Professional ways of concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it is actually still a young but growing industry. Because of an elevated shelling out for infrastructure projects and residential & commercial construction, India holds tremendous potential with regards to diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of these sophisticated methods will be the constantly rising labour costs. In the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and expenses involved with most sawing and cut to length machine, the rate that the task is done is now vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator trial and error only lead to waste of money and time. Today, as a way to remain competitive, the contractors are under pressure to embrace modern-day types of concrete sawing & drilling.
“The industry for floor saws, wall saws and high powered drilling machines happen to be in a nascent stage today but growing at about 40% each year as the fee for labor rises, using machines to increase work and increase productivity and quality of work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines happen to be in operation. Low Powered Handheld Drilling and sawing have been in many thousands which is very difficult to give even an approximate number.” – M.Venkatesh, Executive Director, Diabu Diamond Tools
Professional diamond concrete cutting systems offers significant advantages over conventional concrete removal methods. Included in this are reduced downtime, precision cutting, repair of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
There are actually very few organized players inside the core cutting arena. Most of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. As in any other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell inexpensive, poor machines from China with the objective of making quick money. These machines, however, do not have post sales support nor would be the machines suited and made to are employed in the Indian environment. Mr. Akhil Jain, authorized and exclusive distributor of Husqvarna’s power tools in India says, “Users with low budget prefer to consider low quality Chinese makes but only turn out spending more about repairs.”
With respect to manufacturing facilities in India, no more than 25% are manufactured indigenously, the others imported along with the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is applying it as its manufacturing facility to advance develop and expand the development facility for diamond tools and disks as well as strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Throughout the last 5-10 years, the technologies have matured to some stage where even on residential sites, coring is the preferred technology for fast, vibration-free penetrations. Right now we see the market for coring at a lot more than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the current market size of controlled concrete dismantling in India is near INR 120 crores. Including branded and unbranded market at the same time. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines is capable of doing drilling up to 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven Stack core cutting machine highly suitable for drilling at runways. TYROLIT has 27 Global Production Units and its core cutting machines and drills are created in Switzerland, Austria, U.S.A. along with other parts on the planet. These machines include a manufacturing warranty of one year. Also these are quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides a few of the service requirement at site to manage emergency Breakdowns.
Diabu Machines has entered the Indian market. Designed bearing in mind the Indian working conditions as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are constructed in the platform of robust, rigid and productivity. Diabu uses good quality and right configuration steel, extended life and easy to maintain bearings, dust and water protected motors, bearings and all of sliding and rotating parts. Most if not completely fasteners are made of either stainless steel or rust proof and tensile steel. In addition to being user friendly, maintenance is additionally very simple with simple to access grease and oil points.
“There can be a significant need for education about controlled dismantling as being a technology within the construction industry. Other challenges relate to acceptability and adaptability in the technology in a number of the major projects, drilling and sawing vis-à-vis the standard chisel and hammer, economics of the technology since this is expensive, application with illiterate labor and localized availability of the technology.”
Choosing the right blade (for that saw, the content and the job) is an essential element in getting maximum performance. Various other variables also affect blade performance. Changing any variable may have an effect on cutting speed and blade life.
Concrete cutting becoming an application oriented process, blades are supplied based on end application requirement and job site requirements. The principle concrete cutting tools that happen to be utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is generally specified to cut precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible with the wall saw. The wall saw can also be a fantastic choice for creating precise openings in virtually any concrete structure. Flat sawing is usually utilized to cut horizontal flat surfaces including floors, bridge decks, and pavement. Flat saws are normally used to provide expansion joints, remove damaged pavement sections, clean and repair random cracks dexqpky76 repair, and take off concrete sections for demolition purposes. Core drilling techniques are utilized when precise, circular cuts are important like openings for plumbing, electrical and HVAC installations, creating holes for routing cables or placing anchoring bolts, installing load carrying devices or dowel bars, or even for concrete sample analysis. Wire sawing can be used removal of thick sections of concrete. It is perfect for removing large parts of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in locations where work space is restricted.
Most of the decision of cutting wet or dry depends upon ones preferences and job requirements. Some sawing or drilling is wet, conditions including water scarcity in sites, requirement to maintain the site clean water/slurry on account of proximity with existing office/ factory /commercial/residential space, proximity to electrical or other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is always better to use saws which are laser welded or atleast have special reinforced brazing. Using such blades be sure that the very high heat generated during dry cutting will not damage the blade which can also cause injury and cause accidents.”
Besides the type of cutting and dry or wet cutting, forms of concrete also influence your decision when choosing a blade. The size of curing time after concrete flows greatly affects just how a diamond blade will communicate with it during cutting. Curing can be impacted by weather (temperature, moisture and period) and the composition (admixtures, aggregate and sand). Cured concrete is normally set at least 48 hrs. The sand is completely bonded with the mortar and also the concrete reaches full hardness. Concrete is normally in its green state for 6 to two days after it is actually poured. Within this early state, the sand is not really completely bonded with all the mortar and also the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely in the slurry, and produces much more abrasion on a diamond blade. Undercut protection is vital when cutting green concrete in order to avoid excessive wear on the steel core with the segment weld. Green concrete sawing is normal when taking care of new construction projects including; motorways, runways, driveways & industrial flooring.
Both the size and kind of aggregate have a great effect on the complete hardness of concrete along with the blade to select. The aggregate will make up as much as 75% of the total volume. For the most part, larger aggregate tends to make your concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is area of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is generally sand. Sand either can be sharp (abrasive) or round (non-abrasive). To discover the sharpness of sand, you have to know in which the sand is from. Crushed sand and bank sand tend to be sharp; river sand is normally round.
Selection for core drilling operation will likely requires understanding the diameter from the final hole required, surface finish in the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and ease of use are also required for choosing the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter in the core, entire core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Straight core cutting machine, anchor or vacuum fixation help in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated large amounts of dust. While wet cutting or drilling operation does not generate dust as it uses water, the instance of dust is practically totally avoided. However, the slurry generated has to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Apart from saw speed, the ease of transport and installation is necessary in jobsites which have single doors or window openings being cut out or where the saw needs to be constantly moved in one floor to the next. Some machines work in a modular system thus attracting certain advantages, as the single component could be easier transported and installed.
When it comes to costs, this equipment is not so expensive machines and if regularly maintained, the fee for maintenance might be kept only any machine an annual spend of approximately 6% – 10% of the cost of the machine.
The craze is clearly lighter, lesser, faster and much more profitable. But what comes with this development is actually a stronger demand that operators be trained effectively. Also, contractors should be made aware or there must be experts who can recommend the most effective techniques and equipment for the most efficient and cost-effective cutting at any stage of your project.
“On the service front, Prime Technologies has a band of service engineers who definitely are always roaming and actively engage themselves in providing solutions and technical advice to clients. They are also involved with training the dealers and customers’ maintenance personnel. They perform a crucial role inside the daily operation of our company. “Akhil Jain, CEO, Prime Technologies.