Common Problems with Rock Breaker Chisels and How to Solve Them

If you are in the construction industry, you may have run into some major issues with your rock breaker chisels. For example, a gradual decline in demolition performance, the chisels losing their sharpness, etc. We know the important role of rock breaker chisels in demolition and excavation projects. They are essential in breaking through concrete, rock, and other tough materials.

Therefore, it is important to understand what truly leads to their declining performance over the period. The most common reason for this can be traced to the overall condition the chisel is in. However, there are several factors that contribute to this problem, which we will discuss in detail in this article and give you proper ways to solve them.

What are Rock Breaker Chisels and What is their Role?

These chisels are specialised tools that are mounted to a hydraulic breaker, which is attached to an excavator. To function, they convert the hydraulic energy into mechanical force. This force allows them to produce fractures on hard surfaces like rock, concrete, and asphalt. The rock breaker chisels are made out of high-grade alloy steel, giving them extreme durability. Furthermore, they have precisely engineered tips to maximise impact force and are available in various shapes such as pointed, flat, moil, and blunt, for different tasks.

These chisels are employed in different construction-related works, such as demolishing concrete foundations or demolishing old buildings. On the other hand, they are also useful for breaking large rocks for mineral extraction. Chisels are also used in quarrying by fragmenting stone into transportable pieces. You can also see them being used in breaking asphalt and concrete for repairs or new construction of roads. But that’s not all, they also come in handy for digging channels in tough ground for trenching purposes. But how do we ensure its long-term durability? Let us find out.

How to Stop Rock Breaker Chisels from Getting Excessive Wear and Blunting?

It is pretty common for rock breaker chisels to become blunt and develop wear, thanks to their heavy workload. In particular, the tip of a chisel is designed to be tough; however, with constant impact and friction, it will inevitably wear down. Thus, down the line, the constant wear finally makes the tip blunt, distributes the force over a wider area of the target material, and in the process reduces its PSI (pounds per square inch) force.

This loss of force often takes place due to an improper angle of attack on the material or even using the chisel on an abrasive material like sand. That’s not all, prolonged use without proper rotation of the chisel can also accelerate the blunting. Moreover, using a chisel on a much harder material than it is rated for can also cause premature wear. So, what should one do or rather avoid, to put a stop to the accelerated wear of the chisel?

Well, to begin with, you can simply resharpen the chisel that will restore the lost tip sharpness and gain the concentrated breaking force. The sharpening process involves a grinding wheel with ample coolant to prevent overheating. However, if the temperature is not taken care of, it can compromise the steel's temper, which in turn makes the tip brittle and prone to chipping.

After the restoration process, ensure the operator strikes the material precisely at a 90-degree angle to maximise force and minimise side-to-side friction. Also, to avoid any premature wear, ensure the material of the chisel is well-suited for the target material. High-carbon or chromium-molybdenum steel alloys are common and effective. Lastly, regularly rotate the chisel during usage to ensure that even wear takes place across all faces of the tip.

How to Prevent Chipping and Cracking of the Rock Breaker Chisels?

The problem takes place where small pieces are chipped off from the tip of the rock breaker chisels. This breaking of tiny material from the chisel results in reduced effectiveness and even creates a safety hazard from flying shrapnel. But why does it happen? Well, there are two ways this chipping happens: first, a manufacturing fault, where improper heat treatment makes the chisel brittle and prone to cracking. On the other hand, a chisel can also end up brittle during the resharpening process, which we already discussed earlier.

Furthermore, during operations, striking too hard on unyielding materials like reinforced steel rebar at a poor angle can cause stress fractures and chipping. Moreover, using a chisel that is too long or too small for the breaker's power can lead to undue stress. So, how to avoid such problems? To start with, ensure the rock breaker chisels are from a reputable manufacturer. Good manufacturers carry out proper heat treatment and ensure a balance of hardness and toughness.

On the other hand, when you are resharpening the chisels, keep the proper balance of the heat temperature. To avoid overheating, use proper coolants and employ a slow grinding speed. Remember, if the steel turns blue or purple, it's a sign of a compromised temper, making the chisel more prone to chipping. Another practice that creates more cracks in a chisel is using it as a pry bar. Keep in mind that prying places with immense lateral stress on the tool can lead to immediate cracking or bending of the chisel, as it is not designed to withstand that kind of force.

Conclusion

Before we wrap up, here is another thing that you should keep in mind. The "piston end" or "shank" of the rock breaker chisel is the part that fits into the breaker's housing and is struck by the internal piston. Due to a lack of proper lubrication, this housing can deform over time, which causes it to get stuck in the breaker. To prevent this, use a high-quality, high-temperature, copper-based or graphite-based grease that is specifically designed for hydraulic breakers. With all that being said, we hope that these solutions will come in handy for your day-to-day operation and bring the maximum value out of your rock breaker chisels.