Anybody use an angle grider with 4-1/2" x 1/4" abrasive wheel to cut electrical wire chases in the ICF foam?

I cut some EPS foam the other day using my 14" chop saw and abrasive blade and was impressed with how easy it was and also the fact that there was no mess - the blade essentially just melted through the foam.  That got me to thinking about using my angle grinder to "melt" a 1/4" wide x 2" deep groove for electrical wiring.  I've read on here and elsewhere that an electric chainsaw is one of the preferred methods for doing this, but I don't have one and from what I understand this makes quite a mess with foam beads everywhere.  I guess I just need to get out and try the angle grinder and see how it does, but just thought I would throw the idea out there while I was thinking about it.

Alan

Electric chainsaw works very well. You may be able to find one a Lowes or HD for around $50.00 or so. I use a chansaw for the grooves and a hot knife for the boxes.

 

Good Luck

Bunt

Arkie, Was there much buildup on the chop saw blade? And no foam bits floating around or clinging to the saw housing? Dave

None at all - it was like it cauterized the foam - completely clean with no mess.

I've since bought a 12" abrasive masonry blade for my compound miter saw and a 6-1/2" blade for my cordless circular saw and intend to try some cuts with those.

I tried the angle grinder on a piece of scrap foam tonight and it cut a groove just fine - melted right through it. The only problem is that a 4-1/2" grinder wheel will only cut ~1" deep, at least on my grinder. It looks like it will take a 7" grinder wheel to cut the necessary 2" deep groove. That either means a larger heavier angle grinder rated for 7" or larger wheels or one of the smaller ones that has variable speed so you can slow it down to match maximum RPM of the 7" grinding wheels.

I use a cheap jig saw. Cut thru the block interlocks for your horizontal chases. It saves time cutting thru the webs and in faster than a hot wire cutter with less mess than a chainsaw.

I should have said, by not cutting thru the webs.

Why not just use a hot knife? They don't make any mess and cost under $100. Jim Hunter Mountain Realty Builders, LLC Asheville, NC

I think it is an interesting idea. Please, let me know how it works. If it works, I think my customers will be happier.

A hot knife is relatively slow when cutting long channels.  Also, if you have any "cream" get in the joints between foam blocks during the pour, this essentially stop a hot knife.