tools of the trade 2016 world of concrete special issue

1 Tools of the Trade

Spring 2015

TOOLSOF THE TRADEHands On. All Pro. Pure Tools.2016 WORLD OF CONCRETE SPECIAL ISSUE

VIBRATION AND DUST CONTROL

DEFINES TOOL SAFETY

ESSENTIAL CONCRETE

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Concrete Cutting BladesCordless Grinders Come of Age

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TOOLSOF THE TRADE

2016 World of Concrete Special Issue

Cordless Grinders Come of Age, 18

Cutting Edge, 6Choosing a Diamond Blade, 28Contents6 Cutting EdgeDecreasing tool vibration; sorting out finishing trowels; battling concrete dust

12 Concrete Innovations| By Michael SpringerWhats new in the top power-tool categories for the concrete trades

18 Cordless Grinders Come of Age| By Michael SpringerTodays models may not be production tools, but theyre surprisingly strong

24 Tough Tech| By Clayton DeKorneA jobsite-worthy smartphone requires more than just clever marketing

28 Choosing a Diamond Blade| By Chris ErmidesThe age and mix of the concrete, as well as the cut-type, drive blade selection and performance

34 Ad Index

35 Product WatchFloor leveling machine; jobsite storage for tech; rotary laser; ladder racks; work light; compressor; generator; water tank; cement mixer; handler; power screed; excavator; more

On the cover: For cutting concrete, choosing the right cutting blade is just as important as choosing the right saw. Photo courtesy Stihl USA.

Product Watch, 35

Tools of the Trade 1toolsofthetrade.net


TOOLSOF THE TRADE

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While not mandated in this country (yet), European vibration-control standards for power tools benefit U.S. workers. Impact and vibration wont kill you, but they can kill productivity. Sustained vibration can cause damage to nerves and blood vessels in workers hands and arms. Vibration also tends to make muscles tighten up. The tighter you grip the tool, the more vibration gets transmitted to your hands and arms, making injury more likely. In the most ex-treme cases, hand-arm vibration syndrome (HAVS)the term used in the industry for a range of cumulative trauma disorders caused by vibrationcauses blood vessels to collapse and prevents oxygen from reaching tissues.

One of the most common HAVS caused by impact tools like breakers and rotary hammers is often called white finger dis-ease. In this case, sustained vibration caus-es the capillaries in the hand and fingers to constrict, which blanches and numbs the fingers. When the blood finally returns, the tingling and pain can be uncomfortableeven more so in cold weather.

HAVS can manifest also as arthritis, ten-donitis, and changes to muscle tissue that result in a persons loss of grip, reduced mo-bility, and pain in the hand and arm.

Jack hammers and breakers, scalers, rotary hammers, hammer drills, jumping jacks, and other compactors, are among the most notorious for causing problems, some that manifest within just a half-hour of work. But extended use of many other tools, including grinders, impact drivers, vibra-tory screeds and concrete vibrators, takes a toll on workers. Even if a worker doesnt suffer from HAVS, fatigue from sustained vibration can sap productivity, so theres no reason not to opt for anti-vibration technology.

VIBRATION LIMITSIn the European Union, tools must be tested and rated for vibration magnitude, which is measured in m/s2. Its an inverse relation-ship: the lower the vibration, the longer the tool can be used, and as long as its not too wimpy to get the job done, the more attrac-tive it may be for an employer to buy.

U.S. workers benefit from EU vibration-control standards

Decreasing Tool Vibration

Cutting Edge// BY CLAYTON DEKORNE

6 Tools of the Trade 2016 World of Concrete Special Issue

Demo breakers, as well as rotary hammers, scalers, and hammer drills, are among the power tools that transfer the greatest vibration to users. Sustained use can take a serious toll on a workers musculoskeletal health.

EU standards set two limits: Exposure Action Valuethe total vibration allowed from the tooland Exposure Limit Valuethe total vibration a worker is legally al-lowed to see in a day. Its this latter value that toolmakers selling in EU markets typ-ically focus on. The ELV for better-quality impact tools on todays market typically ranges from 4 to 6 hours, but as technology advances, some are achieving an 8-hour rating. Vibration limits are plotted on a chart, which is used to determine how long a worker can legally be allowed to use a tool.

ANTI-VIBRATION FEATURESNot surprisingly, the EU market has spawned a surge in industrial design aimed at reducing power-tool vibration. In our global economy, we benefit from the inno-vations toolmakers have employed in order to sell in the EU. Here are some examples of a total package for anti-vibration on a tool like a rotary hammer:

Counterbalance mechanism. Rotary hammers get their name from a rotary mechanism that drives a piston up and down in a cylinder. This piston has 0-rings (shown in blue in photo 1) to create a tight seal in the cylinder.

As the piston moves, it pushes (or pulls) a slug of air, which in turn pushes and pulls the strikera free-floating, flying

piston that when pushed slams into the impact bolt behind the bit to create the hammer effect on the rotating bit. It needs the air to cushion this blow. You can imag-ine the effect if the piston beat directly on the impact bolt; the intense shock would destroy the rotary mechanism. (Hammer drills essentially have this direct mecha-nism, just with much less force.) Despite the air cushion that softens each blow on the rotary drive-train, the tool as a whole still vibrates with the high-speed blows to the impact bolt. The tool user absorbs these impacts through the handles. In an effort to further reduce this overall force, some manufacturers add a counterbalance that is driven by air from the cylinder, which is re-directed to move weights in side chambers in the opposite direction from the striker. This effectively cancels some of the impact force and reduces the overall vibration.

Vibration-absorbing housings. Even less vibration gets transferred to a user through the main handle, which is de-signed to move independently of the motor and drive mechanism (2). The same isola-tion can be applied to the side handle.

A damper spring is sometimes in-stalled at the base of the impact bolt to ab-sorb impact vibrations from the drill bit.

Lock-on or trigger. If a user doesnt have to constantly grip the handle, but can

relax the hand, the blood vessels in the hand will not be strained as quickly. Along with a lock-on trigger, tools often feature electronic speed control that automatical-ly applies additional power to the motor to maintain speed under load, allowing the tool to complete the job more efficiently.

Soft start suppresses start-up reaction for more control and better accuracy.

Assuming a tool is designed not to ex-ceed the Exposure Action Value, dont un-derestimate raw power and better bits (such as a four-way cutter instead of an ordinary two-way) to complete the job faster. Work-ing the tool for less time means a worker is exposed to less vibration.

Finally, during the time the worker is exposed, the following will help:

Keep the hands and entire body warm and dry.

Wear gloves made with a vibra-tion-absorbing foam.

Avoid smoking; nicotine enhances the ability of blood vessels to go into spasm.

Seek medical attention immedi-ately if finger tingling, numbness, or blanching is experienced. The sooner you address a developing HAVS problem, the easier it is to avoid long-term tissue and nerve damage.

1 2


The hammer action of a rotary hammer comes from a free- ying piston, or striker, that repeatedly slams into the impact bolt. The striker moves on a cushion of air to reduce wear on the rotary driver train. Counterweights are often installed to further reduce this impact.

A shock-absorbing handle like this one on a Milwaukee rotary hammer isolates the rear handle from the main body.

Both float types are available with surfaces 3 to 4 inches wide and 12 to 20 inches long. The purpose of floating with an actual float is to embed the coarse aggregate particles, remove surface imperfections such as ridges from bull floating, create a smooth surface, and bring some mortar to the surface. Floating also cuts down high spots and fills holes as well as reestablishes the moisture in the surface mortar that was lost to evaporation.

Always float the surface before finishing with a trowel or fresno. Start floating after the bleedwater sheen has disappeared and a finisher using kneeboards has left no more than about a 18-inch indentation. Trapping bleedwater beneath the top surface, or finishing bleedwater into the surface, can cause delaminations or dusting.

While floating with either a wood or a magnesium float, do not tilt the float. Keep the blade as flat as possible or in full contact with the surface of the concrete to avoid densifying and sealing the surface.

To prevent blisters and delaminations, the surface must be kept open so bleedwater and entrapped air can escape. Increasing the blade angle will reduce the contact area between the blade and the concrete, which increases the blade pressure. Too much pressure can seal the surface by compacting and densifying the mortar along the surface.

Trowels. Troweling is done in the final stages of finishing and only after the surface has been floated. Troweling makes the sur-face hard and dense. Hand finishing trowels should be made of steel, usually 3 to 5 inches wide and 10 to 20 inches long. Use large sizes for the first troweling to spread the blade pressure over a large area, which minimizes the risk of prematurely sealing the surface. Keep the trowel blade as flat as possible.As the surface becomes harder, perform subsequent trowelings with smaller trowels (in width and length). Also, progressively increase the tilt angle of the trowel blade to increase blade pressure. Increasing the blade pressure compacts and densifies the surface mortar to create a smooth, hard, and more wear-resistant surface.

Fresno trowels. A fresno is a large,

Use finishing tools in the proper sequence to avoid surface defects

Sorting Out Finishing Trowels

Q: Several finishers on my crew argue about the best tools for finishing hard-troweled floors. Some use a fresno instead of a magnesium float to smooth the surface, saying that a fresno is faster and better. Others claim the surface should first be floated with a magnesium float before troweling or using a fresno. What are the differences in use between a magnesium float, trowel, and fresno? Does it really matter how or when these tools are used?

Kim Basham, president of KB Engineering, responds: A hand-held magnesium float, steel trowel, and fresno are different tools and should be used in the proper sequence when finishing

a hard-troweled floor. Using them improperly or out of sequence can cause surface defects, including blistering and delaminations.

Floats. While hand floats are primarily available in wood and magnesium, the most popular ones are magnesium. This is because magnesium floats are extremely durable and easily slide across the surface. Wood floats are rougher and typically limited to floating non-air-entrained and high-slump concretes. (Always use non-air-entrained concrete for troweled floors. Air-entrainment significantly increases the risk of trapping escaping air bubbles below the top surface, which leads to blisters and delaminations.)

Cutting Edge


1 2

3 4

long-handled trowel that looks similar to a bull oat, except the blade is made of tem-pered or blue steel. Blades are typically 5 inches wide and 18 to 48 inches long with rounded corners, but square corners are available. Handles are attached to the blade with adjustable or swivel brackets. A fresno is a steel trowel and should be used just like a hand-held steel trowel. And as with a steel trowel, only use a fresno after the surface has been oated with a wood or magnesium oat. Otherwise, a fresno may seal the surface too soon, causing blistering or delaminations. Fresnos are useful when troweling slabs that do not require a hard, steel-troweled surface but where speed of troweling is important.

Start with a oat. Keep oat blades as at as possible to avoid sealing the top surface. Sealing the surface can trap escaping bleedwater and air bubbles directly below the surface, which can cause blisters and delaminations.

For initial troweling, keep the trowel blade at as possible. As the concrete hardens, progressively increase the angle of the blade to increase surface pressure for a smoother surface. As concrete gets harder still, switch to a smaller trowel (see lead photo, facing page).

When hand-nishing, it is common practice for experienced nishers to oat (right hand) and then trowel with a large trowel (left hand) before moving the kneeboards.

A fresno trowel is a long-handled steel trowel and should be used just like a hand-held steel trowel. Always oat the concrete before using a fresno.

SEQUENCE FOR FINISHING A TROWELED FLOOR1. Place fresh concrete.2. Screed or strike off the concrete to the proper elevation.3. Bull oat to remove ridges and ll voids left by the screeding operations, and to slightly embed the large aggregate particles before bleedwater collects on the surface.4. Wait for the concrete to stiffen and for bleedwater to escape and disappear.5. Edge along form edges to densify and compact the concrete. This minimizes edge chipping.6. Joint (tooled) to control random slab cracking.7. Float to embed the coarse aggregate particles, remove surface imperfections, and create a smooth surface. Use a wood or magnesium oat and dont seal the surface.8. Trowel to create a smooth, hard surface. Use a steel or fresno trowel, depending on the desired surface hardness.


Battling Concrete Dust

the curve. It has already mandated strict controls on silica dust, and toolmakers selling in EU markets have ready-made solutions, whichnot surprisingly given OSHAs attentionare increasingly showing up in the U.S. power-tool market. These solutions include dust-containment shrouds with vacuum attachments for drills and rotary hammers (1) and for dry-cut concrete saws (2). Integral are jobsite vacuums with self-cleaning filters optimized for picking up fine dust.

Whether or not the OSHA rule passes, there is a secondhand benefit to sharing a market full of tools and equipment born under more stringent dust-control standards: We enjoy a cleaner jobsite and breathe less dust, and that affords a level of convenience and efficiency that helps productivity. Wouldnt you rather clear dust from a drilled fastener hole with a vacuum than use a rubber bellows or compressed air, letting all that dust blow up in your face?

Silica rules are likely coming, but toolmakers have some answers

1 2

In the battle against dust on the jobsite, the enemy is silicaairborne crystalline silica dust, that is. Its found in abundance in sand and rock, so its everywhere on most concrete jobsites.

OSHA has proposed rules to limit exposure. The ruling has yet to become an OSHA mandate, but the proposals have been bouncing among stakeholders for years now. Most industry experts say its only a matter of time before an exposure limit will pass. The proposed limit for worker exposure currently stands at 25 micrograms per cubic meter of air averaged over an eight-hour day.

If the limits implemented, OSHA could require any worker cutting into concrete, stone, masonry, and ceramics to employ a host of engineering controls. These center on the use of wet saws, vacuum dust collection, work-site isolation strategies, and personal protective equipment. An N95 NIOSH-certified respirator, such as the one shown in the photo above, will likely become mandatory for every worker on any job requiring concrete mixing, jack hammering, rock drilling, concrete and masonry drilling, and sawing.

As with European Union vibration standards (see Decreasing Tool Vibration, page 6), the EU is ahead of

Cutting Edge

// BY CLAYTON DEKORNE


Quite a few of the tools that concrete pros rely on stay relatively unchanged year upon year. Your favorite hand trowels, oats, and screeds, and even compressors and genera-tors could be around long enough to be con-sidered classics. But many of the commonly used power tools are evolving rapidly.

TECHNOLOGY TRENDSHeres a look at some of the trends that are transforming tools for the concrete trades.

Cordless tool technology. As the pow-er and runtime of cordless tools and their battery packs increase, so does the viability of replacing corded tools on the job with the convenience of cordless. Drills, circ saws and recip saws are a given, but cordless hammer drills and angle grinders (see Cordless Grind-ers Come of Age, page 18) are also finding their way into the concrete trades. There are even battery-powered combi-hammers and concrete saws powering into the pro market.

High-frequency electric power. Cord-ed electric tools provide a way to avoid the

Whats new in the top power-tool categories for the concrete trades

CONCRETE INNOVATIONS


din and toxic exhaust fumes of gas engines, but they typically lack some of the power. A 15- or 20-amp circuit on 120-volt line voltage can provide wattage equivalent to only two to three horsepower, and thats power into the tool, not output power. As a result, high-de-mand indoor tools have traditionally been powered by hydraulic pumps. To overcome the limitations of line voltage, companies have been developing higher voltage (often called high frequency) tools. Some require a special gas generator to create three-phase power while others have inline voltage converters or inverters to raise voltage or transform AC electricity into DC. Still other systems have air- or liquid-cooled power packs that change single- or three-phase power of different voltages into a conguration that can be used effectively by the tool. Electroni-cally commutated (brushless) motors are used in these tools to enable them to run on multi-ple frequencies and current levels.

Vibration reduction. Stringent limita-tions on vibration throughout the European Union have afforded innovations that protect workers and improve productivity (see De-creasing Tool Vibration, page 6). To reduce the vibration transferred to tool users, man-ufacturers have introduced features such as counterbalance mechanisms, shock-absorb-ers built into tool bodies to isolate handles, and vibration-absorbing tool grips.

Dust control. The EU has also implement-ed dust-exposure restrictions for protecting workers respiratory health (see Battling Concrete Dust, page 10). As OSHA irts with imposing similar restrictions on silica dust in this country, U.S. workers benet from a va-riety of dust-collection attachments that are showing up from Europe on concrete-working power tools sold here.

The following are examples of some of the ways these trends are manifested in new tool models designed for the concrete trades.

HANDHELD CONCRETE SAWSWhether you call them cut-off saws, demo saws, quick saws, or power cutters, cir-cular-blade concrete saws are a mainstay for cutting into slabs, walls, cast concrete pipes, and all types of masonryeven re-bar and other metals, when tted with an abrasive wheel. Besides the tried-and-true two-stroke engine, a few new power sourc-es have been developed for these saws.

1

2

// BY MICHAEL SPRINGER

Except for handheld concrete saws, most gas-powered equipment used on concrete jobs has a four-stroke engine. To address the issue of having to keep a separate fuel mix around for this one tooland to prevent the damage done when a two-stroke engine is accidentally run on plain gasMakita came up with the EK7651H cut-off saw (1), which features a four-stroke engine. The saw ts a 14-inch blade and puts out 4.1 horsepower. Besides running quieter and cleaner than a two-stroke engine, this saw is claimed to be more fuel efficient.

Electric saws plugged into standard line voltage cant deliver as much power as a gas or hydraulic saw. To overcome that limitation and make electric saws more competitive with the alternatives, Husqvarna came up with the Prime system, featuring new tools that connect to high-voltage power packs. The power packs plug into 240-volt sin-gle-phase power or three-phase power from 180 to 530 volts. This gives saws connect-ed to the power packs 3,800 to 5,500 watts of output power versus about 2,200 input watts available to 120-volt tools. The new K6500 series includes a 16-inch-blade cut-off saw, ring saw, and deep-cutting chain saw, which are used with the PP65 portable power pack. High-tech brushless motors in the tools let them deal with the wide range of input powera feat not possible with typ-ical motors.

To add to its line of 36-volt battery-pow-

ered outdoor equipment, Stihl developed the TSA230 Cutquik cordless cut-off saw. This compact saw has a 9-inch blade capable of cutting 2 34 inches deep, and an onboard wa-ter-feed system like its bigger, gas-powered brothers. Benefits include quiet operation via the models brushless motor and an elec-tric brake that stops the blade quickly once you release the trigger. Expect 15 to 20 min-utes of runtime with the brands standard AP180 battery pack, and about a 30-minute charging time with the AP500 quick charger.

The newest addition to the brands cord-less line is the AP300 increased-capacity bat-tery pack. Its 6.3-amp-hour rating represents 28% more storage capacity than the pack the saw was tested with, so a longer runtime should be expected when using this battery. A backpack battery rated at 25 amp-hours is available for much longer runtime, but being tethered to the tool takes away some of its portable convenience.

Tackling the challenge of dust control, iQ Power Tools cut-off saws feature an internal dust collector. When the user is dry cutting concrete and masonry, a built-in mechani-cal vac powered by the saw motor sucks in much of the dust to prevent the billowing cloud that usually surrounds the work area within seconds. The dust container can col-lect about ve pounds of dust before it needs to be emptied. To keep the lter from getting clogged, you must occasionally twist a knob that rotates an internal brush around the l-ter. The all-around model iQPC912V (2) has a retractable guard to keep dust from escaping around the blade, and the iQPC912SK has a paver skate for controlled depth cutting on horizontal surfaces. Both saws have a 93cc two-stroke engine and t a 12-inch blade.

WALK-BEHIND CONCRETE SAWS For cutting expansion joints or grooves for decorative surfaces, or even for grinding out joints or cracks for repair, small walk-be-hind concrete saws offer more control than handheld cut-off saws. Many companiesMakita, Stihl, Husqvarna, Wacker Neuson, Hilti, and othersoffer rolling carts to t their handheld gas-engine cut-off saws so you can perform horizontal cutting tasks without having to buy a separate saw.

For improved accuracy and earlier cutting into green concrete, there are dedicated walk-behind saws in a range of sizes and cut


Despite all the advancements in cord-less rotary hammers, for boring larger holes in concrete, corded tools are still the ones to grab. The newest rotary hammers from Hitachi are a series of large SDS Max tools, redesigned for harder-hitting power and low-er vibration. And to add extra performance features and longevity to the tools, the man-ufacturer is using new AC brushless motors. The circuitry controlling the motor can deal with drops in voltage due to long extension cords or generators, without damage to the motor, and also allows for four digitally con-trolled speed settings. The 2 116-inch Hitachi DH52MEY (6) model also has an internal User Vibration Protection (UVP) feature with a leaf spring attached to a pivoting weight that moves counter to the motion of the tool to reduce user-felt vibration. This model de-livers 16.2 foot-pounds of impact energy with a vibration level rated at 9.8 m/s2.

Makita recently developed reduced-vibra-tion SDS Max rotary hammers featuring its new Advanced AVT (Anti-Vibration Technol-ogy). Mechanically decoupled front and rear handles via a free-oating outer body that moves independently of the motor and drive mechanism provides the passive part of the system, while a balanced pair of pistons moving counter to the drive piston, along with an internal dampening spring in line with the bit, provide active vibration con-trol. The 1 916-inch model HR4013C delivers 8.4 foot-pounds of impact energy and has a vibration rating of 5 m/s2. Electronics in the tool provide soft-start and constant speed functions and also provide alerts to the user about wear to the motor brushes or common electrical faults by illuminating LED service lights on the tool.

4 53


capacities. One such compact saw thats par-ticularly versatile is the GC25EUP early entry/green concrete push saw by Norton Con-struction Products. Its electric motor means that it can be used indoors (or out), and its up-cutting blade ejects dust and debris into the units integral vacuum port for cleaner dry cuttingnecessary for indoor jobs where you cant ood the surface for wet cutting.

MK Diamond Products, a brand famous for tile and stone saws, has a new saw for cut-ting concrete, wet or dry. The MK Diamond CX-3E1 (3) has a 1.5-hp motor that runs on 120 volts so its well suited for remodeling jobs. When tted with a 14-inch blade, the saw can cut up to 5 12 inches deep, and the side position of the blade lets the saw cut within 1 inch of a wall. For continuing a horizontal cut in the oor vertically into the wall, the blade guard pivots up and out of the way.

ROTARY HAMMERSRotary hammers of all sizes represent a quickly evolving segment of the tool mar-ket, and cordless tools are the fastest grow-ing segment in this market. Advances in motor and battery technology have made many of them effective enough to compete with corded models.

So far, all the cordless rotary hammers have one thing in common: They all take SDS Plus bits. Milwaukee is introducing the rst cordless model to use larger SDS Max bits, and its doing so in its standard size 18-volt cordless platform. The Milwaukee 2717-22 (4) will be one of the rst tools to come with the brands new 9.0-Ah High Demand battery packs, and like all tools with the FUEL des-ignation, it features a brushless motor for higher efficiency. Its maximum twist bit size

is 1 916 inches, and unlike smaller tools with a rotation-only mode, this is a two-mode tool with rotation-and-hammer for drilling and hammer-only for chipping. The vibration rating for this hammer was not available at the time of publication.

Unlike some other brands that let their higher-voltage cordless lines go dormant, Boschs 36-volt platform is still going strong. This territory is reserved for its strongest cordless saws and rotary hammers and the new 1 18-inch RH328VC-36 Bulldog (5) is no exception. Bosch asserts that its the fast-est-drilling and longest-running cordless rotary hammer available. Even if its not, its still the most powerful ever from Bosch. The SDS Plus tool puts out 2.4 foot-pounds of impact energy for drilling and chipping and comes with the brands upgraded 4.0-Ah 36-volt battery packs for extra runtime. Fea-tures include a gentle start that delivers less power to improve accuracy when starting a hole and an inertial sensor that stops the tool when it binds in a hole and suddenly jerks.

An active dust extractor mounted to a cordless rotary hammer may look unwieldy, but it can be less of a hindrance than drag-ging a dust-collecting vacuum around a building when drilling numerous anchor holes. For the latest in slightly bulky conve-nience, enter DeWalts 1-inch, 20-volt Max cordless rotary hammer, the DCH273P2, and its accessory D25303DH dust extractor (sold separately). When connected, both units are powered by the tools 5.0-Ah battery pack, but the dust extractor does have its own mo-tor. On its own merits, the rotary hammer features a brushless motor that generates 1.5 foot-pounds of drilling or chipping impact energy, with a vibration rating of 6.6 m/s2.


BREAKERS AND DEMO HAMMERS Full-size electric concrete/pavement break-ers were always trying to live up to the per-formance of pneumatic jackhammers, but now some brands gure they have them beat in more than one measure. The conve-nience benet of electric breakers that run on standard line voltage is a given, and elec-trics are also superior in vibration control. By now, new, more powerful models have some manufacturers comparing their per-formance and productivity directly against pneumatics. And as this category of tools as a whole keeps improving its shaking and breaking abilities, smaller breakers and demo hammers are able to take over some jobs that used to require full-size breakers.

One of the biggest names in electric breakers is the venerable Bosch Brute. But an even bigger one is the Bosch Brute Tur-bo BH2770VCD (7). Even after the reboot of the original Brute made it 50% stronger than before, Bosch decided to make a model that went all the way to 11 with the Turbo. The 63-pound tool hammers out 43 foot-pounds of impact energy at up to 1,000 blows per min-ute. The brands Active Vibration Control and extended air cushion in the hammer mech-anism provide the tool with an 8 m/s2 vibra-tion rating. The breaker comes standard with a hand truck, complete with two points and two chisels onboard in dedicated slots.

Makita has a new 69-pound breaker that its comparing to the performance of a 60-pound pneumatic hammer. The HM1812 boasts 53.9 foot-pounds of impact energy at up to 870 blows per minute with a vibration rating of 6.5 m/s2. This is one of the brands few signature tools that feature its Advanced AVT (Anti-Vibration Technology), which

76 8

uses a mechanical counterbalance in the drive system and a oating top housing and handle assembly that moves independently of the motor and hammer mechanism. Elec-tronics in the tool provide soft-start action and activate LED service lights at the end of the motor brush life or to warn of electrical faults present. When turned on but idling, the hammer function disengages to save unnecessary wear on the tool.

Adding on to the smaller side of Hiltis breaker family, the TE 800-AVR (8) is the latest demolition hammer from that manu-facturer. At 23.4 pounds and 23 inches long, this tool is light and agile enough to use on vertical as well as horizontal surfaces with the help of its front D-handle. The hammer punches out 15 foot-pounds of impact energy at up to 1,890 blows per minute with a 9.0 m/s2 vibration rating. Onboard electronics pro-vide diagnostic alerts and a digital switch to set the tool to full power or 70% power. At the reduced power setting, an electronic control system assists with beginning your chipping precisely. The hammer also features a built-in power boosterto maintain performance when long extension cords or generator output drop the voltage to the tooland an active cooling system that moves air over the electronics, motor, transmission, and ham-mer mechanism.

INTERNAL CONCRETE VIBRATORSNicknamed the smart poker, the new high-frequency AHFV22 vibrator from Al-len Engineering uses internal sensors to ne tune its performance. This feature is said to let the tool control its vibration to run at the optimum level (up to 12,000 vpm) when it senses variations in concrete den-

sity. And the feature also reduces the vibra-tion speed if the head gets tangled in rebar, to keep it from getting stuck. The electronic circuitry is housed in a protective alumi-num module that also contains an elec-trical converter, which allows the unit to run at high frequency without the need for a special generator. Just plug the 50-foot cord into a standard 120-volt outlet and its ready to go. The head diameter is 2.2 inches and the shaft length is just over 16 feet for good reach.

Wacker Neuson added two upgraded motor units to its HMS ex shaft vibration system with the M1500 and M2500. Both mo-tors are lighter than their predecessors and are designed to run up to 500 hours between motor brush changes. And to better survive dusty jobsite conditions, the models have ex-ternal air lters that can be replaced easily without opening the tool housing. The larg-er M2500 unit can t all of the accessories in the system including ex shafts from 1.5 to 30 feet long, and heads from 1 to 2 34 inches in diameter.

HANDHELD GRINDERS ANDPOLISHERS For smoothing uneven surfaces, removing form seams, and grinding off coatings, an aggressive portable concrete grinder is the go-to tool. And rather than making a dusty mess with every task, its nice to have the option to use built-in dust collection. With that in mind, the 5-inch CSG15 grinder from Bosch looks like a good choice. Powered by a 12.5-amp motor, this tool is designed to grind at a consistent 9,300 rpm due to its constant-response electronic controls. The same controls provide soft starting and


motor-overload protection. And a generous sized wraparound handle at the front of the grinder provides ample grip options for hor-izontal or vertical uses. The real beauty of the tool is that its able to effectively collect dust when connected to a dust-extracting vac. Bosch designed the shroud and brush skirt to create airow that gets under and lifts the dust so a vac can capture more of it. For grinding tight against perpendicular surfaces, the dust shroud can be rotated out of the way. The grinder comes with a dia-mond cup wheel and a spare brush ring.

For the attest and nest nish on stone and concrete surfaces, nothing beats the ran-domized action of a planetary polisher. The latest updated version from the originator of these tools is its most powerful model to date. The Inter-Tool DS3011 (9) features a 14-amp motor made by Fein Power Tools that rotates the outer 12-inch platen at 405 rpm and the three inner 5-inch planets at 2,200 rpm. For wet use, there is a central coolant feed hose, and for dry use, there is a vacuum attach-ment tting that lines the vacuum hose up with the units power cord. During either op-eration, the improved, extended brush skirt reduces the mess. One other detail is that the transmission has been designed with posi-tive airow to keep out debris while the tool is running. The polisher is available in 115- or 230-volt congurations.

DUST-COLLECTING VACSWhen compared with traditional shop or utility vacuums used mainly for clean-up duties, vacuums used primarily for collect-ing dust have a few major differences. Hoses for dust collection are smaller in diameter. This prevents them from being able to gob-ble up large chunks like clean-up vacs can, but the thinner hose creates higher velocity airow, which is ideal for capturing dust. Fine-dust collection (and containment) also requires vacs to use higher efficiency lters and seals than those of most utility vacs. Dust-collection vacs built for the rig-ors of the concrete jobsite have some kind of self-cleaning feature that operates at a reg-ular interval to keep the lters from clog-ging and causing a loss of suction.

Similar to most utility vacs, these dust extractors can also be used for water and slurry pickup, which is useful for wet grind-ing, polishing, and coring operations.

The Husqvarna DC1400 (10) vac has a maximum tank capacity of 14 gallons dry when used without a lter bag, and 10 12 gallons wet. When the vac reaches its wet capacity, internal electrodes sense the water level and turn the unit off. And for draining liquid contents without lifting or tipping the vac, there is a drain hose at the back. Generously sized casters and a tall handle make it easy to steer the 37.5-pound vac around the jobsite. To clear hoses and curbs, just tilt the whole thing back onto its rear wheels to roll it around like a hand truck. The vac moves air at 123 cfm, develops suc-tion of 89 inches of water lift, and runs at a quiet 67 decibels.

DUST-COLLECTION ATTACHMENTSJust a few years back, it was difficult to nd many concrete working tools with integrated dust-collection attachments. These days, more manufacturers are tak-ing concrete-dust management more seri-ously and designing solutions to go along with dust-creating tools. Saws and grinders are the most obvious offenders, but break-ers and rotary hammers also produce their share of dust and debris.

Effective dust-collection attachments consist mainly of a shroud that keeps the dust contained at the source and a port that connects to a jobsite vac that sucks up the dust and contains it. Universal-t aftermar-ket attachments are available that can be adapted to tools that lack integrated ttings or attachments, but dust collectors pur-pose-built for a specic tool by the manufac-turer are typically more effective and easier to use. Ease of use is important; workers are much more likely to attach and use dust-col-lection ttings if it doesnt create too much of a hassle or rob them of productivity while using a tool.

A good example of manufacturer-specic dust-collection ttings is the Bosch HDC-D1 (11) dust-extraction attachment kit. The exible shrouds are purpose-built to t the brands SDS Max rotary and demo hammers and combine a quick snap-on attachment and a small-diameter, high-velocity vac port for easy and effective use.

Michael Springer is the former executive editor of Tools of the Trade.

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Better motors and batteries have brought todays models to the verge of corded performance

CORDLESS GRINDERS COME OF AGE


1 2

// BY MICHAEL SPRINGER

In the not-too-distant past, tool makers referred to cordless grinders as cut-off tools as a way to lower users expectations of how much work they could get out of these small machines. But better motors

and higher-capacity batteries have made the latest 18-volt models good enough to be called grinders by every brand. These arent tools you would use for production cutting and grinding operations. But to my surprise, most of these cordless tools do a decent job of mak-ing the sparks y during rigorous grinding work for a short while, at least.

TESTING METTLE ON METALTo determine how well these tools might hold up on the job, I chose Grade-40, #4 rebar for the test medium. Besides being a familiar material, the carbon steel in rebar is a uniform material, as veried by the government specs to which it must conform.

To keep things even, I installed an identical, new 4 12 inch wheel on each tool prior to each test. I used 4 12-inch cut-off and grinding wheels from Norton for every test, even though some of the tools could also accommodate 5-inch wheels.

For the results evaluating runtime, grinding speed, and cutting speed, see Grinder Testing, on page 22.

FEATURES TO LOOK FORAt minimum, each grinder comes with a side handle, adjustable guard, and wheel-attachment wrench, but some of the tools include a few extra accessories. Every brand has a switch circuit that pro-

tects the user against accidental startup. If you put the battery in with the switch turned on, the tool wont run until the switch is turned off rst, then turned back on.

Beyond these basics, a number of other features on some models stood out. The following will help explain the comments found for each model on pages 20 and 21: Grinder guards that do not require tools to attach or reposition

are the key to efficient guard-adjusting. Each tool comes with an open-bottom (Type 27) grinder guard.

Those models that also include an enclosed-bottom (Type 1) guard have additional utility and safety.

All of the tools have spindle lock buttons that let you tighten wheels with just one wrench, and a few of the tools have tool-free options for removing and even attaching wheels.

Grinders with lock-on switches allow more freedom of move-ment and create less fatigue than those with a paddle switch or trigger that must be held on.

The grinders that t 5-inch wheels allow you to use longer-last-ing cut-off wheels; however, the extra torque required for grinding with a larger wheel may sap the tools strength.

Grinders with motor brakes increase productivity because you can set the tool down immediately after use, instead of waiting for the wheel to stop.

Two of the top models feature high-tech brushless motors with electronic instead of brushed commutation designed for high-efficiency operation.

Type1 vs. Type 27 Guards. The Bosch, DeWalt, and Milwaukee (shown) each come with two guards: a standard Type 27 grinder guard (on right) and a more enclosed Type 1 cut-off wheel guard that provides greater protection from ying shrapnel. Grinders that provide 5-inch guards allow use with either 4 12- or 5-inch wheels.

Switch Styles. Three types of grinder switches: A trigger switch (left) can be locked off but not locked on; it offers the least grip exibility. A lock-on slider switch (center) offers the most freedom of motion. A paddle switch (right), also known as a dead man switch, is long enough to provide some exibility.


TOOL TEST: 18-V GRINDERS

BOSCH CAG180-01

Weight: 5.1 poundsRPM: 10,000Switch type: lock-on slider switchGuard: 4 12-inch grinder guard, 4 12-inch cut-off wheel guardGuard adjustment: requires hex wrench (stored onboard tool)

Web price: kit $399; bare tool $125 Includes: tool, 2 batteries, charger, cut-off guard, wheel wrench, fabric duffel bagCountry of origin: tool, Germany; battery, Malaysia

Comments: Solid third-place tool with great runtime and a light, agile form, but it slows under load more than the top two.

Pros: Separate grinder and cut-off guards; small switch positioned to the side keeps it well out of the way; slender body easy to grip.

Cons: A hex wrench is required to adjust the guard, which slows down the process.

METABO WP18LTX115

Weight: 5.5 poundsRPM: 8,000Switch type: paddle switch (lock-on slider-switch model also available)Guard: 4 12-inch grinder guardGuard adjustment: tool freeOther features: rotating battery, removable lter screen, overload warning light

Web price: kit $399; bare tool $103Includes: tool, 2 batteries, charger, wrench, plastic caseCountry of origin: tool, China; battery, Hungary

Comments: First in every test says it all; hands-down the best tool for serious cutting and grinding with powerful and predictable performance.

Pros: Unique rotating battery lets you optimize the tools form and balance for different grinding and cutting positions; lter screen a nice extra for protecting the motor.

Cons: Would rather have the sliding-switch version (W18LTX115) rather than the paddle-switch version for ease of use; lacks cut-off guard.

MILWAUKEE FUEL M18

Weight: 6.0 poundsRPM: 8,500Switch type: lock-on slider switch (paddle-switch model also available)Guard: 5-inch grinder guard, 5-inch cut-off wheel guardGuard adjustment: tool freeOther features: rubber bushing in handle, removable lter screen, brushless motor

Web price: kit $399; bare tool $169Includes: tool, 2 batteries, charger, cut-off guard, wrench, spare lter, plastic caseCountry of origin: tool, China; battery, Korea and China

Comments: Strong, smooth second-place tool. A real comfort standout. Comes with useful accessories and extras.

Pros: Fast motor brake; separate grinder and cut-off guards; 5-inch guards let tool t wide range of wheels; rubber bushings on front handle and slender, rubber- covered rear handle provide a great feel in use; wheel nut can be removed without a wrench; lter screen protects motor. Note: Since this test was conducted, Milwaukee introduced a second-generation M18 Fuel grinder that includes a brake, a clutch to prevent kickback, and a nut that allows quick changes of accessories without tools.

Cons: Extra length can reduce maneuverability in some uses.


DEWALT DCG412M2

RPM: 7,000Switch type: triggerGuard: 5-inch grinder guard, 5-inch cut-off wheel guardGuard adjustment: tool free

Web price: kit $299; bare tool $119Includes: tool, 2 batteries, charger, cut-off guard, wrench, fabric duffel bagCountry of origin: tool, Mexico; battery, Japan

Comments: A strong tool that gets extra torque from its slower motor, but its bulky rear handle with a trigger is not preferred over a standard grinder design.

Pros: Separate grinder and cut-off guards; 5-inch guards lets tool t wider range of wheels.

Cons: Biggest and heaviest; bulky handle design; having to hold on to trigger adds fatigue and diminishes grip versatility; grip with handle way at the back makes it cumbersome, especially when following curves.

HILTI AG 500-A18

Weight: 6.1 poundsRPM: 9,500Switch type: paddle switchGuard: 5-inch grinder guard, plastic cover for cut-off useGuard adjustment: tool free

Other features: tool-free wheel nut; brushless motor, metric M14 shaftWeb price: kit $559; bare tool $329 (manufacturers list price)Includes: tool, 2 batteries, charger, cut-off guard cover, wrench, 25 cut-off wheels, fabric duffel bagCountry of origin: tool, China; battery, China

Comments: This fast cutter shares third place, but its at its best when applied in short intervals; when pushed hard for very long, its speed wavers under load.

Pros: Fast motor brake; cut-off guard cover plate snaps onto grinder guard without tools; 5-inch guard let tool t wider range of wheels; nice wrench-free wheel nut can save time.

Cons: Once motor speed dipped under load, it took a while with the pressure let up before the brushless motor found the top of its range again; this characteristic seemed to slow output more noticeably during longer periods of use; paddle switch onlywould prefer a sliding switch.

HITACHI G18DSL P4

Weight: 5.0 poundsRPM: 9,100Switch type: lock-on slider switchGuard: 4 12-inch grinder guardGuard adjustment: requires screwdriver (not included)

Web price: bare tool $90Includes: tool, wrenchCountry of origin: tool, China; battery, China

Comments: Light-duty tool with only modest power and runtime; outclassed by other tools in the test but its compact form was appreciated for lighter nishing work.

Pros: Light weight, good balance, and lots of rubber grip surfaces made this downsized tool a standout for one-handed nishing work.

Cons: Limited to light work; screwdriver is required to adjust the guard, which slows down the process; unlike the others, which have multiple LEDs on the battery, has a more rudimentary fuel gauge with two LEDs on the tool itself; lacks cut-off guard.


TOOL TEST: 18-V GRINDERS

Grinder TestingThe charts on the left show the results of a series of torture tests cutting and grinding grade 40, #4 rebar. During testing, materials to be cut and ground were secured in a vise and supported along their length to minimize vibration. Identical, new 4 12-inch cutting or grinding wheels were installed on each tool prior to each test. These tools also spent time in a professional welding and fabrication shop in the skilled hands of grinding maestroscraftsmen who wield an angle grinder with the ease and grace of a conductors baton. These guys provided great feedback regarding the nesse and ergonomics provided by these smaller, cordless machines.

THE BOTTOM LINEOnce the ying sparks had bounced their last, the grinding swarf had all settled, and the hot steel had cooled, I had to admit that I was impressed by the performance of these 18-volt cordless angle grinders. Of course, like many cordless tools, the minutes of actual runtime under a decent load can be counted on one hand, but when you consid-er that equals about 45 cuts through #4 re-bar, its a respectable amount of work. All the tools could do the light grinding of nishing work, such as smoothing welds and putting a radius on sharp corners, but when pushed harder, the more powerful tools proved their worth for serious grinding and cutting.

The Metabo takes the top spot, as it won every single power, speed, and runtime test. It also has advanced features.

In the No. 2 spot for this test is the Mil-waukee, with a great combination of power when it counts the most and many advanced features. Since we ran this test, Milwaukee introduced a new M18 Fuel grinder that de-serves a fresh look.

Great performances by Bosch and Hilti have them sharing third, and the powerful yet clumsy DeWalt follows. The light-duty Hitachi was a comfort standout, especially for nishing work that required nesse.

Michael Springer is the former executive editor of Tools of the Trade.

Cutting SpeedThe chart above shows the time in seconds to make 10 cuts non-stop through 12-inch rebar on a fully charged battery. Test-ed with Norton RightCut Type 1 cut-off wheels, .040-inch thick.

RuntimeThe chart above shows the number of cuts through 12-inch rebar on a fully charged battery. Each grinder tested with .040-inch-thick, Type 1 Norton RightCut cut-off wheels.

Grinding SpeedThe numbers in this chart represent the grams of steel removed per minute during two, 2-minute trials of heavy grinding on a fully charged battery. Tested on rebar with Norton Gemini Type 27 grinding wheels. A corded model was included as a point of reference.


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In the world of cellphone marketing, durable sometimes just means a device that can survive a beach party. But a few companies have gotten wise to the real-world demands of people who work for a living.

TOUGH TECH


1// BY CLAYTON DEKORNE

No one will argue that the jobsite isnt tough on tools. Tool manufacturers spend a lot of time and money coming up with ways to make their tools last longer in the face of ev-eryday battles with dirt, rain, ladder drops, and other forms of workload abuse. And why shouldnt they? We invest our hard-earned money into those tools, relying on them to work regardless of the days weather and site conditions.Few trades have the luxury of being precious about their tools, though. And as our smartphones, tablets, and laptops become more and more common on jobsites, we are ever-more mindful of protecting these rather delicate devices. Not all manufacturers get this; rugged often means it can survive a day at the beach or a spilled drink. Heres a run-down on a few of the specs to look for in the growing handful of smartphones, tablets and laptops designed for people who actually work for a living.

What to Look forDont buy a new device based on clever marketing speak. Instead, rely on published standards that actually measure how a device passes testing. In practical terms, ruggedness is really about water resistance, dust resistance, and shock resistance.

Water and dust resistance is measured by an IP, or Ingress Protection, rating developed by the IEC (International Electrotechnical Commission). This rating system classifies different degrees of dust and water intrusion with a two-digit code (for example, IP68). The first number indicates the level of dust resistance, the second the level of water resistance. Dust-resistance levels go from 0 up to 6; water-resistance measures go from 0 to 9. (o an IP68 is excellent). The higher up the IP scale, the better a smartphone or tablet may offer protection.

That said, be aware that in practice, achieving the published water resistance requires that a series of rubber gates built into the phone case be manually sealed shut. It may require a concerted adjustment in handling your phone to ensure it stays protected when it does eventually drop out of your shirt pocket onto a muddy jobsite or to the bottom of a foundation form during a pour.

Shock resistancea measure of how well a device is likely to survive a tumble down a ladder or a flight of stairsis just one of the measures in the MIL-STD 810 standard. The Military Standard was first developed in 1962 by the U.S. Department of Defense to evaluate product durability in demanding conditions and was most recently revised in 2008. It covers eight different tests: for high temperature, low temperature, rain, humidity, sand and dust intrusion, immersion, vibration, and shock. The shock test, which is most often cited for phones and computers, relies on a drop testor actually 26 four-foot drops onto plywood-covered concrete (marketing often shortens this to read simply concrete). Each drop is meant to evaluate every conceivable side and edge of the device. If the device works after each drop (and survives all the other tests), it can be labeled with MIL-STD 810. Note that while your average pretty phone is unlikely to pass, the 810 shock test provides no guarantee that


The CAT S40, a rugged 4.7-inch, Android-based smartphone designed specically for the construction trades is MIL-STD 810certied with an IP68 rating. It includes such features as a Gorilla Glass 4 display and an 8MP, geo-tagging camera.

The Sonim XP7 is the opposite of daintyan ultra-rugged, Android smartphone featuring a 4-inch touch screen that can be viewed in direct sunlight and operated with wet work gloves. Its 4,800 mAh battery is rated for 40 hours of talk time. No surprise: Its pricey.

TOUGH TECH

a phone will survive a drop from the top of a 6-foot step ladder onto a bare concrete slabnot an unusual jobsite scenario. This is, after all, the type of minimal performance we need from a jobsite phone. Some manufacturers, such as Cat, a well-known equipment manufacturer in our industry that recently launched the S-40 Smartphone, has applied the 810 testing procedures at higher drop distances (Cat uses a 6-foot-drop test for the S-40). And further evaluation of the materials the device is constructed from might provide additional reassurance.

Screen materials. One of the most fragile parts of a phone or tablet is the display. In a real-world fall, its the glass display that most commonly shatters. Two rugged screen materials hold real promise of not shattering: Cornings Gorilla Glass and a sapphire display.

Now in its fourth generation, Gorilla Glass is primarily a scratch-resistant glass first brought to portable electronic devices by Apple, but now used on a host of others (and is reportedly to be used on the Ford GT sports car beginning this year). Gorilla Glass3 is fairly common on rugged devices; the latest version, 4, is reportedly stronger, but that may mean it is just made thinner. Still its far more likely to hold up against the abrasive materials on concrete sites and resist deep scratches that are the most likely to eventually result in a cracked screen. The downside is that it shows fingerprints readily.

Sapphire screens are made from industrial sapphireoften touted as the worlds second-hardest material after diamonds. Long used for watch crystals and camera lenses, the initial marketing (driven by Apple) did a good job suppressing sapphire

3 4


Water resistance on most IP-rated smartphones relies on sealed buttons, but also depends on the user to manually seal ports. This example, a Kyocera Duraforce, features a 4.5-inch HD display that users can operate with work gloves. Its a MIL-STD 810certi ed, IP68 Android phone with a 3,100 mAh battery rated at 17 hours talk time.

Tridents Kraken AMS cases are the only aftermarket phone cases we know of that meet MIL-STD 810 requirements. Like the phones rated to keep out water and dust, this case requires manually sealing the rubber ports in order to achieve the water- and dust-in ltration ratings of the 810 standard.

as a suitable material for larger electronic displays. That approach quickly fell apart, however, as sapphire is a super-hard, super-clear material (Apple eventually began to push sapphire screens as a selling point of the latest iPhone6). The jurys still out on whether Gorilla Glass or sapphire is the better display material. Chances are high, though, that you want a jobsite-ready device with one of them.

Aftermarket CasesBuying a rugged smartphone is actually an extreme buying decision. A more natural impulse for a lot of us is to look for a rugged case that will protect the phone we already have. Finding one, however, is not so easy and Im sure Im not the only one who has had to rely on trial and error . with plenty of disappointment from the error part of that. There are plenty of aftermarket phone cases that will bulk up your phone but may do little to actually cushion it from a real fall, and they usually all have annoying screen covers that either make it difficult to operate the phone or are finicky to apply with only marginal protection.

We know of only one line of rugged cases for smartphones and tablets that actually meet MIL-STD 810 (granted, only at the minimum 4-foot-drop test). The Kraken AMS Series from Trident provides three layers of shock-absorbing TPE and hardened polycarbonate protection with built-up, impact-resistant, corners. Kraken Series cases use TPE plugs to pass the IP ratings for preventing construction debris, sawdust, and other dirt from blowing into audio jacks and power-ports.

The age and mix of the concrete, as well as the cut-type, drive blade selection and performance

CHOOSING A DIAMOND BLADE


Choosing the right cutting blade is just as important as choosing the right saw. When properly matched to the job and the saw be-ing used, diamond blades cut fast and provide long service life. But using the wrong blade or a saw that turns the blade at improper speeds can shorten blade life and raise cut-ting costs.

Because diamond blades come in a wide variety of sizes and performance levels, se-lecting the right blade is not an easy task. Blade costs can vary widely and stretch into the thousands, depending on quality. And although it may be tempting to buy a lower- cost blade, in the end it will likely be wiser to buy a more expensive, high-performance blade thats designed to last longer.

Several factors affect blade life, including blade quality, characteristics of the concrete being cut, and saw speed. Knowing how a diamond blade works and the characteristics that affect blade life and performance can help you improve productivity and economy.

DIAMOND BLADE BASICSDiamond blades are the go-to choice for cut-ting concrete, no matter if its green or fully cured. They cut by grinding away at the surface of the concrete, using diamonds as an abrasive. The metal core, which is a steel disc that attaches to the saw, holds diamond crystals in place at the outer edge. These di-

// BY CHRIS ERMIDES

amond crystals, which are synthetically grown to specic sizes, shapes, and tough-ness, are what actually grind through the concrete. The blades edge can be continuous, serrated, or segmented (1). Segmented blades have slots cut into the core that allow water and air to ow, providing faster cooling. The diamonds can be bonded to the blades edge in varying concentrations. A blade with a greater diamond concentration will typical-ly cut longer.

As the blade is manufactured, pressure and heat embed the synthetic diamonds into a metal matrix, which holds the crystals in place (2). The matrix is either laser welded or soldered to the perimeter of the core. Dia-monds are set in layers within the matrix from the core outward. With each rotation of the blade, the metal matrix wears away slow-ly, then new layers of diamonds embedded deeper are exposed. The matrix is manufac-tured in a range of hardnesses, each meant for different cutting applications. The harder the matrix, the longer diamonds will stay bonded to the blade. CONCRETE AFFECTS BLADE WEARThe best way to extend the life of your blade and achieve maximum cutting efficiency is to use a blade suited to the material being cut (3). Concretes compressive strength, ag-

gregate hardness and size, sand type, and amount of steel and whether the concrete is green or cured all impact blade wear and per-formance. The best time to cut a joint into atwork is when the concrete is greenone to two hours after nishing, or the next daybecause it is softer and easier to cut. Green concrete, though softer than the same con-crete after its cured, is also more abrasive because sand in the mix hasnt bonded to the mortar. Its for this reason that blade manu-facturers make hard-bonded diamond blades specically designed for cutting green con-crete. Sawing through cured concrete, how-ever, requires some investigation.

Cutting into dense, hard concrete of 6,000 psi or more or into concrete containing hard aggregates causes diamond particles to fracture faster. Thats why knowing the type of aggregate in the concrete mix is an import-ant factor in blade selection.

Hard aggregates like int and granite are difficult to cut. Dense concrete or concrete with a hard aggregate should be cut using a blade thats equipped with a softer metal ma-trix. The soft metal matrix wears more read-ily, exposing new layers of diamonds, which makes the blade cut more efficiently (4).

Aggregates like limestone, slag, and coral are relatively soft and abrasive and are the least difficult to cut, as is green concrete. A blade with a hard metal matrix is the best

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The edge of a diamond blade can be serrated, continuous, or segmented. Segmented edges are said to provide faster blade cooling because water and air can ow between the segments. As the blade cuts, a bond tail is formed that trails the cut and supports the diamonds.

Synthetic diamond crystals are embedded into the blades metal matrix in layers. As the rotating blade wears, fresh diamonds are exposed.


CHOOSING A DIAMOND BLADE

choice here because it will hold the diamond particles longer.

Along with the type of aggregate, its also helpful to know its size. The larger the size, the slower the cut and slower the blade will wear. Aggregates smaller than 38 inch are easier to cut, but they wear the blade faster. Concrete comprised of large int aggregate is much more difficult to cut than a mix with small int aggregate in it, for example. Some finer aggregates can wear a blade quickly. Natural quartzite sands, which have been rolled around by water for years, are smooth and dull, but manufactured sands have sharp, abrasive edges that wear the blade quickly.

Cutting rate is slowed by harder aggre-gates like int and granite, which require more power and shorten the life of a blade. Segmented blades built with tough dia-monds and a soft metal bond matrix are the best choice for cutting hard aggregates. A blade with a hard metal bond matrix will cause the diamond particles to wear even with the bond surface; the blade will glaze over and will no longer cut. Segments for cutting soft aggregates should have a hard metal bond matrix so that the diamond crystals dont wear before their cutting life is up.

WET VS. DRY BLADESBlades are available for either wet- or dry-cut-ting applications. Dry-cutting blades can usually be used with or without water and are designed to work in higher temperatures. Wet-cutting blades, however, should not be used dry, because theyre designed to be op-erated with a continuous spray of water. Us-ing a wet blade dry can result in ying debris as segments and teeth become disengaged from the blade.

Wet-cutting is often the best method to use. Water cools the blade, reducing heat build-up and extending blade life. Water also dampens cutting nes and eliminates dust. Some jobs require dry cutting, like when youre using an electric saw (5). Cold weather can make wet cutting impractical as well because of potential freeze problems. Wet-cutting is necessary when using a con-crete-cutting chain saw (6).

When cutting dry, dont cut more than 1 to 2 inches deep in one pass, and allow the blade to cool periodically. Doing so will keep

5 4

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76 the blade from overheating; overheating can shorten the blades life.

MATCH THE BLADE TO THE SAWWhile considering the material being cut, you also need to match the blade to the saw in which it will be used. The chart below is a good guide, but in general you can cut faster and extend blade life using lower-perfor-mance blades on low-horsepower saws, and higher-performance blades on high-horse-power saws.

Blade-shaft speed is another consider-ation along with horsepower. A saw that ro-tates the blade at the wrong speed can cause the blade to wobble, warp, and wear exces-sively. For most saws, blade-shaft speed (mea-sured in RPM at no load) will be higher than the recommended operating speeds shown in the chart. Under normal sawing conditions, the actual shaft speed will slow under load and fall within the optimum speed range. Before purchasing a blade, tell the supplier the model and rpm of the saw you plan to use.

You can maximize blade performance by using the right blade in the right operating conditions, such as the speed of rotation and the material being cut. Manufacturers de-sign these blades for specic purposes and offer recommended maximum operating speeds based on blade size, saw type, and the material being cut (7).

Increasing operating speeds can make the blade perform as if it is harder than it ac-tually is and will therefore lengthen its lifebut higher operating speeds also slow down the cutting. The converse is true, too: De-creasing the blade speed decreases the blade life. When in doubt, start with a lower speed and work up to an increased speed once the blade is cutting well.

All blades these days come with a lettered Blade Application Code developed by the Con-crete Sawing and Drilling Association (csda.org). The code indicates whether the blade is rated for wet or dry use, the type of surface being cut (cured vs. green concrete, for example), as well as what type of saw the blade is meant for. Blade manufacturers offer blade-buying guidance within their blades specs, via an online buying guide with drop-down menus, or both.

Chris Ermides is a senior editor for Tools of the Trade.

Concrete-cutting chain saws use chains that have adapted diamond blade technology. Each chain contains diamonds embeded in mesh. Each link is interconnected in a way that resists slurry and dust from seizing the blade.


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Our goal for June 6-10, 2016, is to build, renovate or repair 300 homes across the nation.

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2016 World of Concrete Special Issue

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Toolsofthetrade.net provides the most up-to-date information on the latest tools, accessories and equipment available to residential construction pros. It is the online source for tool information and readers rely on us for honest, thorough and up-to-date news on the latest products.

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FLOOR LEVELING MACHINEWhen installing ooring on top of a concrete slab, you need to ensure the surface is at and smooth. Floor leveler and patching is commonly used to ll voids and raise the oor to the high spots, but additional grinding is often needed and this process requires time and added material costs. Grinding down the high spots, however, can easily be achieved using a WerkMaster machine equipped with its Badger Tooling technology. Because the machine works as a planer, it acts like hundreds of little scabbler heads jackhammering down the high spots, leaving the surrounding area unaffected. Available in several size and power congurations for a variety of project types, The WerkMaster Badger Tooling can also be used to create CSP ratings from 3 through 6. WerkMaster / werkmaster.com

TECH-SAVVY JOBSITE STORAGEKnaack has developed two toolboxes that bring project management software securely on site for easy access. The DataVault Mobile (model 118-M) comes equipped with a 32-inch touchscreen monitor, as well as a large storage locker and locking drawers for locking up tools. The unit comes with casters and is compact enough to roll through a 28-inch door frame. The larger of the two, the DataVault (model 118-01, shown here), comes with a 40-inch monitor, color laser printer with wireless printing capabilities, a USB switch and hub, four GFCI power outlets, a 1,500-watt back-up power supply, and a crane lift kit as well as skid access. The 118-01 DataVault can t through a standard 36-inch-wide steel frame door. Both DataVaults are made of 16-gauge steel and feature Knaacks well-known dual Watchman IV independent locking design for secure storage.Knaack / knaack.com

Self-Leveling Rotary Laser KitBoschs rotary-laser kit comes fully equipped with a receiver, tripod, and grade rod. The GRL 500 H Rotary Laser requires pairing with the LR 50 receiver in order to function; both devices must be present for the laser to work, which is part of an integrated theft-deterrence system. The laser is also equipped with a movement sensor that triggers an alarm and locks all functionality on both the laser and the receiver if a sudden acceleration is detected. Integrated Li-ion batteries allow both laser and receiver to be charged simultaneously. The LR 50 receiver also doubles as a remote control and allows for manual slope conguration. A centerline mode helps nd a center mark, and a calibration reminder alerts users to check for recalibration.Bosch Power Tools / boschtools.com

Product Watch


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SKILSAW WORMDRIVE METAL-CUTTING SAWEquipped with a 40-tooth Diablo Cermet blade, Skilsaws 8-inch Outlaw (SPT78MMC) is the rst wormdrive saw designed to cut through metal. With the power and functionality of a true worm drive, the left-mounted blade is fully housed above the foot plate to capture metal chips. A blade window offers visibility to the cutline. The 15-amp motor and gear come in a magnesium housing while the foot plate is made of stainless steel, giving the saw a total weight of about 15 pounds. A 8-foot-long power cord allows maneuverability and the blade wrench stores onboard the footplate. At 90 degrees, the Outlaw can cut up to 2 78 inches. Expected March 2016 with an MSRP of $319.Skilsaw / skilsaw.com

DROP-DOWN LADDER RACKSWeather Guards EZGlide2 provides easier, safer access for loading and unloading heavy ladders and electrical conduit, which is particularly cumbersome on high-roof vans. Powder-coated aluminum ensures a rust-free and lightweight rack that wont negatively impact gas mileage. In addition to being lighter than the rst-generation EZGlide model, the EZGlide2 is less expensive as well. The rack can t extension ladders up to 40 feet and step or podium ladders from 3 to 12 feet, and 100 pounds per side. An optional third cross-member accommodates a conduit carrier as well. A variety of mounting kits are available for attaching the ladder rack to a wide selection of van models.Weather Guard / weatherguard.com

POWERFUL NEW BREAKER HAMMER Powered by a 15-amp motor, the HM1812X3 hammer delivers 53.9 foot-pounds/72.8 joules of impact energy. The three-component AVT system is synchronized, reducing vibration to 6.5m/s2. A counterbalance system also reduces vibration and directs impact energy to the work surface. The vibration-absorbing housing moves independently of the motor and hammer mechanism, which isolates more vibration away from the user. Rubberized xed handles dampen vibration while soft-start technology allows for better accuracy on start up. The automatic no-load function reduces motor speed when it is not in use. An LED power light indicates switch failure or cord damage, while a service light alerts user when the service life on brushes is eight hours or less; an automatic brush cut-off protects the commutator. The breaker comes equipped with a 16.4-foot power cord and cord guide and a hammer cart for transporting the breaker hammer, as well as two 1 18-inch-by-20 12-inch at chisels and two 16-inch self-sharpening bull-point bits. The breaker accepts 1 18-inch hex bits.Makita / makitatools.com


PORTABLE POWERGenerac Power Systems, a manufacturer of backup power generators and engine-powered tools, unveiled its new diesel-powered portable generator, the XD5000E, designed for high-intensity needs associated with professional use. Ideal for professionals and contractors looking to power tools, lights, and other equipment, the XD5000E is uniquely engineered for the rugged demands associated with construction jobsites and agricultural applications. Specically, the sturdy steel frame provides added durability while the Tier IVcompliant, industrial-grade diesel engine offers a more efficient unit that requires less maintenance. Easy, hassle-free start-up is achieved thanks to the single-touch electric start. Plus, the large-capacity 12-gallon fuel tank with fuel gauge provides a long runtime of 32 hours at 50% load, which reduces jobsite interruptions from having to continuously refuel. Generac also incorporates its patented TruePower Technology, which allows electricity to be generated with low total harmonic distortion for clean, smooth operation of electronics and equipment.Generac Power Systems / generac.com

RUST-RESISTANT COMPRESSOR Multiquips DIS185SSI4F is a 185-cubic-feet-per-minute compressor, powered by a 49-horsepower Isuzu diesel engine that meets EPA Tier 4 Final engine emissions. The e-coated air tank resists common rust problems due to condensation. Fuel is ltered in a two-stage ltration system with a manual primer. The weather-resistant steel housing is fully lockable for safe, unattended operation. A spacious, lockable internal toolbox is large enough to store tools and hoses. The sound-attenuated cabinet reduces engine noise during operation. A state of the art LED digital control panel displays the compressor temperature, fuel level, engine temperature, and speed and also provides engine diagnostics. Multiquip / multiquip.com

LET THERE BE LIGHTMilwaukees M18 LED Stand Light is a portable work light that is powered by the M18 cordless battery platform. The light delivers up to 2,000 lumens and has three output modes for optimizing brightness and battery run-time. The rotating and pivoting head can be adjusted to a height of 4 to 7 feet, providing good overhead illumination and options to help minimize shadows. The battery at the very base of the tool keeps the center of gravity low to increase stability. The stand and light collapse down to a 40-inch unit with a nice carrying handle for easy transport and storage. When packed away, the head nests into a protective shroud that should help keep it intact when it bounces around the back of the truck.Milwaukee Tool / milwaukeetool.com


TWIN-HANDLED POWER SCREEDThe compact, single-beam vibrating screed allows contractors to level concrete in a variety of applications, including garage oors and driveways, as well as in conned areas. The BV30 weighs as little as 28 pounds and is available with ve blade sizes, ranging from 6 to 14 feet long. The screed is equipped with a V-shaped, rigid bottom plate that prevents the blade from twisting to ensure stable and consistent leveling. And because the screed vibrates, it eliminates the need for pokers while leveling concrete as deep as 5 inches. Atlas Copco / atlascopco.us

COMPACT EXCAVATORSThe Gehl Z55 and Mustang 550Z excavators, both from Manitou, feature a Yanmar Tier IVcertied turbocharged, diesel engine with 47.6 hp and an angle blade with oat that can be registered 25 degrees in either direction to eliminate repetitive re-positioning when backlling. A digital operator interface shows real-time system information, service reminders, fuel consumption, and 90 days of operating history. The cabs feature elevated travel pedals, wrist rest, and a three-way adjustable seat with retractable belt to keep the operator comfortable throughout the workday. Standard auxiliary proportional hydraulics give the operator innitely variable control of the hydraulic ow. This allows the operator to set the ideal ow for the attachment and application. ECO Mode can be activated from the cab with a switch. When activated, the engine speed is reduced by 10%, reducing fuel consumption and operating costs. Auto deceleration lowers noise and emissions levels when the hydraulic movement has not occurred for more than four seconds. Gehl / gehl.com and Mustang Mfg / mustangmfg.com

ELECTRIC CORE DRILL MOTORCS Unitecs PLD 450 B core drill motor is ideal for wet drilling up to 18-inch-diame-ter holes in concrete, reinforced concrete, asphalt, and natural stone. Weighing only 28 pounds, it has a powerful 30-amp high-torque motor and a rugged three-speed gearbox with drilling speeds of 190, 400, or 840 RPM. The PLD 450 B fea-tures soft start and overload protection and has a mechanical slip clutch to pro-tect it in case of jamming. A universal tool holder/slide mount connects the motor to a core drill stand. CS Unitec / csunitec.com

Product Watch

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REMOTE-CONTROLLED FLOOR GRINDERHusqvarnas remote-controlled oor grinder with integrated battery, the PG 820 RC, is easy to transport to and from the jobsite thanks to its long battery life. And thanks to the remote control, the operator is not exposed to the vibrations and sideways forces on the machine and is free to perform other necessary tasks as the machine executes the task. Husqvarna Construction Products / husqvarna.com/us

headlinebody Price: $xxx / COO: xxx /xxx.com

FASTER IMPACT DRIVERDeWalts 20V MaxXR Impact Driver (DCF887) is reportedly 30% faster and backed by more powerful brushless motors and better ergonomics than previous DeWalt models. The 14-inch 3-Speed Impact Driver with its easy-grip drop and load chuck is smaller, at 5.3 inches long, and provides 17% more torque compared with its previous model. At 2.9 pounds with a 2.0Ah 20V Max XR battery, the DCF887 has three speeds that achieve the speed and torque that a pro demands. The 20V Max XR Brushless 14-inch 3-Speed Impact Driver also features PrecisionDrive technology, which allows the impact driver to stall for one second before impacting. This protects the fastener and material surface and provides the user with maximum control during applications. The driver also comes with a dust- and moisture-resistant coated and sealed

tools of the trade 2016 world of concrete special issue

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