Professional ways of concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it really is still a young but growing industry. Because of an elevated spending on infrastructure projects and residential & commercial construction, India holds tremendous potential regarding diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of the sophisticated methods will be the constantly rising labour costs. During the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Due to the high labor and expenses involved in most sawing and cut to length machine, the speed in which the job is carried out has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator experimentation only lead to waste of money and time. Today, in order to remain competitive, the contractors are under pressure to embrace modern-day types of concrete sawing & drilling.
“The niche for floor saws, wall saws and powered drilling machines happen to be in a nascent stage today but growing at about 40% each year as the price of labor rises, the use of machines to speed up work and increase productivity and excellence of work increases phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines will be in operation. Low Powered Handheld Drilling and sawing are in many thousands and is particularly tough 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. Such as reduced downtime, precision cutting, upkeep 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 in the core cutting arena. Many of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. Like some other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell low priced, poor machines from China with the aim of making quick money. These appliances, however, have zero post sales support nor are definitely the machines suited and made to work 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 get inferior Chinese makes only end up spending much more about repairs.”
With respect to manufacturing facilities in India, approximately 25% are manufactured indigenously, the rest imported as well as the bulk coming from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is employing it as its manufacturing facility to help develop and expand the development facility for diamond tools and disks and also to strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the last maybe five or ten years, the technologies have matured to your stage where even on residential sites, coring may be the preferred technology for fast, vibration-free penetrations. Right now we see the marketplace for coring at greater than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the marketplace scale of controlled concrete dismantling in India is near to INR 120 crores. Including branded and unbranded market at the same time. TYROLIT has a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can perform drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven transformer core cutting machine highly ideal for drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are produced in Switzerland, Austria, United statesA. and also other parts on the planet. These appliances include a manufacturing warranty of one year. Also these are typically quite sturdy machines and require extremely low mainte-nance. TYROLIT’s Unique Service Concept provides a number of the service requirement at site to take care of emergency Breakdowns.
Diabu Machines has entered the Indian market. Designed remembering the Indian working conditions and the Indian operator, Diabu’s floor saws, wall saws and drilling machines are made in the platform of robust, rigid and productivity. Diabu uses good quality and right configuration steel, long 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 from either stainless steel or rust proof and tensile steel. Aside from being easy to use, maintenance can also be very easy with very easy to access grease and oil points.
“There is a significant need for education about controlled dismantling as a technology from the construction industry. Other challenges correspond with acceptability and adaptability in the technology in some of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics linked to the technology as this is expensive, application with illiterate labor and localized availability of the technology.”
Choosing the right blade (to the saw, the information along with the job) is the most essential element in getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable may have an impact on cutting speed and blade life.
Concrete cutting becoming an application oriented process, blades are supplied depending on end application requirement and job site requirements. The key concrete cutting tools which can be utilized range from the wall (or track) saw, the flat (or slab) saw, the core drill, as well as the wire saw. Wall sawing is typically specified to slice precise dimensional door, vent and window openings. Straight along with bevel cuts are possible together with the wall saw. The wall saw is additionally an outstanding selection for creating precise openings in every concrete structure. Flat sawing is usually employed to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are generally used to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and take off concrete sections for demolition purposes. Core drilling techniques are used when precise, circular cuts are essential including openings for plumbing, electrical and HVAC installations, creating holes for routing cables or placing anchoring bolts, installing load carrying devices or dowel bars, or for concrete sample analysis. Wire sawing can be used for removal of thick sections of concrete. It is ideal for removing large sections of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in places that work space is fixed.
Often the decision of cutting wet or dry is dependent upon ones preferences and job requirements. Some sawing or drilling is wet, conditions such as water scarcity in sites, requirement to maintain the website clean water/slurry due to 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 usually is wise to use saws which are laser welded or atleast have special reinforced brazing. Using such blades be sure that the extremely high heat generated during dry cutting is not going to damage the blade which could also cause injury and cause accidents.”
Besides the form of cutting and dry or wet cutting, types of concrete also influence the choice in selecting a blade. The length of curing time after concrete flows greatly affects just how a diamond blade will communicate with it during cutting. Curing may be affected by weather (temperature, moisture and time of the year) and the composition (admixtures, aggregate and sand). Cured concrete is typically set at least two days. The sand is utterly bonded with the mortar and also the concrete reaches full hardness. Concrete is usually in the green state for 6 to 2 days after it really is poured. Within this early state, the sand will not be completely bonded with the mortar along with the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely from the slurry, and produces much more abrasion with a diamond blade. Undercut protection is essential when cutting green concrete to prevent excessive wear around the steel core on the segment weld. Green concrete sawing is typical when taking care of new construction projects for example; motorways, runways, driveways & industrial flooring.
The two size and type of aggregate possess a great effect on the entire hardness of concrete along with the blade to pick. The aggregate could make up up to 75% of your total volume. As a general rule, larger aggregate will create the concrete act harder, slowing drilling process. Smaller aggregates make a blade cut faster. Sand is area of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is usually sand. Sand can either be sharp (abrasive) or round (non-abrasive). To look for the sharpness of sand, you should know where the sand is produced by. Crushed sand and bank sand are generally sharp; river sand is generally round.
Choice for core drilling operation will also requires understanding the diameter of your final hole required, surface finish in the drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and simplicity will also be important for selecting the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter of the core, entire core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Silicon steel core cutting machine, anchor or vacuum fixation aid 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 fails to generate dust since it uses water, the instance of dust is nearly totally avoided. However, the slurry generated must be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Apart from saw speed, the simplicity of transport and installation comes into play in jobsites that have single doors or window openings to be cut out or where saw needs to be constantly moved from a floor to another. Some machines function in a modular system thus bringing in certain advantages, as being the single component can be easier transported and installed.
With regards to costs, this equipment is not expensive machines and if regularly maintained, the cost of maintenance could be kept as little as any machine an annual spend of around 6% – 10% of the price tag on the equipment.
The trend is clearly lighter, lesser, faster and more profitable. But what includes this development can be a stronger demand that operators be trained effectively. Also, contractors ought to be made aware or there should be professionals who can recommend the best techniques and equipment for the most efficient and price-effective cutting at any stage of the project.
“On the service front, Prime Technologies includes a band of service engineers who definitely are always roaming and actively engage themselves in providing solutions and technical advice to clients. Also, they are associated with training the dealers and customers’ maintenance personnel. They perform a vital role within the daily operation in our company. “Akhil Jain, CEO, Prime Technologies.