Quick Answer

A wall saw cuts precise, square openings in reinforced concrete walls by running a diamond blade along a tracked rail fixed to the wall. The process is: survey and rebar detection, mount the rail, drill a plunge hole, set the blade depth, cut the two vertical sides and one horizontal side (or all four with a plunge cut), then break out the core. Choose a laser-welded wall saw blade sized to the wall thickness and the rebar density, and always drill wet to keep the blade cool.

What Is a Wall Saw and When Do You Need One?

A wall saw (also called a concrete wall saw or track saw) is a hydraulic or electric saw mounted on a rail fixed to a vertical wall. It is used where a floor saw cannot reach: openings in basement walls, elevator shafts, stairwells, and building facades. Unlike a hand-held saw, it can cut to a precise depth and produce a straight, vertical cut that needs no further finishing.

JOY TECH supplies wall saw blades from 800 mm up to 1600 mm diameter, laser welded for reinforced concrete. Browse our diamond saw blades category for the full range.

Step by Step: Cutting a Concrete Wall

• Survey first. Scan the wall with a rebar detector. Locate the steel, conduits, and post-tension cables before any cut.
• Mount the rail. Drill anchor holes, fix the rail perfectly vertical or horizontal, and test the saw carriage along the rail.
• Plunge hole. Core-drill a hole at the corner of the opening large enough to admit the blade. This lets you cut a closed box without a free plunge.
• Set depth. The blade must cut through the full wall thickness with about 10 mm to spare. Pick a blade whose maximum cutting depth equals half its diameter.
• Cut in passes. Do not force the full depth in one pass. Cut in 30-50 mm passes, letting the blade breathe. Keep water flowing.
• Support the core. Once three sides are cut, support the concrete block with a prop or vacuum lift before the final cut, so it does not fall uncontrolled.

Choosing the Right Wall Saw Blade

Wall saw blades are classified by the depth they must reach. As a rule, maximum cutting depth is roughly half the blade diameter:

• 800 mm blade → ~360 mm cut
• 1000 mm blade → ~480 mm cut
• 1200 mm blade → ~600 mm cut
• 1600 mm blade → ~800 mm cut

For walls with heavy rebar, choose a soft bond with higher diamond concentration. For plain concrete, a hard bond lasts longer. More on this in our guide to wall saw blade sizes.

Safety Tips

• Always cut wet. Dry wall sawing creates silica dust and overheats the segments.
• Isolate the slab below the cut; use shoring for anything over 100 kg.
• Check the blade max RPM against your saw before fitting. Never exceed the rated speed.
• Wear hearing protection, face shield, and cut-resistant gloves.

Frequently Asked Questions

Q: How thick a wall can a wall saw cut?

A: Up to about 800 mm with a 1600 mm blade. Beyond that, diamond wire sawing is usually more efficient.

Q: Can a wall saw cut through rebar?

A: Yes, laser-welded wall saw blades cut through both concrete and #4 to #8 rebar without skips, provided the bond is soft enough for steel.

Q: Do I need water for wall sawing?

A: Yes. All professional wall saws are wet-cut systems. Water cools the blade, suppresses silica dust, and washes swarf away.

Q: How long does it take to cut a wall opening?

A: A 1.5 m by 2 m opening in 300 mm reinforced concrete typically takes 2-4 hours for an experienced crew, including setup and rail mounting.

Conclusion

Wall sawing is a controlled, precise way to open up reinforced concrete walls. Success depends on three things: correct blade diameter for the wall thickness, soft bond for the rebar you expect, and a rigid, square rail. If you are sourcing wall saw blades, contact JOY TECH for OEM sizes and bond recommendations based on your local concrete mix. laser-welded concrete and asphalt saw blades