Aerated concrete blocks, due to their high technical characteristics, are widely used both in individual construction and in the construction of commercial and industrial buildings. These products are made with minimal variation in geometric parameters: therefore, the masonry seam is very thin. Reinforcement, which must be done every 3-4 rows of masonry using reinforcing mesh, unjustifiably increases the thickness of the masonry joint, which negatively affects the heat-saving properties of the structure. Therefore, reinforcing bars are placed in grooves, for the manufacture of which you will need a wall chaser for aerated concrete.
You cannot do without such a device when arranging internal hidden electrical wiring, as well as when making grooves for pipelines and laying other communication networks (Internet, television cable, wired telephone, etc.).
Nuances of processing aerated blocks
Typically, the following tools are used for processing aerated concrete:
- chisel with hammer;
- hammer drill with a special attachment;
- grinder with a disc for concrete.
Some of the above will probably be found in every owner’s workshop. But high-quality processing of gas silicate cannot be performed with these tools, since they are not intended for such work. Problems encountered:
Handicraft methods of gating have low productivity. The result is low quality of work performed and a lot of wasted time. Careless handling of a chisel can even result in additional repairs to the wall or its complete restoration.
Self-production
DIY equipment must be reliable, versatile and low cost. High precision manufacturing is not required, but the craftsman must be able to process metal and assemble mechanisms.
Universal manual wall chaser
The tool is simple. Craftsmen only need to have a welding machine at home. Procedure:
The handles are wrapped with electrical tape or a rubber hose is put on them - this makes it more convenient to hold the tool. It is preferable to use a metal plate as the cutting edge because it can be sharpened.
Option with electric motor
The basis of an electric wall chaser is an electric motor, which determines the characteristics of the tool. A grinder is used as the basis for a homemade apparatus.
Assembly order:
A homemade electric wall chaser for gas blocks can be converted back into an angle grinder. The owner will save a significant amount on such a device, since he will actually receive two tools in one.
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Problems of high dust generation are solved by making a casing to which a tube from a vacuum cleaner is attached. This way, almost all the garbage will be removed from the work area and will not cause inconvenience.
The casing is made from a plastic bottle or container. The main condition for creation is that it must have the shape of a semicircle and fit tightly to the plane of the material being processed. The pipe is placed in the upper part of the casing so that dust is absorbed more efficiently.
Device diagram
Wall chasers are available either manually or with an electric motor. The first option is characterized by its simplicity of design, and the electric motor allows processing to be carried out faster, without exerting physical effort.
Hand tool
A manual wall chaser is only suitable for working on gas silicate blocks. Hard material cannot be processed with this device. Components:
- tubular frame;
- 2 welded handles;
- cutting edge made of metal arc (some factory products have a diamond tip).
The design is distinguished by its simplicity, and even an inexperienced craftsman can repeat it independently using improvised means. This will slightly reduce construction costs.
You cannot do without physical strength when working with a manual wall chaser. Procedure:
- Apply markings to the wall in accordance with the project.
- The cutting edge is applied to the beginning of the line.
- With your left hand you take the handle, which is located further from the blade.
- With your right hand, grab the handle near the cutting edge.
- With your right hand you press on the handle, and with your left hand you slowly pull the device along the line.
Electric drive
An electric wall chaser is similar to a grinder in its design and operating principle. Only 2 diamond-coated discs are placed in it, which makes it possible to make the boundaries of the grooves parallel to each other.
Features of the electric drive tool:
- Ability to work with harder materials - brick or concrete.
- Requires diamond blades to operate.
- The width of the groove is adjusted by setting the distance between the discs.
- The depth of the groove depends on the degree of penetration of the disk into the material.
- Possibility of connecting a vacuum cleaner.
- High noise level.
A vacuum cleaner can significantly reduce the amount of dust, but it can’t handle it all. It is difficult to create a high-quality dust extraction system in a homemade product, since high precision is required.
Operating parameters of electric wall chasers:
- ability to adjust furrow width;
- minimum and maximum diameter of installed disks;
- method of adjusting the distance between disks;
- number of revolutions per minute and engine power.
The settings affect performance and ergonomics. When working with an electric wall chaser, craftsmen definitely need protective equipment - gloves, overalls, goggles and a respirator. Otherwise, there is a risk of injury.
Homemade manual wall chaser for large volumes of work
For more serious tasks, it is recommended to make a tool with a more complicated design. Here's what you'll need for this:
The sequence of actions when making a tool is as follows:
By moving the wall chaser back and forth, you can quickly make a groove of the required depth.
For ease of use, you can put bicycle handlebar handles on the handles of the tool. If you don’t have any at hand, you can make a replacement from a piece of rubber hose.
Self-production of an electric wall chaser
At home, you can assemble an electric furrower from an ordinary grinder yourself. But, as most masters assure, this makes no sense, and here’s why:
1. A wall chaser made from an angle grinder has low productivity and, in addition, all the disadvantages of a factory device, such as a high noise level and dust generation during the cutting process of the block.
2. To use a homemade tool, you need a powerful industrial vacuum cleaner, otherwise the work will be completely ineffective.
3. If it is not possible to mount two cutting discs on one axis of the angle grinder, cutting each groove will have to be carried out in several stages, and this will increase the working time and the amount of dust.
4. A wall chaser made from an angle grinder does not allow you to accurately adjust the width between the discs, so the result may be of poor quality.
5. Self-assembled devices can be dangerous, because when assembling them, people often do not read the manual or instructions for the wall chaser, and even less often, follow the safety rules.
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Thus, if large-scale work is not planned, it is better to use a simple tool. But it must be remembered that it can only be used to process aerated concrete; a block with a denser structure will be beyond its capabilities.
Assembling the furrow machine takes place in two stages:
- The first cutting disc is installed in the usual way and carefully tightened with a fastening nut.
- The second disk is installed on top of the first and is also tightly tightened with a nut.
The casing can be made from different materials: an unnecessary plastic container or bottle, or from a metal sheet. The main thing is that when creating it, do not forget to make a tube for connecting an industrial vacuum cleaner.
The nozzle should be tightly connected to the vacuum cleaner hose and located in the upper part of the casing so that all dust from the working area is immediately sucked inside.
Not long ago, a furrow cutter appeared on sale in appearance and principle of operation, reminiscent of a hand saw, but with an oval-shaped working attachment at the end. Such a tool quickly and easily makes grooves in the surface, especially if the aerated concrete is completely fresh.
We create a wall chaser with our own hands - cheap and effective
This tool is very good, but it is not profitable to buy it specifically for one-time use, because its cost is quite high... In such cases, you can create everything yourself, using an angle grinder and a vacuum cleaner. All that remains is to figure out how to make a wall chaser with your own hands. Initially, you need to prepare the appropriate elements, and this is an angle grinder, a couple of disks, several nuts, something like a safety casing and, of course, a vacuum cleaner mechanism. First, the discs are taken and attached to the grinder.
One disk is fastened in the usual way, and the second must be mounted using a special nut with a ring; this is a kind of fixation, extremely reliable, it will not allow the fastener to unwind. Next, another nut is taken and a second disk is attached to it, which is located on the original nut from the grinder. It is advisable that the angle grinder already has a safety cover. It will direct all the dust in the opposite direction from the working person.
If there is no casing, then you will have to find some kind of plastic material and make a simple protection yourself
Then the vacuum cleaner mechanism is secured with clamps, but in such a way that the operation of the disks is not disrupted; by the way, it is important to meet one more condition here - that the motor from the vacuum cleaner is held securely. At this point the homemade furrow maker can be considered complete
Tool for cutting aerated concrete
Making a manual wall chaser
The working part of a manual wall chaser is a scraper, for the manufacture of which you can use a water pipe or strip.
The diameter of the pipe must correspond to the width of the groove. A piece 100-120 mm long is cut from it, one edge of which is cut at an angle of 45°. The resulting scraper is welded to the handle at an angle of 30-40° to ensure the optimal angle when pulling the tool.
Manufacturing an electric wall chaser
Modifications can be done by extending the existing casing or making a new one using its template. The material for both options is sheet metal 1-2 mm thick, from which the walls of the casing are cut and welded.
How to prevent dust from spreading
When you decide to do the repairs yourself, it is important to make sure that dust does not get into other rooms. The most accessible way is to generously wet the working surface with water.
You can use a home vacuum cleaner to catch fine dust.
The following steps will help reduce the spread of dust:
- Floor protection. They are covered with construction film. When the work on installing the grooves is completed, it can be carefully rolled up and taken out of the room.
- Before starting work, it is necessary to close the entrance to the room where repair work will take place. The opening can be protected with a special industrial curtain or covered with a damp cloth.
- Before entering you need to put a damp cloth, then the dirt will not spread throughout the room.
After repairs, you need to do some cleaning. After the grooves are completely made, they should be cleaned. Dust can be swept away with a broom, and then passed through the channels with a vacuum cleaner. Before laying the electrical wire, the channel is primed. Then the cable is placed in it and carefully secured. The surface is sealed with plaster or plaster.
A wall chaser differs from a grinder in that the material is cut using 2 diamond wheels. They are insulated with a casing that covers the point of contact with the surface. Increasing or decreasing the degree of overlap makes it possible to make furrows of different depths.
The suction pipe of an industrial vacuum cleaner can be installed in a special outlet, which is made in a casing. As a result, the cuts and the bottom of the channel are smooth. The electrical cable will not be damaged during installation.
Types of wall chasers for aerated concrete
Aerated concrete belongs to cellular concrete, its density is 4–5 times less than that of ordinary concrete. Therefore, for its processing and gating, you can use not very powerful tools (and even manual ones with success).
- Hand-held devices designed for making grooves on horizontal surfaces. They have a shorter and curved handle and are designed for cutting grooves for laying reinforcing rods.
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- Products designed for cutting grooves on vertical wall surfaces. These devices have a longer and straighter handle.
On a note! The division of manual wall chasers is very arbitrary; everyone chooses their own convenient tool to use.
Both types of manual wall chasers have common advantages:
Design and operating principle
Wall chasers come in several types: manual and electric.
Manual
Hand tools usually have a curved or simply straight handle. The wall chaser with a straight handle has two convenient holders, which are necessary for cutting straight and even grooves on vertical walls.
The curved handle furrower also has two convenient holders, but it also has a double-sided cutter, tightened with a bolt. This hand tool is used to create grooves of the required depth and size in horizontal construction surfaces.
Factory-produced manual wall chaser
Electric
This is a powerful tool that has two rubber rollers that help the wall chaser move easily along the wall surface being processed. This furrower is equipped with comfortable handles and several cutters that move thanks to a built-in electric motor. Designed for cutting grooves in various hard building materials.
This is a fairly simple construction tool, but its use requires certain skills and experience from the master. Also, when working with power tools, you should remember to wear personal protective equipment, as they create a lot of construction dust and noise.
Factory-produced electric wall chaser
Homemade manual wall chaser for large volumes of work
For more serious tasks, it is recommended to make a tool with a more complicated design. Here's what you'll need for this:
The sequence of actions when making a tool is as follows:
By moving the wall chaser back and forth, you can quickly make a groove of the required depth.
For ease of use, you can put bicycle handlebar handles on the handles of the tool. If you don’t have any at hand, you can make a replacement from a piece of rubber hose.
