Tuckpointing Grinder with Vacuum Dust Control

A tuckpointing grinder with vacuum dust control is used to remove dust from the air while removing mortar from between bricks.

Description:

Tuckpointing grinders are used to remove the mortar from between bricks prior to repointing with new mortar. Grinding mortar generates a large amount of dust which is likely to contain high levels of crystalline silica and creates a hazard for everyone in the vicinity.  Vacuum dust controls exist for tuckpointing grinders.  A vacuum dust control (or local exhaust ventilation) for a tuckpointing grinder typically consists of a vacuum with a disposable filter (a high efficiency particulate air –HEPA–filter is recommended when practical), and a hose attached, either directly or with an adapter, to a hood or shroud that partially encloses the blade. The vacuum draws air and dust from the blade, the point of dust generation, into the hood where it is transported through the hose into the vacuum's bag or reservoir.

CS Unitec/FLEX F1509FRD 5-inch Tuck-Pointing Machine with Dust Collection

  • Used to remove deteriorated mortar from the bed and head joints on brick or block structures
  • Cost: $643 (with two diamond blades) (verified 11/2009)
  • Power Requirements: 120 volts, 11 amps
  • Maximum blade diameter: 5 inches
  • Cutting depth: adjustable up 1 inch with 5-inch blade,
  • Maximum blade speed: 10,000 RPM
  • Vacuum take-off diameter: 1-1/4 inches
  • Weight: 8 pounds
  • Sound pressure level: Not available but likely to exceed 90 dBA (OSHA’s Permissible Exposure Limit for an 8-hour time-weighted average)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Compatible CS Unitec, Inc. vacuums: CS 1225 and CS 1500
  • Air flow rate: 130 cubic feet per minute
  • Water lift: 98 inches
  • Available bags:
    • Plastic is ideal for concrete dust
    • Paper is ideal for general debris
    • Water permeable is ideal for concrete slurry
  • Power requirements: 120 volts, 11 amps
  • Filtration: standard filter removes 99.93 percent of 3.0 micron particles, HEPA filter can be purchased for $387 (verified 11/2009)
Models
Costs
Dust Capacity, gallons
Vacuum Weight, pounds
CS 1225
$597
6.6
24.3
CS 1500
$775
13
31

  

 
Industrial Contractors Supply (ICS), Inc. Dust Director Shroud
  • Used with a grinder to remove deteriorated mortar from the bed and head joints on brick or block structures
  • Cost: $195 (available for approximately $300 with a Metabo or Makita grinder) (verified 11/2009)
  • Compatible with most Metabo, Rigid, Hitachi, Makita, Bosch and Dewalt grinders (must specify grinder make and model when ordering)
  • Blade diameter: 4 to 6 inches
  • Cutting depth: 1-1/2 inch with 6-inch blade,
  • Blade width: 0.08 - 0.5 inches
  • Vacuum take-off diameter: 2 inches
  • Constructed from light weight aluminum
  • Sound pressure level: Not available but likely to exceed 90 dBA (OSHA’s Permissible Exposure Limit for an 8-hour time-weighted average)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Industrial Contractors Supplies, Inc. vacuums
  • Maximum static pressure: 97 inches of water
Model
Costs
Air Flow Rate, cubic feet per minute
Dust Capacity, pounds
Vacuum Power Requirements
Sound Pressure Level, dBA
Kut-N-Go
$520
136
40
120 volts, 8.5 amps
67
DC-1-MOTOR
$600
136
60
120 volts, 8.5 amps
67
DC-2-MOTOR
$880
271
120
120 volts, 17.5 amps
78
DC-3-MOTOR
$1,170
407
120
120 volts, 19.5 amps
79

(verified 10/2009)

  

 
Industrial Contractors Supplies, Inc. 30 Gallon HD Poly Cyclone Separator
  • Cyclonic separator that can be connected to ICS DC-2-MOTOR or DC-3-MOTOR vacuums to remove larger particles and increase the time between changing vacuum bags and filters.
  • Cost: $550 (verified 11/2009)
  • Dust capacity: 140 pounds
 
Dustless Technologies CutBuddie Dust Director
  • Used with a grinder for dust collection during tuckpointing, crack chasing and decorative cutting
  • Cost: $102 (verified 11/2009)
  • 5-inch CutBuddie fits most 4 and 5 inch hand grinders, 7-inch CutBuddie fits most 6 to 9 inch grinders
  • Cutting depth: 1-1/2 inch with 6-inch blade,
  • Vacuum take-off diameter: 2 inches
  • Constructed from light weight, see-thru, polycarbonate plastic
  • Sound pressure level: Not available but likely to exceed 90 dBA (OSHA’s Permissible Exposure Limit for an 8-hour time-weighted average)
 
 
 
Bosch 5-inch Tuckpoint Grinder with Dust Extraction Port
  • Used with a grinder to remove deteriorated mortar from the bed and head joints on brick or block structures
  • Cost: $280 (verified 2/2011)
  • Power requirements: 120 volts, 8.5 amps
  • Blade diameter: 4 to 6 inches
  • Cutting depth: 1-1/2 inch with 5-inch blade
  • Maximum blade speed: 11,000 RPM
  • Vacuum take-off diameter: 1.38 inches (35 millimeters)
  • Weight: 6 pounds
  • Sound pressure level: 89 dBA (OSHA’s Permissible Exposure Limit for an 8-hour time-weighted average is 90 dBA)
 

     

 

 

 

 

 

 

 

 

Bosch Airsweep™ Wet/Dry Vacuum

  • Cost: $530 (verified 11/2009)
  • Air flow rate: 130 cubic feet per minute
  • Water lift: 100 inches
  • Hose diameter: 1.38 inches (35 millimeters)
  • Power requirements: 120 volts, 11 amps
  • Weight: 42 pounds
  • Filtration: standard set of two filters remove 99.93 percent of 3.0 micron particles, a set of HEPA filters can be purchased for approximately $200
  • Sounds pressure level: 69 dBA
 

 
Pullman-Ermator single phase electric dust extractors
  • Filtration: cyclonic separator, coarse filter and HEPA filter capable of removing 99.97% of 0.3 micron particles (the most penetrating size)
  • Sound pressure level: 75 dBA or less (OSHA’s Permissible Exposure Limit for an 8-hour time-weighted average is 90 dBA)
Models
Costs
Air Flow Rates, cubic feet per minute
Static Pressure, inches of water
Dust Collection
Filter Area (coarse/HEPA), square feet**
Horsepower
Power Requirements
Weight, pounds
S1200
$2,061
118
90
Longopac® bag system*
6.6/9.1
1.7
120 volts, 9.6 amps or 230 volts, 4.4 amps
62
S1300
$1,559
118
90
3.4 gallons
16/9.1
1.7
120 volts, 9.6 amps or 230 volts, 4.4 amps
62
S2400
$2,479
235
90
Longopac® bag system*
11/18.34
3.4
120 volts, 19.2 amps or 230 volts, 8.8 amps
62
S2800
$2,210
235
90
9.8 gallons
11/18
3.5
120 volts, 8.8 amps
99
(verified 11/2009)
* Longopac® bag system uses a 70 foot long plastic tube that is divided and sealed at the desired length
** Greater area allows more time between filter cleaning or replacement
 
 
Pullman-Ermator three phase electric dust extractors
  • Filtration: cyclonic separator, coarse filter and HEPA filter capable of removing 99.97% of 0.3 micron particles
  • Dust collection: Longopac® bag system which uses a 70 foot long plastic tube that is divided and sealed at the desired length
  • Sound pressure level: 75 dBA or less (OSHA’s Permissible Exposure Limit for an 8-hour time-weighted average is 90 dBA)
Models
Costs
Air Flow Rates, cubic feet per minute
Static Pressure, inches of water
Available Hose Diameters, inches
Filter Area (coarse/HEPA), square feet*
Horsepower
Power Requirements
Weight, pounds
T3000
$5,091
153
125
2
23/6.6
4.8
230 volts, 7.5 amps
183
T3500
$7,386
188
125
2 or 3
15.1/26.9
4.8
230 volts, 7.5 amps
313
T7500
$10,603
353
110
2 or 3
24.8/53.8
10.4
230 volts, 24.2 amps
417
T8600
$9,928
353
110
2 or 3
24.8/53.8
10.4
480 volts, 11.9 amps
439
T12600
$14,726
647
110
3
41/108
17.4
480 volts, 21 amps
716
* Greater area allows more time between filter cleaning or replacement (verified 11/2009)
 
 
 
Pullman-Ermator cyclonic pre-separators
  • Removes approximately 90 percent of particulate and can be used with Pullman-Ermator or other dust extractors
  • Dust collection: Longopac® bag system which uses a 70 foot long plastic tube that is divided and sealed at the desired length
Models
Costs
Inlet Diameter, inches
Weight, pounds
C3000
$1,001
2
49
C5500
$1,912
3
130
 (verified 10/2009)

 

Risks Addressed:

 

Silica dust exposure may cause silicosis or lung scarring with prolonged exposure.  Silicosis is an incurable, sometimes fatal, disease.  The NIOSH-recommended exposure limit is 0.05 mg/m3 as a time-weighted average concentration for up to a 10-hour workday during a 40-hour workweek. This is one-half of the OSHA standard when the dust is pure silica, but still twice the ACGIH-recommended threshold limit value of 0.025 mg/m3.  Silica has also been associated with lung cancer and chronic obstructive pulmonary disease (COPD).  Tuckpointing is among the dustiest tasks encountered in construction.  Individual workers may generate upwards of 60 pounds per day of dust.  Exposures can exceed 100 times the NIOSH recommended exposure limit.

 


How Risks are Reduced:

The shrouds partially enclose the blades of the grinders and have a connection for a vacuum system.  When a vacuum system is connected to the shroud, air is drawn into the shroud and past the blade, capturing dust and silica at the point of dust generation.  These systems capture dust and silica near the source, reducing concentrations in the worker's breathing zone and his or her exposure. For continuous use, a respiratory protection program and respirators may be required.  Tuckpointing is among the dustiest tasks encountered in construction.  Individual workers may generate upwards of 60 pounds per day of dust.  Exposure can exceed 100 times the NIOSH recommended exposure limit.  

In evaluations of engineering controls, Meeker et al. and Yasui et al. respectively observed 93 and 98 percent reductions in respirable silica, compared to use of no control, during the use of a Metabo grinder with an ICS Dust Director shroud and vacuum. 

In evaluations of engineering controls, Meeker et al. and Echt et al. respectively observed 91 and 98 percent reductions in respirable silica, compared to use of no control, during the use of a Bosch grinder with a shroud and vacuum. 
 
Personal air sampling results, reported by Nash and Williams, demonstrated a 94 percent reduction in respirable silica, compared to the use of no control, during the use of grinders with dust collection equipment.

Effects on Productivity:

Vacuum dust control systems can have either positive or negative effects on productivity, but definitely improve the quality of the work by capturing large amounts of airborne dust, which allows a cleaner, more efficient means of removing mortar.

Dust capture also reduces site cleanup times.  Dust capture avoids exposing other workers, members of the public, adjacent property, cars and building occupants, which can increase liability and time-consuming disputes.  Improved worker comfort is a result of reduced airborne dust which may in turn result in less fatigue for the worker and greater productivity.  In some cases, particularly where grinder use is intermittent, vacuum dust control may be adequate to reduce the need to wear a respirator, and the need for an employer respiratory protection program. 
 
A study of a ventilated tuckpointing grinder similar to the Bosch system found that the dust removal provided by the vacuum cleaner provided a clearer view of the work surface and reduced time spent on cleanup (Heitbrink and Collingwood 2005). In this study, a contracting firm reported that the use of a tuckpointing grinder dust control system has not affected their rate of work: this firm does not consider it necessary to include in their contract proposals additional time allowances for use of the dust control equipment.    
 
Some additional issues should be considered. Changing vacuum bags takes time, which will depend on the amount of cutting being done and the size of the vacuum bag or hopper. Workers will need to adapt to working with a vacuum hose attached to the tool. Grinder and vacuum energy requirements may exceed the capacity of a single standard 20 amp circuit when combined requiring access to two circuits or special wiring.

Additional Considerations:

Ventilation for construction tools is often misunderstood. There are some key concepts that can help:

  • The vacuum must be located as close to the dust generation as possible to be effective. A shroud may be needed to contain the dust so the vacuum can capture it. The shroud must be kept as close to the work surface as is practical to provide adequate dust capture. The shroud should be connected to the vacuum with 2-inch, or greater, diameter tubing with a relatively smooth interior.
  • The particles that can do the most damage in the lungs are small enough to penetrate the filters found on many shop vacuums. Additionally, some inexpensive shop vacuums pull the dust through the motors, which can destroy the vacuum on really dusty jobs, eliminating any initial cost savings.
  • For dust containing harmful particles like silica, it is important to use as high efficiency filters as practical. The best available are called HEPA (High Efficiency Particle Air) filters because they capture 99.97% of the most penetrating particles. But HEPA filters also create a greater pressure drop and decrease in air flow rate because it is more difficult to pull air through these denser filters so capture velocity may be reduced. They also require pre-filters to extend the life of the HEPA filters, which are more expensive than other filters. Studies have shown that it may be more effective to direct the exhaust air out of the work area than to attempt to add HEPA filtration for a tool where it isn't an integral part already. HEPAs require routine cleaning or disposal of prefilters, which can cause exposures to those performing the filter maintenance.
  • For operations that generate large amounts of dust, cyclonic collection units, if available, may be the best solution. Rather than require more expensive filters and bags that must be frequently changed, cyclonic units spin the particles and drop them into cheap bags that need to be replaced far less frequently because loading of the bags does not cause a pressure drop.
  • Vacuum performance must be monitored on a regular basis. A vacuum with a pressure gauge allows for frequent and easy monitoring of air flow. For high dust generating tasks, dust caked on the filter may reduce flow to a level where it no longer provides adequate dust capture. Automatic and manual filter shakers, coarse pre-filters and cyclonic collections units are available with some vacuums and may help maintain the air flow rate.
Large electric vacuums commonly require 20 amp electrical circuits in addition to the 20 amp circuit used for the electric grinder.  Cords and extensions must be rated for the tool's power requirements, be inspected regularly, replaced when damaged, and used in combination with ground fault interrupt circuits.
 
The use of gasoline-powered equipment poses the risk of carbon monoxide exposure, particularly in areas where airflow is reduced. Steps to control exposure are important because the gas is invisible, odorless and tasteless. Small, inexpensive personal monitors should be worn by the operator to warn of unacceptable exposures.
 
Masonry grinders frequently generate sound levels that are greater than 90 decibels, the OSHA Permissible Exposure Limit (PEL), and can exceed 100dB, and are hazardous. Hearing protection should be worn when using masonry saws unless an industrial hygienist has conducted noise monitoring and indicated that hearing protection is not required.
 
As is the case with any construction equipment, users should follow manufacturer safety recommendations and comply with any applicable local, state or federal regulations.

Hazards Addressed:

Availability

Dustless Technologies CutBuddie Dust Director
To obtain information, visit http://www.dustlesstools.com or contact 1-800-568-3949

NIOSH Workplace Solutions Sheet
The National Institute of Safety and Health (NIOSH) has published a series of “Workplace Solutions”, which are easy-to-understand recommendations from NIOSH research results. Related to this Construction Solution, please find more information on: Control of Hazardous Dust When Grinding Concrete

Industrial Contractors Supply (ICS), Inc. Dust Director Shroud, Vacuums and Cyclone Separator
To obtain information, visit http://www.icscompany.net or contact 1-412-824-6933 trs@icscompany.net

Blastrac 5-inch Tuc-Pointer and vacuums
To obtain information, visit http://www.blastrac.com or contact 1-800-256-3440

Pullman-Ermator dust extractors and pre-separators
To obtain information, visit http://www.pullman-ermator.se or contact 1-800-232-2635 info@pullman-ermator.com

Bosch 5-inch Tuckpoint Grinder with Dust Extraction Port and AirSweep Vacuum
To obtain information, visit http://www.boschtools.com or contact 1-877-262-2499

CS Unitec/FLEX F1509FRD 5-inch Tuck-Pointing Machine and vacuums
contact 1-800-700-5919 info@csunitec.com

Return on Investment

To calculate the return on investment (ROI) for your specific application, please visit our Return on Investment Calculator. While a specific ROI example has not been developed for this particular solution, the ROI Calculator provides a useful tool and guidance on how to generate your own on investment analysis.