How Diamond Wire Saws Work and Its Uses


It is not widely known, for those who may not be directly involved in the process of, what is a diamond wire saw, how a diamond wire saw works or the applications that would require the expertise of a concrete cutter and their wire saw.

In particular, the use of diamond wire saws in Australia. If you don’t have a background in the mining or construction industry, wire cutting may not be the first thing that comes to mind when organising trades for a project.

And that’s fair enough. We don’t expect you to know everything there is to know about wire cutting, or concrete cutting for that matter, especially since there aren’t many resources on Google that provide an easy 1-stop-shop answer about wire sawing and its applications.

Whether you’re curious about the industry or seeking some quick bite-sized pieces of information on wire sawing/ wire cutting, we’ll guide you from “what is diamond wire saw cutting”, how does it work, why choose diamond wire cutting and the applications it is used for.



What is a diamond wire saw?

Wire saw-HC110-0148
Wire saw-HC110-0148

A diamond wire saw differs from traditional methods of wire cutting, such as the bandsaw which uses saw teeth to cut slab, by utilising an abrasive technique for cutting through material. Why diamond? Because diamond is one of the hardest materials on the planet and is an effective method for cutting through any material that’s softer than diamond, which is practically everything.

The wire used on an industrial wire saw is typically made from a loop of high tensile steel or synthetic rubber (as seen on Husqvarna) that is connected by a mechanical joiner. On the outside, the cable is impregnated with diamond beads and spacers and are coated with an elastomeric compound to help retain the diamond and protect it against corrosion. A wire can consist of one strand or multiple strands braided together to form a single cable.




How does a diamond wire saw work?

Wire saws are most comparable in principle to that of a reciprocating saw or band saw, however, rather than using saw teeth to cut through slab or steel, diamond wire saws utilise abrasion to effectively cut through slab or reinforced steel.

This method can produce a lot of heat and thus there is a need for wire saws to be cooled and lubricated with a constant flow of water, oil or specialised cutting fluids.

View how one of the Husqvarna wire saws work here.



Why use a diamond wire saw?

The reason why most turn to diamond wire cutting is for its ability to cut through just about any material faster and more efficiently than traditional methods of cutting. It produces far less waste when compared to conventional teeth-like blades, which can amount to significant savings especially when cutting expensive materials.

Depending on the type of machine being used, wire sawing is relatively clean, fumeless and quiet, with little to no vibrations, making it suitable for sensitive work environments such as a hospital. It’s also 4 to 5 times faster than conventional cutting methods and requires minimal manpower to operate.


Applications for wire sawing

Diamond wire sawing is an effective concrete cutting method that is ideal for removing large heavily reinforced, thick sections of concrete and other various applications.

  • Demolition projects
  • Dismantling large steel structures e.g. decommissioning mine sites
  • Ideal for cutting thick/reinforced concrete structures: bridges, dams, factory floors, jetties, columns or beams
  • Making angular cuts to vertical and horizontal structures
  • Performing cuts in restricted, confined and sensitive areas
  • Cut through heavy rebar and embedded steel
  • Cut circular openings
  • Extreme applications can include subsea cutting of pipelines, conductors and other various underwater structures


Does your project require diamond wire saw cutting?

If you’re unsure about whether your project needs a wire saw, but you sure as hell know that concrete needs to be cut or removed, don’t try to do it yourself unless you are certified. Contact the professionals at Diamond Cut Concrete today.

With over 25 years of experience in the construction industry, we are able to recommend the best method and machinery to deliver quick and cost-effective concrete cutting and removal services on time and on budget.

Our team of experienced operators use the latest in diamond impregnated cutting technology to effectively cut, alter and remove concrete, brick, steel or asphalt across a wide range of applications.

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