A Complete Guide to Diamond Wire Saws

Diamond wire sawing is a cutting method that involves looping a diamond-beaded wire around the target structure. They excel in specialized environments, including large-scale structures, deep cutting, confined spaces, and underwater cutting.

This page provides a comprehensive overview of diamond wire saw applications, different drive systems, and product examples, as well as their relationship with the upstream and downstream stages involving core drills.

• Why wire saws are preferred for large-scale structures and confined spaces
• Differences between electric servo, hydraulic, and high-frequency motor types and their ideal applications
• The Role of Core Drills in Upstream and Downstream Stages of Wire Sawing

Roles and Applications of Wire Saws

Structures and jobsites where wire saws excel

Wire saws are ideal for cutting thick sections and complex shapes that are beyond the reach of conventional blade-based sawing methods. This is because wire saws are not constrained by cutting depth limitations imposed by blade diameter, and the wire length can be adjusted to allow flexible handling and routing. They are essential for the demolition and major renovation of large-scale structures, such as columns, beams, bridges, and dams.

Wire saws are also ideal for confined spaces with limited equipment footprint, as well as underwater cutting. They are an effective option for jobsites where conventional cutting methods tend to face challenges in maneuverability or cutting depth.

Main materials that can be cut with a wire saw

On construction jobsites, the main cutting materials are concrete and reinforced concrete. Even robust and densely reinforced structures can be efficiently cut using diamond-beaded wire. A key advantage is their versatility in cutting various stone materials, such as granite and marble.

Wire saws are also used for specialized applications, including precision machining of metals, glass, and ceramics.

Types of Wire Saws

Electric servo motor type

This type is driven by an electric servo motor and is an example of a high-output machine that operates on a commercial power supply. Since it does not require a hydraulic unit, the overall system setup is simplified and easy to manage, provided that the power supply requirements are met. For jobsites with an adequate power supply, this type is ideal for balancing ease of handling with high power output.

Hydraulic type

This type is designed to operate in combination with a hydraulic unit. Because power is transmitted via hydraulic hoses, the main unit can be kept compact, enabling flexible installation such as floor mounting or wall mounting. The hydraulic type is an ideal choice for small-scale jobsites and confined work areas due to its excellent portability.

Some models are designed to handle exceptionally thick walls and deep cutting, offering the versatility to adapt to a wide range of jobsite conditions.

High-Frequency Motor Type

This is a high-output electric system that utilizes high-frequency motors and high-frequency power packs. This type is deployed on jobsites that demand higher power output, including for cutting large-scale structures. Some models also support underwater and dry cutting.

Example of an electric servo motor product

CONSEC Servo Motor Wire Saw DSME-200A

Source: CONSEC Official Website
(https://www.consec.co.jp/article_source/data/en_product/detail/180.html)

This high-torque model is a strong choice for jobsites where reliable power is available

CONSEC's electric servo motor wire saws are specifically engineered for civil engineering and construction applications. It features a 20 kW high-output servo motor, with a maximum output-shaft torque reaching 276 N-m. This saw performs well on jobs that demand stability during the initial cut and on jobs which place a heavy load on the saw.

Power supply is three-phase 400/440 V, with applicable wire diameters from 10 to 11 mm. It is a strong candidate on jobsites where ample power is available.

Specifications (DSME-200A)

Example of a hydraulic product

CONSEC Compact Hydraulic Wire Saw DSM-103A

Source: CONSEC Official Website
(https://www.consec.co.jp/article_source/data/ja_product/detail/42.html)

A high-end hydraulic model featuring a modular design for enhanced portability to confined spaces and elevated locations.

The DSM-103A is the high-end hydraulic wire saw model offered by CONSEC. Featuring a modular design that allows each component to be disassembled, this model is easy to transport and assemble in confined spaces or elevated locations. This model is operated in combination with a hydraulic power pack (sold separately).

The applicable wire diameter is 10 to 11 mm, with a main pulley travel stroke of 1,150 mm. The assembly weight is 170 kg, realizing a design that makes it easy to deliver the saw to the jobsite.

Specifications (DSM-103A)

Husqvarna CS 2512

Source: Husqvarna Official Website
(https://www.husqvarnaconstruction.com/int/wire-saws/cs2512/)

Hydraulic model that balances maneuverability with deep-cut capability

A powerful yet easy-to-handle hydraulic wire saw from Husqvarna. It is operated in combination with a separate hydraulic power pack, such as the PP 455 E. The relatively compact unit is easy to transport to smaller jobsites and confined workspaces.

On the other hand, the magazine's large capacity allows it to handle deep and large-scale cutting operations. It works in both floor-mounted and wall-mounted setups, giving it flexibility for complex site conditions.

Specifications (CS 2512)

Example of a high-frequency motor product

Hilti DSW 3018-E

Source: Hilti Official Website
(https://www.hilti.co.jp/c/CLS_POWER_TOOLS_7125/CLS_DIAMOND_WIRE_WALL_SAWS_7125/r51186)

A high-output electric model ideal for heavy-duty projects and tight construction schedules

A 30 kW high-output electric wire saw from Hilti. With strong drive performance, it is ideal for cutting through tough materials such as high-strength concrete, brick, stone, and steel.

This saw maintains steady productivity on jobs involving tight schedules and the demolition of heavy structures.. With a proven track record in controlled demolition, underwater cutting, and dry-cutting applications, this model is characterized by its exceptional versatility across a wide range of jobsite conditions.

Specifications (DSW 3018-E)

How wire saws and core drills work together

Wire saw cutting work is not completed by the wire saw alone. Across the entire process, from pre-construction preparation to post-cutting procedures, core drills play an indispensable role.

Core drills are employed in various stages, including drilling guide holes for wire threading, performing line drilling to define precise cutting boundaries, and creating lifting holes for the removal of cut blocks.

Drilling through holes (guide holes)

To cut a workpiece with a wire saw, a through hole must first be drilled for threading the diamond wire. In this preparatory step, a core drill is usually used to drill a precise hole. Holes are drilled to the appropriate diameter and depth, optimized for the material and thickness of the workpiece.

Utilizing a core drill for consecutive boring at the corners and edges of the cut line ensures smoother corner processing.

Drilling holes for lifting bolts

After the wire saw cuts the workpiece, the resulting concrete block has to be removed safely from the site. Core drilling is often required even after cutting is finished. The reason for post-cut drilling is that crews need to bore holes for the lifting bolts used to hoist (by crane, etc.) or anchor the cut block.

The combination of wire saw cutting and core drilling for removal preparation enables a complete demolition and renovation workflow.