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 Diamond Blade Material Safety Data Sheet |
| Click here to view or download the MK Diamond blade Material Safety Data Sheet in PDF format. |
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| Speed Guidelines |
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Tile diamond blade speed recommendations |
| Diameter |
Recommended RPM* |
Maximum RPM** |
| 4" |
(102mm) |
9,075 |
15,000 |
| 5" |
(127mm) |
7,260 |
12,000 |
| 6" |
(152mm) |
6,050 |
10,185 |
| 8" |
(203mm) |
5,185 |
8,730 |
| 9" |
(229mm) |
4,540 |
7,640 |
| 10" |
(254mm) |
3,630 |
6,115 |
| 12" |
(305mm) |
3,025 |
5,095 |
| 12" |
(305mm) |
High Speed (Dry) |
|
| 14" |
(356mm) |
2,270 |
3,820 |
| 14" |
(356mm) |
High Speed (Dry) |
|
* Based upon the Optimum Performance Speed calibrated in Surface Feet per Minute (SFM): 9500 + 15%. Not for lapidary blades.
** Based upon ANSI B7.1 & B7.5 guidelines for maximum safe/never exceed speeds.
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Stone diamond blade speed recommendations |
| Diameter |
Recommended
RPM |
Never Exceed
RPM |
| 4" |
(102mm) |
9,000 |
15,200 |
| 4-1/2" |
(114mm) |
8,000 |
13,500 |
| 5" |
(127mm) |
7,200 |
12,200 |
| 5-1/2" |
(14mm) |
6,500 |
11,100 |
| 6" |
(152mm) |
6,000 |
10,100 |
| 7" |
(178mm) |
5,100 |
8,700 |
| 8" |
(203mm) |
4,500 |
7,600 |
| 9" |
(229mm) |
4,000 |
6,700 |
| 10" |
(254mm) |
3,600 |
6,100 |
| 12" |
(305mm) |
3,000 |
5,000 |
| 14" |
(356mm) |
2,500 |
4,300 |
| 16" |
(406mm) |
2,200 |
3,800 |
| 18" |
(457mm) |
2,000 |
3,300 |
| 20" |
(508mm) |
1,800 |
3,000 |
| 22" |
(559mm) |
1,600 |
2,700 |
| 24" |
(610mm) |
1,500 |
2,500 |
| 26" |
(660mm) |
1,300 |
2,300 |
| 28" |
(711mm) |
1,200 |
2,100 |
| 30" |
(762mm) |
1,200 |
2,000 |
| 32" |
(813mm) |
1,100 |
1,900 |
| 36" |
(914mm) |
1,000 |
1,600 |
| 42" |
(1067mm) |
800 |
1,400 |
| 48" |
(1219mm) |
700 |
1,200 |
|
| * Recommended RPM based on 9,500 SFPM |
|
| Back to Speed Guidelines | Back to top |
Lapidary diamond blade speed recommendations |
| Blade |
MK-297 |
MK-301 |
MK-1000 |
MK-303 |
|
Recommended RPM Operating Range
in Surface Feet Per Minute |
|
3000 - 3500 |
3000 - 4500 |
4500 - 6000 |
4500 - 6000 |
| Blade Diameter |
Approximate Arbor Shaft RPM Range |
| 4" (102mm) |
2860 - 3340 |
2860 - 4300 |
4300 - 5730 |
4300 - 5730 |
| 5" (127mm) |
2290 - 2670 |
2290 - 3440 |
3440 - 4580 |
3440 - 4580 |
| 6" (152mm) |
1910 - 2230 |
1910 - 2870 |
2870 - 3820 |
2870 - 3820 |
| 7" (178mm) |
1640 - 1910 |
1640 - 2460 |
2460 - 3270 |
2460 - 3270 |
| 8" (203mm) |
1430 - 1670 |
1430 - 2150 |
2150 - 2870 |
2150 - 2870 |
| 9" (229mm) |
1270 - 1490 |
1270 - 1910 |
1910 - 2550 |
1910 - 2550 |
| 10" (254mm) |
1150 - 1340 |
1150 - 1720 |
1720 - 2290 |
1720 - 2290 |
| 12" (305mm) |
960 - 1110 |
960 - 1430 |
1430 - 1910 |
1430 - 1910 |
| 14" (356mm) |
820 - 960 |
820 - 1230 |
1230 - 1640 |
1230 - 1640 |
| 16" (406mm) |
720 - 840 |
720 - 1070 |
1070 - 1430 |
1070 - 1430 |
| 18" (457mm) |
640 - 740 |
640 - 960 |
960 - 1270 |
960 - 1270 |
| 20" (508mm) |
570 - 670 |
570 - 860 |
860 - 1150 |
860 - 1150 |
| 24" (610mm) |
480 - 560 |
480 - 720 |
720 - 960 |
720 - 960 |
| 30" (762mm) |
380 - 450 |
380 - 570 |
570 - 760 |
570 - 760 |
| 36" (914mm) |
320 - 370 |
320 - 480 |
480 - 640 |
480 - 640 |
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| Back to Speed Guidelines | Back to top |
Masonry diamond blade speed recommendations |
| Diameter |
Recommended
RPM |
Never Exceed
RPM |
| 4" |
(102mm) |
9,000 |
15,200 |
| 4-1/2" |
(114mm) |
8,000 |
13,500 |
| 5" |
(127mm) |
7,200 |
12,200 |
| 5-1/2" |
(14mm) |
6,500 |
11,100 |
| 6" |
(152mm) |
6,000 |
10,100 |
| 7" |
(178mm) |
5,100 |
8,700 |
| 8" |
(203mm) |
4,500 |
7,600 |
| 9" |
(229mm) |
4,000 |
6,700 |
| 10" |
(254mm) |
3,600 |
6,100 |
| 12" |
(305mm) |
3,000 |
5,000 |
| 14" |
(356mm) |
2,500 |
4,300 |
| 16" |
(406mm) |
2,200 |
3,800 |
| 18" |
(457mm) |
2,000 |
3,300 |
| 20" |
(508mm) |
1,800 |
3,000 |
| 22" |
(559mm) |
1,600 |
2,700 |
| 24" |
(610mm) |
1,500 |
2,500 |
| 26" |
(660mm) |
1,300 |
2,300 |
| 28" |
(711mm) |
1,200 |
2,100 |
| 30" |
(762mm) |
1,200 |
2,000 |
| 32" |
(813mm) |
1,100 |
1,900 |
| 36" |
(914mm) |
1,000 |
1,600 |
| 42" |
(1067mm) |
800 |
1,400 |
| 48" |
(1219mm) |
700 |
1,200 |
|
| * Recommended RPM based on 9,500 SFPM |
|
| Back to Speed Guidelines | Back to top |
Concrete diamond blade speed recommendations |
| Diameter |
Recommended
RPM |
Never Exceed
RPM |
| 4" |
(102mm) |
9,000 |
15,200 |
| 4-1/2" |
(114mm) |
8,000 |
13,500 |
| 5" |
(127mm) |
7,200 |
12,200 |
| 5-1/2" |
(14mm) |
6,500 |
11,100 |
| 6" |
(152mm) |
6,000 |
10,100 |
| 7" |
(178mm) |
5,100 |
8,700 |
| 8" |
(203mm) |
4,500 |
7,600 |
| 9" |
(229mm) |
4,000 |
6,700 |
| 10" |
(254mm) |
3,600 |
6,100 |
| 12" |
(305mm) |
3,000 |
5,000 |
| 14" |
(356mm) |
2,500 |
4,300 |
| 16" |
(406mm) |
2,200 |
3,800 |
| 18" |
(457mm) |
2,000 |
3,300 |
| 20" |
(508mm) |
1,800 |
3,000 |
| 22" |
(559mm) |
1,600 |
2,700 |
| 24" |
(610mm) |
1,500 |
2,500 |
| 26" |
(660mm) |
1,300 |
2,300 |
| 28" |
(711mm) |
1,200 |
2,100 |
| 30" |
(762mm) |
1,200 |
2,000 |
| 32" |
(813mm) |
1,100 |
1,900 |
| 36" |
(914mm) |
1,000 |
1,600 |
| 42" |
(1067mm) |
800 |
1,400 |
| 48" |
(1219mm) |
700 |
1,200 |
|
| * Recommended RPM based on 9,500 SFPM |
|
| Back to Speed Guidelines | Back to top |
Diamond core bit speed recommendations |
| Wet Bit Diameter |
Max/Min RPM* |
| 1" - 2" |
(25mm - 51mm) |
1,200 - 1,000 |
| 2-1/4 " - 5" |
(57mm - 127mm) |
1,000 - 500 |
| 5-1/4" - 12" |
(134mm - 305mm) |
500 - 250 |
| Dry Bit Diameter |
Max/Min RPM* |
| 1" - 1-1/2" |
(25mm - 38mm) |
6000 - 2300 |
| 1-3/4" |
(44mm) |
5000 - 1600 |
| 2" - 2-1/4" |
(51mm - 57mm) |
5000 - 1200 |
| 2-1/2" |
(64mm) |
5000 - 800 |
| 3" - 5" |
(76mm - 127mm) |
5000 - 700 |
| 6" |
(152mm) |
5000 - 600 |
|
* Based upon the Optimum Performance Speed
calibrated in Surface feet per Minute (SFM). |
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| Understanding Materials |
| Ceramic Tile | Stone | Masonry | Concrete | Asphalt |
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Ceramic products are varied and depending on their manufacturing processes, they exhibit their own special qualities and properties. The hardness of the ceramic material is directly attributed to its manufacturing process, and generally references the Mohs Scale to categorize its hardness.
The Manufacturing Process
Ceramic tile production begins with the excavation of clays to be used in the manufacturing process. Depending on the type of tile being produced, any number of two to six different types and colors of clay may be necessary to blend together in a mixture.
The selected bulk clays are mixed with water and this mixture is pumped into large, rotating cylindrical mills, where extreme grinding action pulverizes the clay into uniform and homogenous particles. This substrate is called “body-slip,” and has the consistency of a milk shake.
Next, moisture from the body-slip is evaporated by a spray dryer burner, creating fine particles of uniformly sized dry clay called “powder.” The powder is then fed into molds within a hydraulic press, where it is molded under pressure (approximately 4,000 PSI) to form “green ware” (what the tile is called prior to being fired). The green ware is dried again to further reduce the moisture content, and then travels down “glaze lines” where various types of glazes are applied to the surface.
The glazed green ware travels through a kiln and undergoes a 45-50 minute firing where temperatures can reach 2300°F causing the glaze to fuse to the body. The tile that emerges from this process is very hard, durable and impact resistant.
Hardness of Ceramic Tiles
| • |
Water absorption rate, glazes, compression and material all determine the hardness of ceramic tile |
| • |
The percentage of water absorption by the tile body determines whether the ceramic tile is Impervious, Vitreous, Semi-Vitreous, or Non-Vitreous. From Impervious, where absorption rates of 15% and higher, harness factors change |
| • |
Most glazes fall in the 5 to 6 Mohs Scale range. However, certain types of floor and porcelain tiles can have compressive strengths of 10,000 PSI and a Mohs hardness factor of 8 |
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Natural and precast stones vary significantly in their geographic origin, mineralogical composition, and physical and mechanical properties. There are numerous types of stone to select, with each one exhibiting specific qualities of compressive strength and abrasive resistance.
| • Marble |
|
• Sandstone |
| • Granite |
|
• Limestone |
| • Slate/Flagstone |
|
• Precast Stones |
Additionally, these qualities would dictate appropriate diamond-blade selection to effectively handle cutting requirements. Your choice of stone requires a specific type of diamond Blade.
General Characteristics of Stone
The complex nature and variables of Natural and Precast stone make it difficult to generalize their overall physical and mechanical properties.
Unless the operator has had experience in cutting a particular stone, there are methods that can help predict the stone's sawability, and so determine the “best” diamond blade. The American Society of Testing and Materials (ASTM) recognizes several physical property measurements that can identify a stone's hardness:
| • |
Uniaxial Compressive Strength (UCS)
Measuring basic rock strength parameters. Commonly measured in Pounds Per Square Inch (PSI) |
| • |
Cerchar Abrasivity Index (CAI)
Measuring a rocks abrasivity for determining cutting wear rates. Defined by a graduated numerical scale: lower numbers indicating less abrasive qualities, and therefore greater hardness. |
| • |
Mohs Hardness Scale
A scale of hardness applied to minerals that ranges from 1 to 10, and comparatively indicates a mineral's scratch potential. The higher the number the harder the mineral. |
| • |
Shore Scleroscope Hardness Test
A dynamic indentation hardness test using a number to indicate the height of a rebounding hammer off the surface of the material. The higher the number the harder the material. |
It is recommended to review all data relating to a stone's hardness and abrasive qualities to effectively choose the proper diamond blade. No singular Property Measurement Test can define the characteristics a stone would exhibit during the cutting process. As a general reminder for stone diamond blades: tests and industry experience has documented that stone exhibiting a greater degree of hardness and abrasive resistance require softer bond matrixes. |
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Brick manufacturing today follows fundamental procedures pioneered centuries ago. However, better knowledge of raw materials and their properties, better control of firing and improved kiln designs have resulted in a superior product. The production of bricks centers around the type of clay that is used. Clays occur in three forms (Surface Clays, Fire Clays & Shales). Although they share similar chemical compositions, they will differ in their physical characteristics. All properties of brick are affected by the composition of the raw materials and the manufacturing processes. Essentially brick are produced by: (1) mixing ground clay with water, (2) forming them into desired shapes, (3) then drying and firing them. Establishing a homogenous blend is necessary before subjecting the mixture to one of three forming processes (Stiff–Mud, Soft–Mud or Dry–Press). Next, the process continues with drying, firing and cooling. Kiln firing temperatures during manufacturing graduate from 400°F to 2400°F.
Hardness of Bricks
| • |
There are many different types of brick (Building, Facing, Hollow, Paving, Ceramic Glazed and Thin Brick), and different scales of hardness. The strength of a unit is used to determine its durability and cutability. Both compressive strength and absorption are affected by properties of the clay, method of manufacturing and degree of firing. Most bricks have a strength ranging from 3,000 PSI to over 20,000 PSI, with the average being around 10,000 PSI. |
| • |
Brick may also include different size, type and volume of aggregates to further strengthen the mix. |
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|
Four essentials must be known about the concrete to determine proper diamond-blade selection.
1. Compressive Strength
The hardness of concrete is referenced by its compressive strength measured in Pounds per Square Inch (PSI). Cured concrete slabs vary widely in compressive strength; with moisture, temperature, design of mixture additives, cementitious materials and curing processes often determining their measured level of strength. The higher the compressive strength, the harder the material.
Compressive Strength
| Concrete Hardness |
PSI |
Typical Application |
| Very hard |
8,000 or more |
Nuclear Plants |
| Hard |
6,000 - 8,000 |
Bridges, Piers |
| Medium |
4,000 - 6,000 |
Roads |
| Soft |
3,000 or less |
Sidewalks, Patios, Parking lots |
2. Age of the Concrete
The “age,” or length of curing time, greatly affects how the diamond blade interacts with the concrete. Although methods exist to accelerate the curing process, the “state” of concrete from initial pouring to a period of 72 hours and over can be defined in 3 distinct increments, and is influenced by temperature, weather, moisture, aggregate, time of year, admixtures and composition.
State 1 – 0 to 8 hours
The concrete is considered in its “green“ state 0 to 8 hours after the pour, meaning it has set but has not hardened completely. With green concrete, the sand in the mixture has not bonded to the mortar blend firmly and will cause extreme abrasive action once the physics of sawing begins. Further, the slurry generated by green concrete is equally as abrasive and will require special undercutting protection for the steel core of the diamond blade. Typically, sawing control joints of highways, industrial flooring, driveways, runways and similar projects is performed during this state.
State 2 – 8 to 24 hours
The concrete is considered as cured 8 to 24 hours after the pour. The sand is held firmly adhered to the overall mixture. Generally, control joints established in State 1 are widened during this time.
State 3 – 24 to 72
The concrete is considered as cured 24 to 72 hours after the pour. The sand is held firmly in the mortar mixture, and the overall abrasive actions and properties of the concrete are greatly diminished. Now, consideration of the aggregates, compression strength and steel content of the concrete become important factors in determining proper diamond-blade selection.
3. Aggregates and Sand
Aggregates are the granular fillers in cement that can occupy as much as 60 to 75% of the total volume. They influence the way both green and cured concrete perform. Aggregates can be naturally occurring minerals, sand and gravel, crushed stone or manufactured sand. The most desirable aggregates used in concrete are triangular or square in shape, and with hard, dense, well-graded and durable properties. The average size and composition of aggregates greatly influence the cutting characteristics and selection of the diamond blade. Large aggregates tend to cause blades to cut slower; smaller aggregates allow the blades to cut faster.
| Difficulty |
Average Aggregate Size |
| Harder to Cut (Blade wears slower) |
1-1/2" or more
1-1/2" to 3/4"
3/4" to 3/8" |
| Easier to Cut (Blade wears faster) |
Pea gravel (less than 3/8") |
Aggregate hardness is referenced by the Mohs Scale. This scale assigns arbitrary quantitative units, ranging from 1 through 10, by which the scratch hardness of a mineral is determined. Each unit of hardness is represented by a mineral that can scratch any other mineral having a lower-ranking number. The minerals are ranked from talc or 1 (the softest), upward through diamond or 10 (the hardest). Hard aggregates shorten blade life and reduce cutting speed.
Sand composition is another factor in determining the hardness characteristics of the cement and the abrasive properties of the mortar. Three types of sand are generally used in the mixture:
• River Sand (round nonabrasive)
• River Bank Sand (sharp abrasive)
• Manufactured Sand (sharp abrasive)
River Bank Sand and Manufactured Sand are more abrasive than River Sand. The more abrasive the sand is, the harder the bond-matrix requirements. Sharper, more geometrically defined sands also require harder bonds.
Mohs Hardness Scale
| Aggregate Classification Map of the United States |
|
| |
Soft |
|
Medium Soft |
|
Medium |
|
Medium Hard |
|
Hard |
|
|
Aggregate Classification
|
One of the key factors that determines the performance of diamond saws and drill bits is the type of aggregate in the concrete or asphalt being cut.
Aggregate is defined as the stone, gravel and sand used in paving materials like concrete and asphalt. Aggregate may be crushed or uncrushed. Crushed aggregate may be limestone, granite, sandstone, traprock, etc. Sand and gravel are typically found in natural deposits, like riverbeds, stream courses or Lake Basins.
Aggregate is generally divided into “fine aggregate” (passes through a No 4 sieve, 0.187’ square opening) and “coarse aggregate” (almost all of which is retained on a N0 4 sieve and may range in size up to 3’ particles).
While recognizing that aggregate size and type can change completely in a short distance on a given project (say highway). It is generally true that aggregates are similar in certain geographical areas. This is primarily due to local availability of one type of material and the prohibitive cost of importing anything else.
This aggregate map is not intended, nor should it be used to precisely define all aggregate in a given area. Instead, it is published as a “general guide” to the predominant aggregate hardness (as it relates to sawability) likely to be encountered in the area defined by the various colors.
It should also be pointed out that any aggregate can be sawed. However, the cost of sawing is usually directly related to aggregate hardness and size. This map is simply a reference tool to provide a general sense of aggregate similarity in various areas of the country. A brief description of the predominant aggregate in each state follows.
|
| Alabama |
Aggregates vary from favorable materials such as limestone, sandstone, and blast furnace slag to hard materials such as quartzite and chert. The harder aggregate materials are found in the Central and Southwest sections of the state. |
| Alaska |
The predominant aggregates are gravel and crushed rock and would be classified as medium-hard. |
| Arizona |
A medium-hard gravel aggregate is encountered in most of the state and a medium-soft decomposed granite in some areas in the northern part of the state. The sand content tends to be highly abrasive. |
| Arkansas |
A medium-hard granite aggregate is encountered in the southern two-thirds of the state and a hart chert river gravel aggregate in the northern and northeastern part of the state. |
| California |
Medium-hard gravel aggregates are encountered in the El Centro through San Diego area as well as in the northern part of the state. A medium to medium-soft aggregate is encountered in the San Clemente, Los Angeles, Paso Robles, Lancaster and Bakersfield area. |
| Colorado |
The northern part of the state has medium to medium-soft aggregate comprised of decomposed granite. The Denver area and southeastern and eastern sections have medium-soft decomposed granite, limestone and gravel. The Colorado Springs area consists of a medium-hard gravel. |
| Connecticut |
Generally the aggregates consist of medium to medium-hard traprock and dolomite. |
| Delaware |
The major portion of the state contains medium-soft traprock and limestone aggregates. The Wilmington area does produce a medium-hard gravel aggregate. |
| Florida |
Generally the aggregates are composed of soft shell and argillaceous, siliceous and dolomitic limestone. The northern area sometimes uses hard Georgia and Alabama aggregates |
| Georgia |
Aggregates in the northern part of the state are medium-soft sandstone and limestone. The southern three-quarters of the state has medium-hard to hard granite, schist, gneiss, and quartzite aggregates. |
| Hawaii |
Aggregate conditions throughout the islands are of the medium-hard, basaltic type. |
| Idaho |
Generally medium-hard crushed stone and gravel aggregates. |
| Illinois |
Aggregates in this state may be divided into three sections, the northern area medium to hard gravel, the central section medium gravel and limestone, the southern area soft limestone. |
| Indiana |
The state has generally soft crushed limestone except in the southern and northwestern sections where medium-hard Ohio and Wabash river gravel occur. |
| Iowa |
In the Des Moines and central Iowa area medium-hard pit and river gravel are typical. Aggregates found in the eastern, central and southwestern sections are soft limestone. The eastern border along the Mississippi River has hard chert river gravel. Medium-hard pit gravel with quartzite is found in the northwestern section. |
| Kansas |
The aggregate conditions generally found are soft limestone. Medium-hard limestone, dolomite and hard chert gravel are found in the southeastern section, and medium-hard pit gravel in the north central area. |
| Kentucky |
Approximately 90% of the state has aggregates of medium-soft limestone and sandstone. The northern section along the Ohio River has medium-hard quartzite river gravel.
|
| Louisiana |
Aggregate conditions in the state range from soft shell to hard chert.
|
| Maine |
In general a medium-hard dolomitic gravel and some traprock is encountered in this state.
|
| Maryland |
About 60% of the state has medium-soft limestone aggregate. The balance of the state has a medium-hard river gravel. |
| Massachusetts |
The aggregate generally found is medium traprock except in northern section bordering New Hampshire where the aggregate is medium-hard.
|
| Michigan |
Generally medium-hard glacial gravel is found. The Pontiac, Flint, Mount Clemens area contains fair amounts of hard chert or flint. |
| Minnesota |
Aggregate in the central and northern part of the state consists of medium-hard glacial gravel. In the southern section medium-soft quarried limestone prevails. |
| Mississippi |
Hard and medium-hard aggregates are found in the southwest section of the state and consist of the chert and quartzite. |
| Missouri |
Soft limestone aggregate predominates in this state with a hard chert aggregate in the St. Louis area (Meramec River gravel) and a similar hard flint aggregate in the Joplin area. |
| Montana |
The eastern section is a hard aggregate area, the Great Falls area contains a medium-hard gravel and crushed stone aggregate and the Glasgow and Miles City areas have a hard quartz and chert aggregate. |
| Nebraska |
Eastern and Central sections contain a medium limestone and gravel mixture and the Western areas have a straight medium-hard gravel aggregate. |
| Nevada |
The predominant aggregates are medium to medium-hard gravel and crushed decomposed granite. |
| New Hampshire |
Generally medium-hard to hard granite gravel aggregates are encountered. |
| New Jersey |
The predominant aggregates are a medium traprock and a hard river gravel. |
| New Mexico |
Northern areas contain medium-soft aggregate shipped in from Colorado. A medium limestone with some quartz aggregate is encountered in the southern part of the state (Gallup, Alamogordo, Deming and Lordsburg). The Tucumcari area has a medium-hard gravel aggregate. A medium-hard to hard gravel is encountered in the Albuquerque area. |
| New York |
There are three predominant aggregates in this state, a medium-soft limestone, medium traprock and medium to medium-hard granitic gravel. |
| North Carolina |
Medium-hard and hard aggregates exist throughout the state and consist of granites, schist, gneiss and quartzite. There is some scattering of a medium limestone. |
| North Dakota |
In general a medium-hard glacial gravel is encountered consisting of limestone, granitic gneiss, basalt, quartzite and chert. In the eastern half of the state the aggregate combinations are medium-soft. |
| Ohio |
Generally a medium-soft pit gravel is encountered throughout the state except in the areas along the Ohio River where a medium-hard river bed aggregate is used. |
| Oklahoma |
Soft limestone is generally encountered except in the western section where a medium-hard granite aggregate is used. |
| Oregon |
The western section contains a hard granite aggregate an on the east side of the mountains a medium crushed gravel is encountered. |
| Pennsylvania |
Generally medium-soft limestone and medium traprock aggregate are encountered except in steel mill areas where soft slag might be used. Pit gravel is commonly used in the Philadelphia area. |
| Rhode Island |
A medium hard traprock aggregate is generally used throughout the state. |
| South Carolina |
Predominantly the aggregates consist of a medium-hard quartzite, granite and gneiss with some limited amounts of medium-soft crushed limestone and marble. |
| South Dakota |
There are three types of aggregate encountered in this state. The eastern area consists of hard quartzite aggregate, the central portion has a medium-hard gravel aggregate and soft limestone aggregates in the western section. |
| Tennessee |
In general medium-hard aggregates are encountered throughout the state with some medium quartzite west of Nashville and hard chert aggregate along the Mississippi River. |
| Texas |
The predominant aggregate encountered consist of medium limestone and dolomite with a medium-hard quartzite around the San Antonio area and hard chert along the Coast area. |
| Utah |
Aggregates consist of medium gravel throughout the state. |
| Vermont |
In general medium to medium-hard granitic gravel aggregate is encountered throughout the state. Large aggregate is often encountered. |
| Virginia |
Medium-hard granite gates are normally encountered throughout the state with medium-hard to river gravel in the Norfolk and Washington D.C. areas. |
| Washington |
Medium to medium-hard gravel and crushed stone aggregate encountered on the eastern side mountains and hard gravel aggregate on the western side and in the Seattle Tacoma areas. |
| West Virginia |
The predominant aggregates consist of a medium limestone, except along the Kana where medium-hard to hard river aggregates are used. |
| Wisconsin |
The southern section state contains medium-soft limestone gravel aggregates. The northern have a medium-soft glacial aggregate. |
| Wyoming |
Medium to medium-soft stone and crushed rock are encountered throughout the state. |
|
4. Steel Reinforcement
Further strengthening and structural integrity of concrete is accomplished by introducing concrete reinforcing steel bars (rebar), steel wire strand of wire meshing into the concrete. It costs more to cut concrete that contains reinforcing steel because cutting rates are slower and blade life is reduced. If the cross-sectional area of concrete is 1% steel, the blade life will be about 25% shorter than if no steel were present. Concrete with 3% steel can reduce blade life as much as 75%.
Standard Reinforcing Bars
Metric Size
(mm) |
Diameter |
Imperial Size
(inches) |
Diameter |
| 10 |
9.5 |
#3 |
.375 |
| 13 |
12.7 |
#4 |
.500 |
| 16 |
15.9 |
#5 |
.625 |
| 19 |
19.1 |
#6 |
.750 |
| 22 |
22.2 |
#7 |
.875 |
| 25 |
25.4 |
#8 |
1.000 |
| 29 |
28.7 |
#9 |
1.128 |
| 32 |
32.3 |
#10 |
1.270 |
| Heavy Rebar: |
#6 Rebar every 12" on center or 2 Mats of #4 Rebar every 12" on center |
| Medium Rebar: |
#4 Rebar every 12" on center |
| Light Rebar: |
Wire Mesh, single mat |
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|
Hot Mix Asphalt (HMA) is a mixture of Asphalt Cement (a petroleum-based “glue” that comprises less than 8%, by weight, the total pavement mixture) and Aggregates (various sized stones, dust, hard inert materials and sand, comprising approximately 92%, by weight, the remaining pavement mixture.)
Asphalt does not cure in the sense that concrete does, and once spread and rolled, it can be cut or drilled almost immediately. Unlike cured concrete, sand in asphalt never bonds as firmly, and the slurry created when sawing will be extremely abrasive. A bond matrix similar to cutting green concrete and undercutting protection steel cores are important factors when undertaking asphalt cutting operations. Some unique factors should be observed when cutting asphalt:
| • |
Hard & large sized Aggregates in the asphalt will cause the blade to cut slower |
| • |
The greater the Aggregate-Sand ratio, the faster the blade will cut, but total footage may decrease |
| • |
Total asphalt depth can vary. It is common to cut through the asphalt layer into the sub-base. Generally, the sub-base contains a high content of very abrasive materials such as sand, dirt, dusts and like materials. This undesirable situation causes rapid wear of the diamond blade |
| • |
Chunks or broken-up asphalt to be cut often attract dirt and sand fillers within the cracks. This, too, will make the asphalt more abrasive and affect the life of the diamond blade |
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| Understanding Diamond Blades |
|
1. Diamond Blade Fabrication
Diamond blades consist of four components: diamond crystals, a bonding system, a segment, and a metal core.
Diamond Crystals
The diamond crystals in MK blades are synthetic (man-made) rather than natural. This gives them a consistency that can be relied upon during the enormous stresses they encounter while grinding. The foremost performance factor in diamond-blade sawing is the type, concentration and size of these diamond crystals. The extensive diamond aptitude and sawing expertise MK has acquired goes into the selection of the proper diamond crystals for our wide range of blades.
Bonding Matrix
Diamond crystals are held in place by a sintering process of specially blended metal powders. This bonding matrix is crucial to the overall performance of the MK diamond blade and serves several vital functions:
- Disperses and supports the diamonds
- Provides controlled wear while allowing diamond protrusion
- Prevents diamond “pull-out”
- Acts as a heat sink
- Distributes impact and load as the diamond attacks the cutting surface
During the sawing action, the wearing away of the matrix exposes new diamond crystals providing fresh cutting points for the blade.
Metal Bonds
The diamond crystals and bonding matrix are heated and shaped into specially engineered rims / segments. These rims / segments are wider than the blade core to which they will be attached, and provide the clearance to promote material discharge and discourage blade binding. The rims / segments are specifically designed to wear at a rate appropriate to the material being cut. Large particles of soft, abrasive materials wear down the matrix faster than the small particles removed from hard dense materials. Therefore, softer, more abrasive materials require a “tough to wear” (hard) bond; less abrasive materials require an “easy wear” (soft) bond.
Premium Steel Core
The diamond saw blade cores are made from high alloy, heat-treated steel. Depending on the type of blade selected, the steel cores are specifically designed to support the appropriate rim or segment. About the periphery of the core, the various rims or segments are affixed through a brazing or laser welding process. An arbor hole is precisely bored in the center, and the entire core is “tensioned” or tuned so that the stresses of centripetal force are minimized, permitting the blade to spin true on the spindle.
2. Understanding Diamond Blades As Cutting Tools
In general, a diamond blade's performance is measured in two ways. The first is how proficiently the blade grinds through the material; the second is the life of the blade or total footage yielded by the blade. There are a variety of MK diamond blade models and designs from which to choose. Each blade is meticulously engineered to provide cutability, longevity and safety. When you select the best-suited diamond blade for the job / application / material, you will ensure peak performance and maximum investment return.
How the Diamond Blade Works
Diamond blades do not really cut, instead they grind material through an action of friction with the synthetic diamond-bonding matrix. The diamond crystals, often visible at the leading edge and sides of the rim / segment, remove material by scratching out particles of hard, dense materials, or by knocking out larger particles of loosely bonded abrasive material. This process eventually cracks or fractures the diamond particle, breaking it down into smaller pieces. As a result of this phenomenon, a diamond blade for cutting soft, abrasive material must have a hard metal matrix composition to resist this erosion long enough for the exposed diamonds to be properly utilized. Conversely, a blade for cutting a hard, non-abrasive material must have a soft bond to ensure that it will erode and expose the diamonds embedded in the matrix. These simple principles are the foundation of “controlled bond erosion.”
Types of Diamond Blade Cutting
There are two basic types of cutting – dry or wet. The best choice of blade depends upon:
| • |
The requirements of the job |
| • |
The machine / tool utilizing the diamond blade |
| • |
The preference of the operator |
In the case of DRY cutting, the overwhelming popularity and quantity of hand-held saws and the flexible nature of MK Diamond blades to professionally handle most ceramic, masonry, stone and concrete materials, make the DRY cutting blade a very attractive tool.
When using a DRY blade, the user must be aware of distinct operating practices to ensure optimum performance. DRY cutting blades require sufficient airflow about the blade to prevent overheating of the steel core. This is best accomplished by shallow, intermittent cuts of the material along with periods of “free-spinning” for several seconds to maximize the cooling process.
For WET cutting applications, MK has the exact blade to complement both the material to be cut and the wet-cutting machine to be used. During cutting operations, liberal amounts of water act as a coolant to support the cutting effectiveness and longevity of the WET blade. Additionally, using water adds to the overall safety of cutting operations by keeping the dust signature down.
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| Diamond Blade Troubleshooting |
|
|
|
|
|
| Cause |
Shaft bearings are worn (masonry and concrete). |
| Remedy |
Install new blade shaft bearings or blade shaft, as required. |
|
| Cause |
Engine is not properly tuned on concrete saws, causing surges in blade rotation. |
| Remedy |
Tune engine according to manufacturers' manual. |
|
| Cause |
Blade arbor hole is damaged from previous mismounting. |
| Remedy |
Replace worn shaft or mounting arbor bushing. Bond is too hard for material, causing a “rounding” and wearing one half of the blade more than the other. Make certain that drive pin is functioning. Use proper blade specification |
|
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|
|
| Cause |
Blade is too hard for material being cut. |
| Remedy |
Use a softer bonded blade. Select proper blade specification for material being cut. |
|
| Cause |
Blade has become dull as a result of being used on too hard a material |
| Remedy |
Improper blade specification; blade is too hard for the material being cut. Use a softer bonded blade to reduce operating stresses. |
|
| Cause |
"Dull" Blade |
| Remedy |
"Open" blade by dressing segment on abrasive block. |
|
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|
|
 |
| Cause |
Insufficient water (usually on one side of blade). |
| Remedy |
Flush out water system and check flow and distribution to both sides of blade. |
|
| Cause |
Equipment defects cause the segments to wear unevenly. |
| Remedy |
Replace bad bearings, worn arbor shaft or misalignment to spindle. Concrete saws, engine must run smoothly to prevent harmonic vibration. |
|
| Cause |
Saw is misaligned. |
| Remedy |
Check saw head alignment for squareness both vertically and horizontally |
|
|
| Back to Diamond Blade Troubleshooting | Back to top |
|
|
| Cause |
Blade collar is not properly tightened, permitting blade rotation or vibration on the shaft. |
| Remedy |
Tighten the shaft nut with a wrench to make certain that the blade is adequately secured. |
|
| Cause |
Blade collars are worn or dirty, not allowing proper blade clamping. |
| Remedy |
Clean blade collars, making sure they are not worn. |
|
| Cause |
Blade is not properly mounted. |
| Remedy |
Make certain the blade is mounted on the proper shaft diameter before tightening shaft nut. Ensure the pin hole slides over drive pin. Make sure that drive pin is in pin hole. |
|
| Cause |
Loose Belt on saw. |
| Remedy |
Tighten belts. Check to see if arbor on saw is running true. |
|
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| Back to Diamond Blade Troubleshooting | Back to top |
Undercutting the Steel Center |
|
 |
| Cause |
Abrasion of steel center due to highly abrasive fines generated during cutting. |
| Remedy |
Use as much water as possible to flush out fines generated during cutting, or use wear-retardant cores. |
|
| Cause |
Cutting through material into sub-base. |
| Remedy |
Wear-retardant cores are not always the ultimate solution to eliminating undercutting. Your best defense is to always provide an adequate water flow to the steel center area immediately adjacent to the segment. This is especially important when making deep cuts. |
|
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| Back to Diamond Blade Troubleshooting | Back to top |
|
|
 |
| Cause |
Blade is too hard for material being cut. |
| Remedy |
Use a blade with a softer bond. |
|
| Cause |
Blade being "forced" through the cut causing chattering |
| Remedy |
Run Saw at normal speed. "Open" blade by resharpening in abrasive material. |
|
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| Back to Diamond Blade Troubleshooting | Back to top |
|
|
 |
| Cause |
Blade runs at improper speed. |
| Remedy |
Check for bad bearings, bent shaft, or worn mounting arbor.
Speed of the saw is either too fast or too slow for the size of the blade: RPM of the saw should be verified to the specific speeds established by the NASI Standards for minimum and Maximum blade speeds; make certain that blade shaft is running at recommended RPM to match tensioned speed of blade. Should the blade continue to wobble after verification of the saw RPM, then the blade should be returned to the manufacturer to be retensioned and flattened. |
|
| Cause |
Blade collar diameters are not identical. |
| Remedy |
Check blade collar discs to make sure they are clean, flat and of correct diameter |
|
| Cause |
Blade is bent as a result of dropping or being twisted in the cut during operation. |
| Remedy |
Blade should be returned to the manufacturer to be retensioned and flattened. |
|
| Cause |
Loss of blade tension. |
| Remedy |
loss of tension |
|
|
| Back to Diamond Blade Troubleshooting | Back to top |
|
|
 |
| Cause |
Overheating due to lack of water. |
| Remedy |
Check water feed lines and make sure flow is adequate on both sides of blade. |
|
| Cause |
Steel center is worn from undercutting. |
| Remedy |
Use sufficient water to flush out the cut. |
|
| Cause |
Defective blade collars are causing blade misalignment. |
| Remedy |
Clean blade collars or replace if collars are under recommended diameter. |
|
| Cause |
Blade is too hard for material being cut. |
| Remedy |
Use proper blade specification for material being cut. |
|
| Cause |
Blade is cutting out of round, causing a pounding motion. |
| Remedy |
Replace worn bearings; realign blade shaft or replace worn blade mounting arbor. |
|
| Cause |
Improper blade tension. |
| Remedy |
Ensure blade is running at correct RPM. Blade is tensioned for correct RPM. Tune engine according to manufacturers' manual. |
|
|
| Back to Diamond Blade Troubleshooting | Back to top |
|
|
 |
| Cause |
Blade flutters in cut as a result of blade losing tension. |
| Remedy |
Tighten the blade shaft nut. Make sure blade is running at proper tensioned speed and that drive pin is functioning properly. |
|
| Cause |
Blade specification is too hard for the material being cut. |
| Remedy |
Use a softer blade bond to eliminate stresses that create cracks. |
|
| Cause |
Bad blade shaft bearing. |
| Remedy |
Replace blade shaft bearing. |
|
| Cause |
Overheating due to lack of water. |
| Remedy |
Check water feed lines and make sure flow is adequate on both sides of blade. |
|
|
| Back to Diamond Blade Troubleshooting | Back to top |
|
|
 |
| Cause |
Steel center has been overheating as a result of blade spinning on arbor. |
| Remedy |
Check water flow, distribution and lines. Tighten the blade shaft nut. Make certain the drive pin is functioning (on concrete saws). |
|
| Cause |
Steel center has been overheating from rubbing the side of material being cut. |
| Remedy |
Make certain blade RPM is correct so the blade operates at its tensioned speed. Tune engine according to manufacturers' manual. |
|
| Cause |
Unequal pressure at blade clamping collars. |
| Remedy |
Blade clamping collars must be identical in diameter and the recommended size. |
|
|
| Back to Diamond Blade Troubleshooting | Back to top |
|
|
| Cause |
Blade bond or matrix too soft. |
| Remedy |
Use a harder matrix blade. |
|
| Cause |
Overheating due to lack of water. |
| Remedy |
Check water feed lines and make sure flow is adequate on both sides of blade. |
|
|
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| Documents |
Tile Product PDFs | Stone Product PDFs | Masonry Products PDFs
Concrete Products PDFs | Coring Products PDFs |
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