The cutting disc is a central tool for precise cuts in construction materials and metals. It enables clean, planned interventions in concrete, steel, and natural stone—from controlled deconstruction to strip-out. In combination with hydraulic tools from Darda GmbH, such as concrete demolition shears or rock and concrete splitters, the demolition process can be material-appropriate, low-emission, and structure-preserving: The cutting disc creates defined kerfs that make subsequent splitting, crushing, or lifting of components easier.
Definition: What is meant by cutting disc
A cutting disc is a rotating, disc-shaped cutting component used on cut-off grinders, angle grinders, floor saws, or wall saws. It separates materials by chip removal with a geometrically undefined cutting edge (for resin-bonded fiber or grinding wheels) or by microscopically cutting grain tips (diamond or CBN segments). Depending on design and bond, it is suited for concrete, masonry, asphalt, natural stone, and metals such as reinforcing steel.
Design, materials, and segment technologies
Cutting discs consist of a core (steel or fiber carrier) and a working layer. In diamond cutting discs, sintered or brazed segments with embedded industrial diamonds perform the cutting; in resin-bonded discs, mineral abrasives (e.g., alumina, silicon carbide) in an organic or ceramic matrix perform the material removal. Segment shape, bond hardness, and grain distribution are matched to the material, cutting speed, and cooling.
Types of cutting discs for concrete, steel, and natural stone
Diamond cutting discs
Diamond cutting discs are the standard for concrete, reinforced concrete, masonry, clinker, asphalt, and natural stone. Their segments combine diamond grains with a bond that controls wear: In abrasive materials (e.g., asphalt, autoclaved aerated concrete) the bond is harder; in hard materials (e.g., granite, high-strength concrete) it is softer, so that new diamonds are continuously exposed. Variants with straight, slotted, or turbo segments influence cooling, chip space, and smooth running. Wet cutting increases service life and cut quality; dry cutting is common for short cuts and mobile applications.
Resin-bonded fiber discs
These cutting discs use alumina or silicon carbide in an organic bond and are frequently used for steel, cast iron, nonferrous metals, and thin-walled profiles. They cut reinforcing steel, sheet metal, and fittings, for example during deconstruction. They produce sparks and heat—in sensitive areas, using steel shears, Multi Cutters, or tank cutters from Darda GmbH can be a low-spark alternative.
CBN and special discs
CBN discs (cubic boron nitride) are designed for very hard, ferromagnetic materials but play a subordinate role in construction and demolition contexts. Special segments for reinforced concrete address the interaction of the mineral matrix and reinforcement to minimize interruptions during cutting.
Selection criteria and parameterization
The suitable cutting disc results from the material, machine, and process objective. Key criteria:
- Material: Concrete, reinforced concrete, natural stone, asphalt, steel—determines grain type, bond hardness, and segment geometry.
- Machine: Angle grinder, handheld cut-off saw, wall saw, floor saw—defines diameter, arbor hole, flange configuration, and permissible circumferential speed.
- Cutting mode: Wet or dry cutting; wet cutting reduces dust and temperature, dry cutting offers mobility.
- Cutting depth and kerf: Diameter and segment width determine cutting depth and kerf width—relevant for controlled separation and material loss.
- Reinforcement: For reinforced concrete, segmented diamond discs suit alternating hardness in the composite; for heavy reinforcement, combining with steel shears or Multi Cutters is advisable.
- Circumferential speed: The recommended maximum speed of the disc must not be exceeded; machine rpm and disc diameter must match.
Machines, compatibility, and cutting strategy
Cutting discs work on handheld angle grinders and cut-off saws as well as on wall saws and floor saws. Decisive factors are a suitable flange, arbor hole and clamping system, stable bearings, and an intact guard. For line-accurate, low-vibration cuts in walls and slabs, rail-guided systems are advantageous; for floor joints and separation cuts in pavements, floor saws are appropriate. In deconstruction, relief cuts are often made to relieve stresses and facilitate subsequent gripping with concrete demolition shears.
Use in concrete demolition and specialized deconstruction
In concrete demolition and specialized deconstruction, the cutting disc contributes to controlled dismantling:
- Pre-cutting slabs, beams, and walls to create defined break lines.
- Producing slots that rock and concrete splitters use to open the component in a targeted manner.
- Separating overlays and toppings before concrete demolition shears reduce the remaining structure.
- Setting down components in transportable segments; rebar remnants can be post-processed with steel shears or Multi Cutters.
Strip-out and cutting
In strip-out operations, the cutting disc enables dust- and vibration-reduced cuts in masonry, screed, and metal installations. In sensitive environments, sparks and dust are minimized as far as possible through wet cutting, dust extraction, and coordinated cutting sequences. Where heat input and sparking are critical, tank cutters, steel shears, or combination shears from Darda GmbH can be a low-spark complement.
Rock excavation and tunnel construction
In rock excavation and tunnel construction, diamond-equipped cutting discs are used for flank finishing, contour cuts, and openings in linings. Frequently, weakening cuts are made to make subsequent work with rock split cylinders and rock and concrete splitters more effective and gentle on materials. The combination of cutting and hydraulic splitting reduces vibrations and benefits adjacent structures.
Natural stone extraction
In natural stone extraction, diamond cutting discs serve the precise cutting of raw blocks and formats. Cut quality, segment design, and cooling are crucial to avoid spalling at exposed edges. After cutting, splitters facilitate controlled opening along the set kerfs, while concrete demolition shears can be used for secondary size reduction.
Special deployment
For special deployments—such as in explosion-hazard areas or when dismantling tanks and pipelines—the method selection is safety-driven. Cutting discs generate sparks and heat; depending on the risk assessment, tank cutters, steel shears, or hydraulic concrete demolition shears from Darda GmbH may be a suitable alternative or complement to minimize ignition sources.
Combination with concrete demolition shears and rock and concrete splitters
Cutting discs and hydraulic tools are deliberately coordinated. A common process chain:
- Marking and weakening: Line-accurate cuts define edges and reduce cross-sections.
- Hydraulic splitting: Rock and concrete splitters or rock split cylinders open the component along the kerfs with low vibration levels.
- Crushing and separating: Concrete demolition shears reduce remaining pieces; steel shears or Multi Cutters cut reinforcement.
- Finishing: Fine cuts for fitting or to blunt edges.
This sequence limits dust, noise, and edge damage, which is particularly important in specialized deconstruction and existing buildings.
Occupational safety and health protection
Using cutting discs requires consistent protective measures. General notes:
- Personal protective equipment: Eye protection, hearing protection, hand protection, dust-tight respirator; cut-resistant clothing depending on the task.
- Dust and wet cutting: Silica-bearing fine dust is greatly reduced by wet cutting and dust extraction.
- Sparks: Keep the work area clear, protect combustible materials; consider alternative methods (e.g., steel shears, tank cutters).
- Machine condition: Intact guard, correct flange, appropriate speed. Do not use damaged or aged discs.
- Cooling breaks: With dry cutting, regularly relieve the tool to avoid overheating and segment loss.
Legal requirements and standards must be checked according to location and task; implementation takes place within the framework of a general hazard assessment.
Quality assurance, fault patterns, and remedies
Lateral runout and imbalance
Causes: damaged flange, incorrect clamping force, warped disc. Remedy: Check components, clean flange surfaces, ensure correct seating.
Glazing and lack of feed
Causes: bond too hard for the material, insufficient infeed, overcooling. Remedy: Softer bond, intermittent cutting, sufficient feed; for reinforced concrete use segmented diamond discs.
Overheating and burn marks
Causes: excessive contact pressure, inadequate cooling, dull disc. Remedy: Optimize cooling, proper speed, change the tool.
Segment loss
Causes: exceeding circumferential speed, impact loads, incorrect application (prying). Remedy: Observe operating limits, guide according to the material, remove damaged discs immediately.
Sustainability and resource efficiency
The combination of precise cuts and hydraulic splitting reduces energy demand, noise, and secondary damage. Wet cutting lowers dust emissions; water treatment and recycling are advisable. Segment technologies optimized for service life, proper storage, and adjusted feed rates reduce tool consumption. Where possible, splitting with rock and concrete splitters can partially replace cutting, reducing material and disc wear.
Standards, markings, and practical parameters
Cutting discs carry information on maximum rpm, circumferential speed, application materials, and direction of rotation. European safety and quality standards exist for diamond tools and resin-bonded discs; using appropriately marked products supports safe operation. In practice, circumferential speed, cooling, and cutting sequence are selected so the disc operates within its specification, achieves the required cutting depth, and protects adjacent components.
Practical tips for combined use
- Relief cuts first: Before using concrete demolition shears, make relief cuts to direct shear forces effectively.
- Plan for reinforcement: Probe rebar layers; cut steel content specifically with steel shears or Multi Cutters.
- Cut guidance: Multiple scoring passes instead of a single deep cut reduce disc load and improve accuracy.
- Fixing points: Define anchor points and load paths in advance for large components; align cuts accordingly.
- Match hydraulic power packs: When switching to hydraulic tools, align the performance of the Hydraulic Power Units with the process step.
This makes the cutting disc a precise building block in a coordinated deconstruction chain, in which hydraulic tools from Darda GmbH—from rock and concrete splitters to concrete demolition shears and steel shears to tank cutters—can deploy their respective strengths in a controlled manner.