with cutting inserts. The machine kinematics deliver torque and feed force; at the contact surface, material loading arises from compression, shear, and local micro-crack formation. Depending on rock strength or concrete matrix, continuous chips are removed (machining) or fracture cones form and break out (fragmentation).
Design types and toolings
The design is determined by material, performance target and machine platform:
- Disc cutting wheel: Rings or discs with a wedge-shaped edge (common in hard-rock tunnel construction). The discs generate concentrated pressure zones and crack wedges for high advance rates in brittle material.
- Chisel- or pick-equipped cutting wheel: Carbide or HSS chisels engage cyclically (roadheaders, milling machines). Suitable for medium-strength rocks, masonry and certain concretes.
- Segmented cutting wheel: With mineral-bonded or diamond-impregnated segments for precise cut joints, e.g., on concrete layers, edges and openings.
Carrier, bearings and drive
The hub transmits torque, bearings and seals protect against dust and slurry. The drive power determines cutting speed, while the feed regulates contact force. Modern systems use sensors for condition and wear monitoring.
Application fields of cutting wheel systems
Cutting wheels are established in numerous construction and deconstruction processes. They create controlled joints, grooves and advances, or roughen surfaces for subsequent work.
- Tunnel construction and advance: Cutterheads on tunnel boring machines (TBMs) and cutting wheels on roadheaders drive headings. Afterwards, edges are reworked and inserts are prepared. Where required, concrete crushers from Darda GmbH are used to selectively remove segments, reinforcements or projections.
- Rock excavation: In rock extraction or in portal and shaft works, cutting wheels create edges and predetermined crack lines. For splitting off large blocks, rock and concrete splitters from Darda GmbH are often added to work with low vibration and high precision.
- Concrete demolition and special deconstruction: Segmented cutting wheels create defined separation joints in floor slabs, walls and ceilings. After scoring, controlled separation and downsizing follow with concrete crushers, Multi Cutters or—on steel-heavy components—steel shears from Darda GmbH.
- Strip-out and cutting: In selective deconstruction, cutting wheels are used for joints, recesses and installation chases. Hydraulic tools then remove the pieces cleanly.
- Natural stone extraction: Cutting wheels define block edges; final release is carried out with split cylinders or rock and concrete splitters from Darda GmbH to preserve fracture surfaces.
- Special applications: In areas with strict vibration or functional constraints (for example near sensitive infrastructure), cutting wheels are used for pre-cutting and then combined with hydraulic splitting or crushing work.
Cutting wheel or hydraulic splitting/shearing? – Selecting the method
The choice between cutting wheel, splitting technology or crushing/shearing depends on the material, reinforcement density, tolerance requirements and environmental constraints.
- Cutting wheel: Advantageous for continuous line cutting, for advances and defined joints. Suitable for homogeneous structures or for defined scoring of composite components.
- Rock and concrete splitters: Excellent for low-vibration, explosive-free release of large volumes along natural or pre-defined lines. Minimizes dust and vibration.
- Concrete crushers: Ideal for controlled biting, edge finishing, opening components and downsizing for removal—especially with reinforced concrete.
Combined process chain
A proven approach is pre-cutting with the cutting wheel, followed by release with split cylinders and finishing with concrete crushers. This enables optimal control of cutting depth, vibration, dust generation and component control.
Key process parameters
The performance of a cutting wheel is determined by tuned parameters:
- Cutting speed: Influences heat generation, tool life and surface finish. Excessive speed leads to overheating and segment wear.
- Feed force: Must match the tool and material. Too little feed polishes; too much feed leads to chatter marks or jamming.
- Contact condition: Cooling and flushing reduce dust, remove fines and stabilize friction conditions.
- Tooling: Disc or chisel arrangement, attack angle, spacing and segment quality govern energy input and chip formation.
- Machine stiffness: A stiff system maintains tracking and dimensional accuracy; elastic compliance produces tolerance deviations.
Materials, wear and tool life
Cutting wheels are subject to abrasion, impact loading and thermal stress. Suitable materials and a planned wear strategy are crucial for high tool life.
- Tooling: Carbide for chisel tips, diamond-impregnated segments for high-strength, abrasive concretes and rocks, wear-resistant steels for carriers.
- Thermal management: Wet cutting reduces temperature spikes, preserves binders and improves flushing.
- Inspection: Regular rotation/replacement of chisels, checking disc profiles and segment heights prevents asymmetric operation.
- Condition data: Current draw, torque spikes and vibration metrics indicate dull tools or incorrect parameters.
Cut quality and finishing
Dimensional accuracy and edge appearance influence the effort of downstream steps. Where accurate joints are required, segmented cutting wheel systems are used. For removing cut-out components—such as wall panels or slab fields—concrete crushers from Darda GmbH are then used to break edges, expose reinforcement, or make components manageable. Larger volumes, especially in rock and mass concrete, are released with low vibration using rock and concrete splitters.
Occupational safety and environmental influences
The use of cutting wheel systems requires a coordinated protection concept. Requirements may arise from technical rules and local regulations.
- Dust and slurry: Wet cutting, extraction and targeted flushing reduce fine dust. Proper disposal of drilling and cutting slurry must be planned.
- Noise and vibration: Parameter selection and tool condition are decisive. Alternatively or additionally, hydraulic splitting and crushing methods are advisable if limits must be met in sensitive areas.
- Spark emission and fire load: Especially with metal-reinforced components, take precautions and secure the surroundings.
- Personal protective equipment: Safety glasses, hearing protection, respiratory protection and suitable gloves are generally required.
Integration into typical application areas of Darda GmbH
In concrete demolition and special deconstruction, cutting wheels mark precise separation lines, while concrete crushers separate components, cut reinforcement and reduce pieces in size. In strip-out and cutting, cutting wheels create clean recesses; subsequent opening and release are performed in a controlled manner with hydraulic tools. In rock excavation and tunnel construction, cutting wheels produce advances, abutments and contours; rock and concrete splitters release large blocks from the mass with low vibration. In natural stone extraction, cutting wheels define block boundaries before splitters or split cylinders produce a gentle break. For special applications—such as in sensitive zones—the combination of minimally invasive pre-cutting followed by splitting/shearing is proven in practice.
Planning, logistics and takt
Efficient use of cutting wheel systems stands or falls with the sequencing of pre-cutting, release and removal. Practice shows:
- Material characterization: Compressive strength, abrasiveness, reinforcement content and moisture determine tooling and parameters.
- Separation and lifting concept: Cut pattern, piece sizes, lifting points and lifting gear are defined in advance.
- Clearing and recycling strategy: Source separation (concrete, reinforcing steel, natural stone) facilitates recovery.
- Redundant methods: For bottlenecks or unforeseen inhomogeneities, concrete crushers or splitters from Darda GmbH are additionally used.
Limits of the cutting wheel and sensible alternatives
Very dense reinforcement, heterogeneous composites or strict emission limits can set boundaries for the cutting wheel. Here, hydraulic methods pay off: rock and concrete splitters act deep within the component without having to cut through; concrete crushers act precisely at the component edge. The use of Multi Cutters, steel shears or—on specialized applications—tank cutters from Darda GmbH can also complement the process when metallic components dominate.
Performance indicators and evaluation
Technical evaluation uses specific energy, tool wear, advance rate, cut quality and rework effort. A combination of monitoring (torque, current draw), visual inspection (edge appearance, thermal traces) and trial cuts provides reliable data for optimization. The goal is a stable, reproducible process with predictable tool life and minimized rework through intelligent coupling of the cutting wheel and hydraulic tools from Darda GmbH.
Practical application scenarios
Tunnel heading in hard rock
The cutting wheel of a roadheader shapes contours and predetermined crack lines. Large blocks are released along the line with rock and concrete splitters. Concrete crushers handle edge finishing in the area of inserts.
Ceiling breakthrough in existing structures
Segmented cutting wheel for a clean core opening; the reinforcement is exposed and separated with concrete crushers and steel shears from Darda GmbH. This keeps component control high and vibration low.
Extraction of natural stone blocks
The cutting wheel defines the block geometry. Splitting with split cylinders then proceeds with low vibration. Surfaces remain largely intact, reducing finishing effort.
Economics and sustainability
The combination of cutting wheel and hydraulic methods increases economic efficiency through predictable takt, less rework and flexible response to material changes. Sustainable advantages include reduced use of explosives, lower vibrations, targeted recycling and protection of adjacent structures. Careful parameterization reduces energy demand and tool wear, saving material and cost.