The wire saw, often also referred to as a diamond wire saw, is a key method for precise cutting of concrete, reinforced concrete, natural stone, and rock. It enables controlled cuts with complex geometries, large cross-sections, and in confined spaces. In combination with hydraulic tools such as concrete pulverizers or hydraulic rock and concrete splitters as well as suitable power units, removal and cutting tasks in concrete demolition and special deconstruction, strip-out and cutting, rock excavation and tunnel construction, natural stone extraction, and special applications can be implemented in a material-friendly and low-emission manner.
Definition: What is a wire saw
A wire saw is a separation technique in which an endlessly circulating cable with diamond beads is guided over drive and deflection pulleys and moved through the workpiece with defined speed and pretension. The grinding and cutting of the diamond beads separate mineral construction materials and—with suitable specification—also reinforcing steel. Water is generally used for cooling and to bind the grinding slurry. Wire saws are considered a low-vibration, low-shock, and shape-flexible method for large openings, segmented deconstruction, and challenging material combinations.
Design and operating principle of the wire saw
A wire saw consists of a drive (often hydraulic), a precise guiding system with pressure and deflection rollers, a tensioning or feed system, and the actual wire (cable) fitted with diamond beads. The closed wire loop is routed through drill openings or by wrapping around the component. With a defined cutting speed and controlled feed, continuous material removal with high cut quality is achieved.
Key components
- Diamond wire with beads, spacers, and wire core (steel or high-strength strand) for durability and flexibility
- Drive unit and power unit for torque, feed force, and sensitive control
- Deflection and guide rollers with protective covers for precise wire guidance even across multiple levels
- Tensioning and feed systems to adapt to component thickness and cutting progress
- Water supply for cooling, dust binding, and removal of grinding slurry
- Operator panel with load and speed monitoring for safe process control
Detailed working process
Before the cut, the wire is brought into the cutting field through boreholes or by transitioning over edges. After tensioning the wire, the drive and water supply are started. Cutting speed (wire speed) and feed are adapted to the material, reinforcement content, and geometric boundary conditions. The engagement of the diamond beads produces controlled material removal with low vibration, protecting sensitive environments and minimizing crack formation.
Areas of application and typical use cases
Wire saws are used whenever conventional cutting methods reach their limits: large cross-sections, heavy reinforcement, restricted accessibility, complex contours, or requirements for minimal vibrations and clean cut surfaces.
Concrete demolition and special deconstruction
In the structural deconstruction of bridges, foundations, shafts, or massive walls, the wire saw enables the segmented separation of large components. Separated elements are often then broken down into transportable pieces with concrete pulverizers. Stone and concrete splitters reduce internal stresses or separate remaining cross-sections when wire routing is difficult. Combination shears, multi cutters, and steel shears can cut exposed reinforcement or attachments.
Strip-out and cutting
When repurposing existing structures, large openings for stairwells, elevators, or service runs are often required. The wire saw creates accurate cut edges with minimal damage to the component; edges can be reworked with concrete pulverizers to produce defined chamfers or allowances.
Rock excavation and tunneling
In geologically sensitive areas, the wire saw enables sharp, precise interventions with low vibration. In combination with stone splitting cylinders and stone and concrete splitters, rock blocks can be targeted and lowered in a controlled way. In tunneling, the technique is used for cutouts, portal areas, or special geometries.
Natural stone extraction
In quarries, the wire saw enables economical extraction of blocks along natural beds. The high cut quality reduces rework and material loss.
Special applications
For thick foundation slabs, densely reinforced nodes, or contaminated areas, the wire saw scores with remote operation and low vibrations. In the deconstruction of tanks and vessels, exposed steel parts are often additionally processed with steel shears; for specialized cutting tasks, supplementary tank cutters are available.
Wire saw in conjunction with concrete pulverizers and stone and concrete splitters
In practice, technologies are combined to achieve safety, quality, and schedule reliability. A common sequence: The wire saw separates the outer contour with a defined target geometry. The separated segments are then broken down by concrete pulverizers. Stone and concrete splitters reduce residual stresses, create predetermined breaking lines, or release parts at hard-to-reach locations where the wire cannot be guided safely. This avoids wire pinching and uncontrolled spalling.
- Create contour: wire saw defines dimensional accuracy and flatness
- Reduce weight: concrete pulverizers divide segments for crane or robotic handling
- Separate remaining cross-sections: splitters apply powerful, low-vibration wedges
- Treat reinforcement: steel shears or multi cutters cut exposed steel
Planning, setup, and cutting strategy
Careful planning is crucial for safe cuts and clean results. This includes measurement, material analysis, reinforcement detection, determination of load paths, definition of anchor points for rollers and machine carriers, as well as planning of hose and water routing. Forward-looking segmentation facilitates shoring, crane logistics, and removal.
Preparation of the cutting contour
- Define boreholes for threading the wire in and out
- Position deflection rollers so that wire angle, contact length, and alignment are correct
- Select fixing points for rollers and machine to minimize vibrations
- Provide fall protection and rigging for segments
Cooling and slurry management
A sufficient water volume prevents overheating and uneven bead wear. The grinding slurry must be captured and professionally disposed of or treated. In sensitive areas, a closed water circuit with filtration helps.
Support and removal
Depending on component size, segments are handled with a crane, lifting systems, or sliding surfaces. Cutting sequence and supports must be chosen to avoid pinching and to prevent unintended activation of residual load-bearing structures.
Technical parameters and key figures
Coordinated parameters are decisive for process stability. Values depend on wire type, material, and machine and must be adjusted on site.
- Wire speed: typically in the two-digit m/s range; with high steel content, lower values are advisable
- Feed force: choose so that uniform removal occurs without wire stalling
- Water volume: sufficient for cooling and slurry removal, adapted to the environment
- Bead spacing and wire diameter: depending on material hardness and target surface
- Deflection angle: moderate angles reduce wear on wire and rollers
Safety and health protection
Working with wire saws requires consistent safety measures. The foundation is operating manuals, instruction, and compliance with recognized rules of occupational safety. Safety zones must be cordoned off; no one may be in the wire and swing range. Pressure lines, power supply, and water routing must be secured against damage.
- Personal protective equipment including eye protection, hand protection, hearing protection, and suitable protective clothing
- Regular inspection of wire, rollers, anchors, and fastenings
- Plan and monitor redundant lifting arrangements for segments
- Route slurry and water in a targeted manner to avoid slip hazards
Quality assurance, fault patterns, and remedies
Typical faults include uneven bead wear, wire pinching, overheating, scoring, and dimensional deviations. Countermeasures include clean guidance, adequate cooling, correct tensioning, adjusted wire speed, and suitable segmentation. If pinching threatens, relief cuts or the targeted use of stone and concrete splitters help to relieve stresses.
Maintenance and care
Regular inspections extend service life: lubricate and check roller bearings, inspect seals and protective covers, check wires for uniform wear and fractures, check hydraulic hoses and couplings for tightness, clean water filters. Store diamond wires dry, clean, and without tight bend radii.
Sustainability and resource conservation
Wire saws operate with low shock and are gentle on materials. This reduces consequential damage to existing structures and lowers the need for rework. With good slurry treatment and water recirculation, water consumption decreases. The clean cut surfaces facilitate source-separated sorting: reinforcement can be separated with steel shears, concrete parts can be further processed with concrete pulverizers or stone and concrete splitters and fed into recycling.
Selection aid: When wire sawing, when splitting or shears?
The choice of method depends on material, component thickness, degree of reinforcement, accessibility, environmental sensitivity, and schedule requirements. Wire saws excel with large cross-sections, complex contours, and high quality requirements for cut surfaces. Stone and concrete splitters are ideal for low-stress releasing when wire guidance is difficult or vibrations must be minimized. Concrete pulverizers are suitable for efficiently downsizing separated segments and for creating defined trimming edges.
- Analyze geometry: contours, threading points, deflection
- Assess material: concrete strength, aggregates, reinforcement
- Consider environment: vibration, noise, water management
- Plan the process chain: wire saw for contour, pulverizers for downsizing, splitting for stress relief
Practical examples from typical projects
For door and elevator openings in existing buildings, the wire saw produces dimensionally accurate cuts along the planned contour; the resulting segment is broken into manageable pieces using concrete pulverizers. In the deconstruction of massive bridge cross-sections, large blocks are cut with the wire saw, lifted, and then further processed with pulverizers or steel shears. In natural stone extraction, the wire saw separates blocks along desired planes; stone splitting cylinders further divide them on site. In the deconstruction of vessels and foundations, wire cuts, tank cutters, and steel shears can be combined to safely separate steel and concrete parts.