Types of milling machines for concrete: selection rules, application

Grinding

Scope

When constructing a wide range of objects and carrying out various tasks during repairs and finishing, a concrete milling machine is utilized. While using the unit might not be feasible in all circumstances, using a milling machine for processing can help you accomplish tasks much more quickly and efficiently in most cases.

  • In the process of leveling the foundation of a concrete floor
  • In order to reduce the height of the foundation/floor
  • When removing the old layer of flooring or road surface, eliminating the destroyed screed
  • When removing layers of paint and varnish, adhesive coatings
  • To create grooves that would prevent slipping
  • In order to remove significant dirt
  • When removing tiles or linoleum from concrete
  • When increasing the angle of inclination of the concrete surface in the process of creating water drainage systems

Design and operating principle of the machine

An engine, a rotor with protruding cutting elements, a drum with a cutting tool, a welded metal frame with handles, and all of this mounted on a rubber chassis make up the structural components of a concrete milling machine.

  • When the engine starts to rotate, centrifugal force is produced.
  • Thanks to the torque, the cutter blades also rotate, they are thrown out with great force and hit the concrete monolith, which is processed, giving the surface the desired appearance (a layer of the specified size is removed, roughness is created, etc.).d.).
  • Depending on the speed of the drum, the engine power changes, which accordingly affects the thickness of the layer being removed. The speed and type, depth of processing directly depend on the size of the unit, engine power, and the cutters used.

It’s important to comprehend the various varieties of concrete milling machines that are available as well as their unique uses. Every kind of milling machine, including ride-on and walk-behind models, has special features that are appropriate for different project requirements. When choosing the appropriate machine, it’s important to take the job’s size, surface type, and desired finish into account. The right choice guarantees quick and easy removal of concrete, which improves outcomes and expedites project schedules.

Types of equipment

Concrete clamping machines are categorized based on a number of factors. Engine types include gasoline, diesel, and electric. by the characteristics of self-propelled and manual movement, or mobility.

Power, weight, engine speed, breadth and depth of processing, etc., all differ. The tasks, the working environment, and the required functions are taken into consideration when choosing machines with particular specifications. Prior to anything else, you must choose the kind of engine.

Relevant for indoor use, comfortable (no exhaust pollution, no need for a ventilation system), able to process areas 20 to 30 centimeters wide, with processing depths per pass ranging from 3 to 7 millimeters, and in extreme circumstances up to 12. A 220/380 V network is required in order for a milling machine with an electric motor to function.

The most potent milling machines are typically those that are portable and outdoor in use. A layer of five to fifteen millimeters is removed at a time, with the passage’s working width reaching forty centimeters. Only when there is ventilation with a high-quality exhaust gas output is indoor work permitted.

These machines are the biggest and strongest available; they can remove layers up to 20 millimeters deep in a single pass, making them ideal for processing large surfaces and demanding tasks requiring accuracy and speed.

Self-propelled and manual machines

The machine’s motion is also crucial, directly affecting productivity and comfort levels. The milling machine has two options: manual or self-propelled.

Self-propelled units are lightweight and intended for non-serious processing (such as removing old paint, glue, plaster, etc.) and removing a layer no thicker than three millimeters. The machine is useful and applicable to private construction; it doesn’t require any particular knowledge or abilities to operate.

Self-propelled devices can be disk or rotary in shape. A layer of concrete monolith is removed by the lamellas on the drum of rotary milling machines. Depending on the size of the job, there may be one or two rotors (single rope units are appropriate for processing areas up to 450 square meters). In certain models, there are two lamella-equipped drums (arranged one after the other) that each do different tasks in a single pass: the first one handles rough processing, and the second one handles finishing.

Lamellas are affixed to the cross-beam of a disk milling machine and allow for surface processing. Every grinding machine has a dust extractor to collect dust and shield the mechanism and operator.

Choosing equipment

When selecting equipment, it is important to have a clear understanding of its intended use, the location of the work, the tasks that will be performed most frequently and in what quantities, and the type of cutting tool that the unit needs.

– Heavy milling machines are more powerful, while light ones are simpler to use. For the home, up to 3 kg is preferred; for large-scale tasks, a milling mill weighing 5 kg is preferable; professional weighers start at 6.

Concrete cutting tool and its choice

A drum with lamellae is the unit’s working component. The mechanism is composed of four or more axes, lamellas with carbide or diamond segments attached in a specific manner (the cutting tool’s performance characteristics are dependent on the type of diamonds used, their size, the bond’s properties, concentration, etc.). d.), modifying the washers that separate the lamellas. For processing concrete, milling cutters with a metal bond are typically utilized.

Choosing a cutter based on the task and grade of concrete:

  • M200 – several corundum segments
  • M300 – diamond
  • For removing varnish, paint – brushes
  • Rough processing of concrete monolith – bush hammers with carbide needle attachments
  • Processing of irregularities of more than 2 millimeters, processing in the process of removing the bulk coating-lamellas from hard alloys (it is worth considering that the furrows remain up to 4 millimeters deep, so mosaic-grinding machines are used for finish processing)
  • Elimination of cement laitance, minor defects – diamond or corundum segments
  • A trefoil-shaped cutter is a relatively new tool that increases the efficiency of processing
  • For precision work – elements of a stamping form made of special steel
  • Cleaning – brushes made of steel or nylon

Processing features

Concrete must fully dry before the surface can be milled. A construction vacuum that can guarantee dust removal is a good idea. The object is cleaned before work is done, first in a direction parallel to the wall and then smoothly in the opposite direction. If the concrete contains reinforcement, it is not allowed to be worked on.

Cost of equipment and work performed

The most widely used nowadays are milling machines with gasoline and electricity-powered engines, both at large-scale construction sites in Moscow and at private facilities.

Although there are many manufacturers to choose from, the Grost and Latokho RM units are the most well-known. MASALTA also manufactures machines that are in high demand. The most well-liked models in the middle segment range in price from 86 to 116 thousand dollars.

The cost of milling work varies depending on a number of factors, including the thickness of the removed layer, the price of components and equipment, and the state of the concrete monolith. Notching concrete costs 250 rubles per square meter, while milling M300 concrete to a thickness of 10 millimeters costs 600 rubles per square meter.

Type of Milling Machine Application and Selection Rules
Handheld Concrete Milling Machine Best for small jobs and tight spaces. Choose one with adjustable depth and easy handling.
Walk-Behind Concrete Milling Machine Ideal for larger areas. Look for models with adjustable speed and dust control features.
Ride-On Concrete Milling Machine Used for extensive surfaces. Ensure it has high power and precision control for even milling.
Vertical Concrete Milling Machine Perfect for vertical surfaces like walls. Select a model with strong suction to keep the work area clean.

Selecting the appropriate concrete milling machine is essential to guarantee project success. Knowing the various varieties—such as planetary, drum, and single-disc machines—will help you choose the one that best suits your requirements. Because every type has different features and uses, it’s critical to match the machine to the needs of the task.

When choosing a milling machine, take into account variables like the project’s size, the kind of surface, and the desired finish. Drum machines offer speed and efficiency for larger spaces. Planetary or single-disc machines provide control and precision for finer work. You can make an informed choice that maximizes time and resources by evaluating these factors.

Recall that the longevity and steady performance of the milling machine are guaranteed by appropriate handling and maintenance. Important procedures include keeping the machine clean, checking for wear and tear on a regular basis, and adhering to manufacturer instructions. Devoting time to these areas not only prolongs the life of the machine but also ensures the excellence of your concrete surfaces.

In summary, better project outcomes result from an understanding of concrete milling machine types and their particular applications. You can produce excellent results quickly by taking into account the needs of the project and taking good care of the equipment. Choosing and maintaining equipment wisely is a necessary step for concrete milling projects to be successful.

Video on the topic

Types of milling machines for metal. Which milling machine to choose

Milling cutting technology on CNC machines. Part 1. Machine tools and milling cutters

Types of milling cutters and milling operations

Which aspect of concrete application are you most interested in?
Share to friends
Dmitry Sokolov

Chief engineer in a large construction company. I have extensive experience in managing construction projects and implementing modern technologies.

Rate author
StroyComfort1.com
Add a comment