Disc Cutters: Wet Cutting vs Dry Cutting, Which Method to Use?

Whether you’re slicing through reinforced concrete or cutting paving slabs to size, the choice between wet and dry cutting with your Disc Cutter isn’t just about the finish you want to achieve. It’s also about your health and the health of your employees or colleagues if on a work site. 

In this blog, we will explore the differences between wet and dry cutting with your concrete saw, and the importance of dust suppression.

Wet Cutting With a Disc Cutter - the Gold Standard

Wet cutting masonry materials involves a constant stream of water, delivered directly to the blade through an attached hose. This acts as a dust suppressant, catching dust at the source and making it into a slurry before it becomes airborne. 

In the UK, employers must adhere to strict COSHH regulations to ensure the safety of their employees. Airborne dust particles from materials such as concrete can mean harmful exposure to high levels of hazardous respirable crystalline silica (RCS) dust. This is especially important to consider when in enclosed spaces.

Benefits of Wet Cutting With a Disc Cutter

• Dust Suppression: Using water when cutting eliminates up to 90% of airborne crystalline Silica dust.
• Blade Longevity: Water acts as a coolant for the blade, cooling the diamond segments, preventing overheating and warping.
• Cleaner Cuts: The use of water when cutting reduces the friction of the blade on the material, giving a smoother finish.

Wet Cutting is the optimal way to cut concrete, it can come with a few drawbacks, but the benefits to your health and the health of your blade and machine far outweigh these.

Some of the cons to consider include:

• The Slurry: This does require clean-up and disposal however, most worksites will have disposal of materials factored in, and it’s much better than risking health and breathing in potentially hazardous dust.
• Equipment: It requires a water source or a pressurised dust suppression water bottle.
• Potential Electrical Hazard: If using a corded model, you need to ensure that it is in good condition and that you are not cutting directly near an electrical outlet. 

How Dust Suppression Water Bottles Work

If you don’t have the advantage of being near a mains tap, a pressurised dust suppression water bottle is a great solution.

At Evolution, our dust suppression water bottles are available as either a manual hand pump or foot pump. Here’s a quick guide to how they work.

1. Manual Pumping: You pump the handle to build air pressure inside the tank.
2. Delivery: A reinforced hose connects the tank to the disc cutters integrated water kit.
3. The Spray: As the blade spins, water is fed through small nozzles on both sides of the disc.
4. The Result: The water binds to the dust particles, turning them into a heavy slurry that drops to the ground rather than floating into the environment and into your lungs.

Why Dust Matters - The Health Implications

Construction dust isn’t always just messy and annoying to clean up, it can also be dangerous, especially to those in regular contact with it. Cutting concrete, brick or stone produces Respirable Crystalline Silica, known as RCS. 

RCS particles are so small they can reach deep into the lungs. Long-term exposure can lead to Silicosis, a permanent scarring of the lungs, and increases the risks of other diseases.

Dry Cutting - For Speed & Small Jobs

Dry cutting relies on airflow to cool the blade. Typically, it is reserved for short, outdoor tasks where water is unavailable, but it should never be done indoors.

Benefits of Using a Dry Cut Disc Cutter

• Portability: No hoses or heavy water bottles required.
• Instant Use: Good for quick, one-off cuts rather than prolonged use. 

Cons to Consider:

• Health Risks: These are especially prevalent with high usage in enclosed spaces and without wearing the correct PPE as dry cutting with a disc cutter creates clouds of dust.
• Blade Wear: Higher heat and friction on the blade can cause the blade to dull faster.
• Visibility: Dust clouds can quickly obscure the cutting line, losing accuracy and increasing the potential for an accident.

Evolution Disc Cutters - Dust Suppression

The Evolution range features models made for different environments and tasks. Below, we outline the dust suppression features of each model.

What PPE Should Be Worn When Operating a Disc Cutter?

Even with wet cutting, PPE is a non-negotiable to prevent injury and to ensure compliance with UK COSHH (Control of Substances Hazardous to Health) regulations.

Evolution Power Tools Concrete Disc Cutters

At Evolution, our Disc Cutters have been engineered with real-world use at the forefront of the design. We offer models for both dry and wet cutting, depending on the use cases.

All of our machines are either corded electric or cordless battery powered models - no added petrol exhaust fumes here. Our corded models feature either 3m or 4m rubber cables, ensuring you are away from the main electrical outlet if using with water. 

Our award-winning cordless model, the R260DCT-Li, is equipped with two batteries for maximum power, with the capabilities to cut through brick and blocks in one pass. Equipped with a thin kerf EVOMAX blade, it is built for optimum performance. Learn more about this market-leading machine, and see what real tradespeople think in our dedicated blog on challenging the giants of the industry. 

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