Professional ways 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 an increased shelling out for infrastructure projects and residential & commercial construction, India holds tremendous potential when it comes to diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of the sophisticated methods is definitely the constantly rising labour costs. In the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Because of the high labor and overhead costs associated with most sawing and cut to length machine, the speed in which the job is done is becoming vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator experimentation only cause waste of time and money. Today, in order to remain competitive, the contractors are under pressure to embrace modern-day methods of concrete sawing & drilling.
“The industry for floor saws, wall saws and powered drilling machines will be in a nascent stage today but growing at about 40% each year as the expense of labor rises, the use of machines to quicken work and increase productivity and quality of work increases phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines are in operation. Low Powered Handheld Drilling and sawing happen to be in many thousands in fact it is tough to give even an approximate number.” – M.Venkatesh, Executive Director, Diabu Diamond Tools
Professional diamond concrete cutting systems can provide significant advantages over conventional concrete removal methods. These include reduced downtime, precision cutting, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the capability to cut heavily-reinforced concrete.
There are not many organized players from the core cutting arena. Many of them are extensions of worldwide manufacturers including Hilti, TYROLIT, Husqvarna and Diabu. As with some other industry, the market 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 machines, however, have no post sales support nor would be the machines suited and built to function 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 choose inferior Chinese makes only turn out spending more about repairs.”
Regarding manufacturing facilities in India, no more than 25% are produced indigenously, the others imported and the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is applying it as being its manufacturing facility to advance develop and expand the development facility for diamond tools and disks and to strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past 5-10 years, the technologies have matured into a stage where even on residential sites, coring is definitely the preferred technology for fast, vibration-free penetrations. We currently see the market 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 current market size of controlled concrete dismantling in India is in close proximity to INR 120 crores. This can include branded and unbranded market at the same time. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling as much as 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is a self-propelled gasoline driven Stack core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units and its core cutting machines and drills are created in Switzerland, Austria, UsaA. along with other parts on the planet. These machines feature a manufacturing warranty of one year. Also these are generally quite sturdy machines and require suprisingly low mainte-nance. TYROLIT’s Unique Service Concept provides a number of the service requirement at site to manage emergency Breakdowns.
Diabu Machines recently entered the Indian market. Designed keeping in mind the Indian working conditions as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are built on the platform of robust, rigid and productivity. Diabu uses excellent and right configuration steel, longevity and maintenance free bearings, dust and water protected motors, bearings and all sliding and rotating parts. Most if not completely fasteners are produced from either stainless or rust proof and high tensile steel. Besides being simple to use, maintenance is likewise very easy with simple to access grease and oil points.
“There can be a significant necessity for education about controlled dismantling as a technology inside the construction industry. Other challenges relate with acceptability and adaptability in the technology in a number of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics linked to the technology as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Choosing the proper blade (for that saw, the information along with the job) is a vital factor 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 being an application oriented process, blades are supplied according to end application requirement and job site requirements. The main concrete cutting tools which can be utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, as well as the wire saw. Wall sawing is usually specified to cut precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible together with the wall saw. The wall saw can also be an excellent option for creating precise openings in every concrete structure. Flat sawing is generally accustomed to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are usually used to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and take away 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 perhaps for concrete sample analysis. Wire sawing can be used removing of thick parts of concrete. It is great for removing large sections of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in locations where work area is fixed.
Usually the decision of cutting wet or dry is dependent upon ones preferences and job requirements. While most sawing or drilling is wet, conditions including water scarcity in sites, requirement to hold the website clean water/slurry because of proximity with existing office/ factory /commercial/residential space, proximity to electrical or some other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is always advisable to use saws which are laser welded or atleast have special reinforced brazing. Using such blades ensure that the extremely high heat generated during dry cutting fails to damage the blade which may also cause injury and cause accidents.”
Apart from the sort of cutting and dry or wet cutting, forms of concrete also influence the decision in choosing a blade. The duration of curing time after concrete flows greatly affects how a diamond blade will communicate with it during cutting. Curing could be influenced by weather (temperature, moisture and period) and the composition (admixtures, aggregate and sand). Cured concrete is usually set at the very least 2 days. The sand is completely bonded with all the mortar as well as the concrete reaches full hardness. Concrete is generally within its green state for 6 to 48 hrs after it really is poured. Within this early state, the sand is not completely bonded using 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 far more abrasion on a diamond blade. Undercut protection is crucial when cutting green concrete to stop excessive wear on the steel core at the segment weld. Green concrete sawing is usual when working on new construction projects including; motorways, runways, driveways & industrial flooring.
The size and type of aggregate have a great impact on the overall hardness of concrete and the blade to select. The aggregate could make up around 75% of the total volume. For the most part, larger aggregate tends to create the concrete act harder, slowing drilling process. Smaller aggregates make a blade cut faster. Sand is part 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 where the sand is from. Crushed sand and bank sand are generally sharp; river sand is often round.
Selection for core drilling operation will even requires understanding the diameter in the final hole required, surface finish of your drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and simplicity will also be essential for selecting the most appropriate tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter from 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 assistance in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated huge amounts of dust. While wet cutting or drilling operation will not generate dust mainly because it uses water, the instance of dust is almost 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 is needed in jobsites which have single doors or window openings to get cut out or the location where the saw should be constantly moved in one floor to the next. Some machines function in a modular system thus attracting certain advantages, as the single component can be easier transported and installed.
With respect to costs, this equipment is not too expensive machines of course, if regularly maintained, the price of maintenance may be kept only any machine an annual spend of about 6% – 10% of the buying price of the appliance.
The popularity is clearly lighter, lesser, faster and more profitable. But what includes this development is actually a stronger demand that operators be trained effectively. Also, contractors should be made aware or there ought to be pros who can suggest the most effective techniques and equipment for the best efficient and price-effective cutting at any stage of your project.
“On the service front, Prime Technologies has a band of service engineers who 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 the company. “Akhil Jain, CEO, Prime Technologies.