Professional methods 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. As a result 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 those sophisticated methods is the constantly rising labour costs. In the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Given the high labor and expenses involved with most sawing and Core cutting machine, the speed which the work is performed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator learning from mistakes only result in waste of time and money. Today, so that you can remain competitive, the contractors are under pressure to embrace modern-day strategies for concrete sawing & drilling.
“The niche for floor saws, wall saws and powered drilling machines will be in a nascent stage today but growing at about 40% yearly as the expense of labor rises, the application of machines to quicken work and increase productivity superiority work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines will be in operation. Low Powered Hand Held Drilling and sawing happen to be in many thousands which is 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, repair of structural integrity, reduced noise, dust and debris, limited-access cutting, and the opportunity to cut heavily-reinforced concrete.
There are actually hardly any organized players from the core cutting arena. Most of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. As with any other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell low cost, inferior machines from China with the objective of making quick money. These appliances, however, do not have post sales support nor would be the machines suited and made to operate 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 go for low quality Chinese makes but only turn out spending more about repairs.”
Regarding manufacturing facilities in India, approximately 25% are produced indigenously, the rest imported as well as the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is utilizing it as a its manufacturing facility to help develop and expand the production facility for diamond tools and disks as well as strengthen its position within the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. During the last five to ten years, the technologies have matured to your stage where even on residential sites, coring is definitely the preferred technology for fast, vibration-free penetrations. We currently see the marketplace 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 dimensions of controlled concrete dismantling in India is near INR 120 crores. This includes branded and unbranded market at the same time. TYROLIT has a wide array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling around 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven EI core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are produced in Switzerland, Austria, UsaA. along with other parts on the planet. These machines come with a manufacturing warranty of 12 months. Also these are typically quite sturdy machines and require suprisingly low mainte-nance. TYROLIT’s Unique Service Concept provides a few of the service requirement at site to deal with emergency Breakdowns.
Diabu Machines has recently entered the Indian market. Designed bearing in mind the Indian working conditions and also the Indian operator, Diabu’s floor saws, wall saws and drilling machines are designed on the platform of robust, rigid and productivity. Diabu uses excellent and right configuration steel, extended life and maintenance free bearings, dust and water protected motors, bearings and all sliding and rotating parts. Most if not all fasteners are made of either stainless-steel or rust proof and high tensile steel. Aside from being easy to use, maintenance is also really easy with easy to access grease and oil points.
“There is actually a significant requirement for education about controlled dismantling like a technology in the construction industry. Other challenges relate with acceptability and adaptability of your technology in a few of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics related to the technology as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Selecting the right blade (for the saw, the material and also 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 as an application oriented process, blades are supplied depending on end application requirement and job site requirements. The key concrete cutting tools which are utilized add the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is generally specified to reduce precise dimensional door, vent and window openings. Straight and also bevel cuts are possible together with the wall saw. The wall saw can also be a great choice for creating precise openings in any concrete structure. Flat sawing is normally employed to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are typically used to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and remove concrete sections for demolition purposes. Core drilling techniques are employed when precise, circular cuts are needed such as 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 removing of thick sections of concrete. It is perfect for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in areas where work area is restricted.
Frequently the decision of cutting wet or dry is dependent upon ones preferences and job requirements. Some sawing or drilling is wet, conditions like water scarcity in sites, requirement to keep the web page clean of water/slurry because 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 will always be wise to use saws that happen to be laser welded or atleast have special reinforced brazing. Using such blades ensure that the very high heat generated during dry cutting is not going to damage the blade which might also cause injury and cause accidents.”
In addition to the type of cutting and dry or wet cutting, forms of concrete also influence your decision in selecting a blade. The size of curing time after concrete is poured greatly affects the way a diamond blade will interact with it during cutting. Curing might be impacted by weather (temperature, moisture and time of the year) and the composition (admixtures, aggregate and sand). Cured concrete is typically set no less than 2 days. The sand is utterly bonded with all the mortar and the concrete reaches full hardness. Concrete is generally in the green state for 6 to two days after it really is poured. In this particular early state, the sand is not completely bonded together with the mortar as well as the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely within the slurry, and produces far more abrasion on the diamond blade. Undercut protection is essential when cutting green concrete to prevent excessive wear in the steel core on the segment weld. Green concrete sawing is usual when taking care of new construction projects including; motorways, runways, driveways & industrial flooring.
Both size and type of aggregate use a great impact on the general hardness of concrete as well as the blade to choose. The aggregate can certainly make up just as much as 75% of your total volume. For the most part, larger aggregate tends to make your 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 generally sand. Sand either can be sharp (abrasive) or round (non-abrasive). To determine the sharpness of sand, you should know where sand comes from. Crushed sand and bank sand tend to be sharp; river sand is usually round.
Choice for core drilling operation will even requires understanding the diameter from the final hole required, surface finish of the drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and ease of use will also be important for choosing the proper 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, Straight core cutting machine, anchor or vacuum fixation assistance in deciding which concrete core cutter to use for the project.”
Conventional concrete cutting and drilling methods generated considerable amounts of dust. While wet cutting or drilling operation does not generate dust as it uses water, the instance of dust is almost totally avoided. However, the slurry generated needs to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
In addition to saw speed, the simplicity of transport and installation is needed in jobsites which have single doors or window openings to get remove or the location where the saw has to be constantly moved from one floor to another. Some machines operate in a modular system thus attracting certain advantages, as the single component might be easier transported and installed.
With respect to costs, these machines are not very expensive machines and when regularly maintained, the cost of maintenance might be kept as little as any machine a yearly spend around 6% – 10% of the cost of the device.
The trend is clearly lighter, lesser, faster and more profitable. But what comes along with this development is a stronger demand that operators be trained effectively. Also, contractors should be made aware or there ought to be professionals who can suggest the most effective techniques and equipment for the best efficient and price-effective cutting at any stage from the 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. Also, they are associated with training the dealers and customers’ maintenance personnel. They perform an important role inside the everyday operation of the company. “Akhil Jain, CEO, Prime Technologies.