Castle & Pryor

Working in the heart of Essex, we had a couple of sunny days removing reinforced concrete internal slab from a private residence.

Removing Reinforced Concrete Internal Slab
We were requested to remove the reinforced concrete slab that measured 350mm deep. This needed to be completed without causing vibration to ensure the adjoining structures were not damaged further. We needed to ensure we had a non-disruptive repair solution.

What did we do?
To prevent overcutting during the sawing process, we formed 178 127mm dia holes drilled in a stitch drilled pattern located at end of cuts and the corners. Holes were formed using a Husqvarna DM340 drill rig and motor.

The next phase of the work was to cut the floor into forty sections, each weighing approx. 50kg. Utilitsing our Tyrolit WSE1217 track saw we formed cuts in the slab in a grid pattern.

In total we cut 106.0mts at 350mm deep.

https://youtu.be/fnOeGT0fv4w?si=lnZIekHES6dZx3e - Removing reinforced internal concrete slab removing reinforced internal concrete slab

Completed neat and tidy
Once the cutting was completed, the blocks were easily removed, giving the company we were working for access to the foundation where they completed further underpinning strengthening works.


Need a price for your project? Speak to one of our team. Call 0800 163 382
https://castle-pryor.co.uk/contact/

Castle & Pryor use diamond blades for cutting because they are cost effective, accurate, and safe. Diamond tipped blades can be used on a variety of tooling including floor saws, track/wall saws, and hand cutters making them very versatile to meet the everyday requirements of the construction industry. The advantages of diamond cutting cementitious construction materials are many faceted in respect you can cut accurately, free of dust and vibration, by hand or using specialist machinery to suit the task at hand.

Large or small sections of concrete or masonry can be isolated or removed in situ without disturbing the remaining structure making modification or refurbishments works easier to carry out. All sections can be cut to size to accommodate weight restrictions or size to suit site ergonomics upon removal.

What are the benefits of using diamond blades?
Cost Efficiency: Although initially expensive, the longevity of diamond tools offsets the need for frequent replacements, saving costs over time.
Faster Cutting Speeds: The strength of diamonds allows for faster material removal, improving productivity in time-sensitive projects.
Minimal Downtime: The durability and sharpness of diamond tools reduce the frequency of tool changes.
Low Heat Buildup: Diamond tools can withstand high temperatures without losing their cutting edge, making them suitable for prolonged use in demanding conditions.
Low Vibration and Noise: These tools reduce vibrations and noise levels.
Less Waste: Precision cutting results in minimal material wastage.
Efficient Resource Use: Reduced material waste and the long lifespan of diamond tools contribute to a more sustainable operation.
Reliability: Their ability to handle tough materials makes them indispensable for demolition, roadwork, and structural projects.
Clean Cuts: Diamond cutting tools ensure straight, precise, and clean cuts, reducing the need for secondary adjustments or repairs.

How do diamond blades work?
Diamond blades don’t technically “cut” materials, they grind through them. The embedded diamond particles induce a shearing effect which progressively wears material off.

How are diamond blades made?
Diamond saw blades are made using a specialist process that combines synthetic diamonds with a metal or resin bond to create a strong and powerful blade. The synthetic diamond crystals are stronger than natural diamonds.

The diamond particles are then exposed on the edge of the blade to cut through materials. The cut is essentially achieved thanks to the exposed diamonds on the edge of the blade slicing through the stone.

How has the manufacturing of diamond cutting blades evolved over the past 20 years?
Diamond Retention: The metal or resin bond matrix has been refined to provide better retention of diamonds, leading to longer blade life and more efficient use of diamond particles.

Higher-quality synthetic diamonds: The use of higher-grade synthetic diamonds has improved blade durability and cutting precision. Modern synthetic diamonds are engineered to have consistent shape, size, and toughness.

Micro-diamond technology: Finer diamond particles are now used in combination with coarse particles, optimising the balance between speed and precision in cutting applications.

Nanodiamonds: The integration of nanodiamonds into the bonding matrix improves cutting performance by increasing wear resistance and heat dissipation.

Auto Array: An Auto Array arranges diamond particles within the blade’s bonding matrix in a highly organised and precise manner, rather than relying on the traditional random distribution of diamonds. This innovation improves the blade’s performance, efficiency, and lifespan.

Precise Diamond Placement:
Diamonds are systematically arranged in layers or patterns within the segment to maximise cutting efficiency. These patterns are designed to ensure that:

The diamonds are uniformly distributed.
Each diamond contributes to the cutting process, minimising waste.
Cutting performance remains consistent over time as the blade wears.
Metal Bond Engineering:
Auto Array blades use advanced bonding techniques to secure the diamonds in place. These bonds are formulated to wear down at a rate that keeps fresh diamonds exposed throughout the blade’s use.

Segment design: Blade segments are now designed with a range of patterns (e.g., turbo, segmented, and continuous rim designs) tailored to specific cutting needs. These designs improve debris removal, cooling, and cutting efficiency.

Cooling holes and slots: Modern blades feature precision-engineered cooling holes or slots in the steel core to enhance heat dissipation and reduce the risk of warping during heavy use.

Noise reduction: Anti-vibration cores and specialised designs reduce noise and vibration during cutting, improvin