Types of Grinding Cutters for Industrial Concrete Floor Grinding Using Grinding Machines and Handheld Tools
Introduction
Industrial concrete floors require high durability, surface integrity, and often a polished appearance, especially in commercial, manufacturing, and logistics facilities.
One of the key processes in achieving such flooring performance is surface grinding, which involves the use of specialized grinding cutters.
These cutters are integrated into floor grinding machines or handheld equipment and are used for leveling, surface preparation, removal of coatings, or polishing concrete substrates.
This article provides a comprehensive overview of the main types of grinding cutters used in the construction and maintenance of industrial concrete floors.
It includes segment-based cutters, PCD (polycrystalline diamond) cutters, bush hammers, and other specialized attachments.
The text also compares applications, advantages, and technical parameters essential for choosing the correct cutter for grinding machines and manual tools.
1. Segmented Diamond Grinding Cutters
Segmented diamond grinding cutters are the most commonly used tools for concrete surface grinding.
They feature diamond-embedded segments brazed or laser-welded onto a metal base.
These segments vary in hardness, size, concentration, and matrix composition, depending on the application.
Types:
-
Single-segment tools – Aggressive removal of high spots and epoxy coatings.
-
Double-segment tools – Balanced grinding performance and longevity.
-
Arrow-segment tools – Fast removal of adhesives, glues, and surface layers.
Applications:
-
Grinding freshly poured concrete slabs
-
Surface leveling
-
Removal of old coatings and adhesives
-
Intermediate polishing stages
Advantages:
-
High grinding speed
-
Wide range of grit sizes (16–120+)
-
Customizable bond hardness for soft, medium, or hard concrete
Compatibility:
Segmented diamond cutters are available in multiple formats (HTC, Lavina, Husqvarna, etc.) for use in walk-behind planetary grinders or rotary machines.
2. PCD Grinding Cutters (Polycrystalline Diamond)
PCD cutters are designed specifically for the aggressive removal of thick surface contaminants such as epoxy, polyurethane, and heavy glue.
They do not grind the concrete but scrape away resilient coatings without excessive wear.
Types:
-
Full-round PCD segments
-
Half-round PCD with sacrificial bar
-
PCD wing cutters for handheld grinders
Applications:
-
Removing two-part epoxy coatings
-
Stripping polyurethane membranes
-
Glue removal after flooring demolition
Advantages:
-
Extremely durable
-
Rapid coating removal
-
Reduced clogging on soft adhesives
Limitations:
-
Not suitable for grinding exposed concrete
-
May leave scratch marks requiring further polishing
3. Turbo Grinding Wheels
Turbo grinding wheels consist of continuous or segmented turbo ridges that allow for fast grinding and excellent heat dissipation.
Commonly mounted on handheld angle grinders or smaller surface machines.
Characteristics:
-
Available in cup wheel or flat wheel forms
-
Typically made of resin or metal-bonded diamond
-
Designed with ventilation holes for dust removal
Applications:
-
Edge grinding and finishing
-
Small area concrete resurfacing
-
Seam blending and spot repairs
Advantages:
-
Portable and lightweight
-
Cost-effective for localized grinding
-
Fast material removal rate
4. Bush Hammer Tools
Bush hammers are multi-pointed impact cutters designed to roughen or texture concrete surfaces.
These tools use rotating rollers studded with tungsten or carbide points.
Applications:
-
Texturing concrete for anti-slip
-
Exposing aggregate
-
Preparing surfaces for overlays or coatings
Cutter Formats:
-
Rotary bush hammer heads for walk-behind machines
-
Handheld bush hammers for corner or stair work
Key Benefits:
-
Uniform surface profiling
-
Compatible with concrete, stone, terrazzo
-
Enhances coating adhesion
5. Metal-Bond Grinding Plates
These plates consist of multiple embedded diamond segments bonded into a metal base, offering long life and consistent cutting performance.
They are used for heavy grinding and surface correction.
Segment Shapes:
-
Rectangular
-
Round (dot segments)
-
Rhombus or arrow-shaped
Grit Sizes:
-
Coarse (16–30 grit) for aggressive removal
-
Medium (40–80 grit) for surface preparation
-
Fine (100+ grit) for finishing
Suitable Machines:
-
Planetary grinders with magnetic plates
-
Compatible with manufacturers like Klindex, Blastrac, etc.
6. Resin-Bond Diamond Tools
Resin-bonded tools are used in the final stages of polishing.
These flexible pads contain synthetic diamond particles in a resin matrix for high-gloss concrete finishing.
Pad Types:
-
Wet polishing pads
-
Dry polishing pads
-
Hybrid (metal-resin) transitional pads
Use Cases:
-
Polishing exposed aggregate floors
-
Achieving satin, semi-gloss, or high-gloss finish
-
Final buffing before sealing
Benefits:
-
Fine scratch removal
-
High-quality finish
-
Available in multiple grit levels (100 to 3000+)
7. Handheld Grinder Cutters
For precision or small-scale work, handheld grinders with specialized attachments are indispensable.
Common Attachments:
-
Cup wheels – Turbo, segmented, continuous rim
-
Edge grinding discs – Designed for hard-to-reach areas
-
Flexible polishing pads – Used on angle grinders with velcro backers
Application Areas:
-
Stairs and corners
-
Wall-to-floor transitions
-
Detail surface preparation
8. Selection Criteria for Grinding Cutters
Choosing the right grinding cutter depends on:
-
Concrete hardness – Use softer bond for hard concrete and harder bond for soft concrete
-
Desired finish – Coarse removal vs. smooth polish
-
Machine type – Planetary grinder vs. single disc vs. handheld
-
Surface condition – New pour, coated, or damaged concrete
9. Tool Maintenance and Lifespan
To maximize grinding tool performance:
-
Regularly clean segments
-
Rotate tool positions on multi-head machines
-
Avoid overheating (cool with water if wet grinding)
-
Store cutters in dry conditions
Average lifespan varies from 500–2000 m² depending on concrete type and pressure applied.
10. Safety Considerations
When working with grinding cutters:
-
Always wear PPE (eye protection, gloves, respirator)
-
Use dust extraction systems to reduce silica exposure
-
Ensure tools are securely fastened to machines
-
Avoid using damaged or worn cutters
Conclusion
Grinding cutters are critical components in the preparation, finishing, and maintenance of industrial concrete floors.
Selecting the appropriate cutter based on material, machine compatibility, and surface requirements ensures efficient operation, reduced labor costs, and enhanced floor performance.
With advancements in cutter design and bonding technology, modern grinding systems offer high precision and long service life, supporting quality flooring solutions across commercial, industrial, and institutional sectors.
