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Porcelain Patio slabs

Hi Everyone, looking for some advice or information if anyone has come across this before.

I am trying to cut a circle out of a 1200 x 600 porcelain patio slab (22mm thick) using a small grinder and porcelain blade but it keeps popping. 

I'm doing the usual cutting at an angle and taking my time not forcing it but i get so far and hear the pop. I have managed to cut the circle out of one and try and clean it up then pop. 

I took one to a specialsit place who cut things by using a water jet and the same thing happened again. 

Never had trouble like this before just wondering if anyone else has had the same issue

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  • onley tip i can offer is use a smooth dimond blade not toothed one water if possable dont cut the full depth in one go do several passes 

    you can get curved blades for cutting bends, curves 

  • PRO

    This solution depends on the diameter is the circle - If big enough i would score round circumference and then cut a cross through the centre of the circle. Then cut out the middle inside that line using straight cuts, so maybe a square or a hex or whatever to remove bulk of material. A lot of the time you remove material by cutting a series of triangles. Then a series of lots of straight cuts very close together out to the cirumference edge. You end up with lots of slivers that you can usually tap loose from the slab and then finally use the blade to grind smooth along circumference line. If the diameter of the hole is on the smaller side you may need to flip the slab over and cut from the back as well to extend the cut lines due to curvature of the blade not allowing you to get as close to the edge as you would like. Hope that helps.

  • PRO

    Drilling the porcelain helps to relieve the in built tension in the porcelain. Drill multiple holes (will kill your drill bits so have plenty on hand) cut out with a grinder then clean up with either diamond flap disc or carefully with diamond cutting disc followed by diamond sanding pad but beware cutting discs can snap without warning if being used for grinding

  • PRO

    Cheers for the advice everyone,

    Tried the drill which cained the bits and a lot of time so scrapped that.

    In the end what i did was mark both sides (top and bottom) Circle was 120mm in diameter scored the top flipped it over scored the bottom, flipped it back over and cut in halfway flipped it over did the same then cut through until i saw a gap.

    I found this relieved some of the tension the blade was causing on the porcelain when cutting. 

    Done 2 only one left to do phew 

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