Professional methods of concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it is still a young but growing industry. On account of a heightened spending on infrastructure projects and residential & commercial construction, India holds tremendous potential in terms of diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of those sophisticated methods may be the constantly rising labour costs. During the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and overhead costs involved with most sawing and cut to length machine, the pace with which the work is completed has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator trial and error only cause waste of time and money. Today, so that you can remain competitive, the contractors are under pressure to embrace more sophisticated strategies for concrete sawing & drilling.
“The industry for floor saws, wall saws and high powered drilling machines have been in a nascent stage today but growing at about 40% per year as the price of labor rises, the application of machines to speed up work and increase productivity and excellence 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 Hand Held 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.
You can find only a few organized players from the core cutting arena. The majority of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. Like some other industry, the market is flooded with Chinese equipment and fly by night traders who sell affordable, poor quality machines from China with the goal of making quick money. These machines, however, have no 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 find yourself spending much more on repairs.”
Regarding manufacturing facilities in India, only about 25% are created indigenously, the others imported as well as the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is using it its manufacturing facility to advance develop and expand the development facility for diamond tools and disks as well as to strengthen its position in the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. During the last 5-10 years, the technologies have matured to your stage where even on residential sites, coring is the preferred technology for fast, vibration-free penetrations. We currently see the market for coring at more than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the current market measurements of controlled concrete dismantling in India is in close proximity to INR 120 crores. Including branded and unbranded market as well. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing drilling around 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is a self-propelled gasoline driven EI 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, U.S.A. and other parts around the world. These appliances come with a manufacturing warranty of 1 year. Also these are typically quite sturdy machines and require extremely low mainte-nance. TYROLIT’s Unique Service Concept provides several of the service requirement at site to care for emergency Breakdowns.
Diabu Machines has recently entered the Indian market. Designed keeping in mind the Indian working conditions and the Indian operator, Diabu’s floor saws, wall saws and drilling machines are constructed in the platform of robust, rigid and high productivity. Diabu uses high quality and right configuration steel, extended life and maintenance free bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not completely fasteners are made from either steel or rust proof and tensile steel. Besides being easy to use, maintenance is likewise very easy with an easy task to access grease and oil points.
“There is really a significant desire for education about controlled dismantling as a technology within the construction industry. Other challenges connect with acceptability and adaptability of the technology in a few of the major projects, drilling and sawing vis-à-vis the standard chisel and hammer, economics of the technology as this is expensive, application with illiterate labor and localized accessibility to the technology.”
Choosing the right blade (for your saw, the fabric and also the job) is the most essential factor in getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable could have an impact on cutting speed and blade life.
Concrete cutting being an application oriented process, blades are supplied depending on end application requirement and job site requirements. The principle concrete cutting tools which are utilized range from 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 along with bevel cuts are possible with all the wall saw. The wall saw is likewise a fantastic option for creating precise openings in virtually any concrete structure. Flat sawing is typically used to cut horizontal flat surfaces for example floors, bridge decks, and pavement. Flat saws are generally accustomed 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 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 perhaps for concrete sample analysis. Wire sawing can be used for elimination of thick parts of concrete. It is fantastic for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in areas where work space is restricted.
Frequently the decision of cutting wet or dry is dependent upon ones preferences and job requirements. While most sawing or drilling is wet, conditions like water scarcity in sites, requirement to maintain the web page clean of water/slurry as a result of proximity with existing office/ factory /commercial/residential space, proximity to electrical or any other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it will always be preferable to use saws which can be laser welded or atleast have special reinforced brazing. Using such blades be sure that the extremely high heat generated during dry cutting will not damage the blade which can also cause injury and cause accidents.”
Apart from the kind of cutting and dry or wet cutting, varieties of concrete also influence your decision when choosing a blade. The length of curing time after concrete flows greatly affects the way in which a diamond blade will connect to it during cutting. Curing could be afflicted with weather (temperature, moisture and time of the year) and also the composition (admixtures, aggregate and sand). Cured concrete is generally set no less than 48 hours. The sand is totally bonded with the mortar and also the concrete reaches full hardness. Concrete is typically in their green state for 6 to 2 days after it is actually poured. In this early state, the sand is not completely bonded together 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 a lot more abrasion on a diamond blade. Undercut protection is crucial when cutting green concrete to stop excessive wear in the steel core at the segment weld. Green concrete sawing is common when working on new construction projects like; motorways, runways, driveways & industrial flooring.
The size and kind of aggregate have a great impact on the overall hardness of concrete and also the blade to decide on. The aggregate can make up around 75% of the total volume. Typically, larger aggregate is likely to have the 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 ascertain the sharpness of sand, you should know the location where the sand is from. Crushed sand and bank sand are generally sharp; river sand is generally round.
Selection for core drilling operation will likely requires learning the diameter of your final hole required, surface finish of the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and ease of use can also be important for choosing the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter of your 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 help in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated a lot of dust. While wet cutting or drilling operation is not going to generate dust since it uses water, the instance of dust is nearly totally avoided. However, the slurry generated needs to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Aside from saw speed, the simplicity of transport and installation is important in jobsites who have single doors or window openings being cut out or where the saw must be constantly moved in one floor to another. Some machines work in a modular system thus attracting certain advantages, because the single component might be easier transported and installed.
Regarding costs, this equipment is not very expensive machines of course, if regularly maintained, the fee for maintenance might be kept as little as any machine an annual spend of around 6% – 10% of the cost of the equipment.
The craze is clearly lighter, lesser, faster and much more profitable. But what includes this development is a stronger demand that operators be trained effectively. Also, contractors needs to be made aware or there ought to be experts who can suggest 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 happen to be always roaming and actively engage themselves in providing solutions and technical advice to clients. They are also linked to training the dealers and customers’ maintenance personnel. They perform an important role from the day-to-day operation of the company. “Akhil Jain, CEO, Prime Technologies.