Professional strategies for concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it can be still a young but growing industry. Because of a higher 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 may be the constantly rising labour costs. Within the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Given the high labor and overhead costs involved in most sawing and cut to length machine, the speed in which the position is performed is now 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 Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator learning from mistakes only result in waste of time and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, as a way to remain competitive, the contractors are under pressure to embrace more sophisticated types of concrete sawing & drilling.
“The market for floor saws, wall saws and high powered drilling machines happen to be in a nascent stage today but growing at about 40% per year as the expense of labor rises, the application of machines to increase work and increase productivity and quality of work boosts phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines are in operation. Low Powered Handheld 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 can offer 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.
You can find not many organized players within the core cutting arena. Most of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. Like 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, have no post sales support nor are 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 consider poor quality Chinese makes only turn out spending much more about repairs.”
When it comes to manufacturing facilities in India, just about 25% are made indigenously, the others imported along with the bulk coming from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is applying it as a 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 last 5-10 years, the technology has 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 a lot more than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the market size of controlled concrete dismantling in India is near to INR 120 crores. This consists of branded and unbranded market also. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing drilling as much as 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 and its core cutting machines and drills are made in Switzerland, Austria, U.S.A. along with other parts around the world. These machines include a manufacturing warranty of 12 months. Also these are quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides some of the service requirement at site to take care of emergency Breakdowns.
Diabu Machines has recently entered the Indian market. Designed keeping in mind the Indian working conditions along with the Indian operator, Diabu’s floor saws, wall saws and drilling machines are built about the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, long life and maintenance free bearings, dust and water protected motors, bearings and all sliding and rotating parts. Most if not all fasteners are produced from either stainless or rust proof and high tensile steel. Besides being user friendly, maintenance is additionally really easy with very easy to access grease and oil points.
“There can be a significant necessity for education about controlled dismantling like a technology within the construction industry. Other challenges relate to acceptability and adaptability from the technology in several of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics linked to the technology since this is expensive, application with illiterate labor and localized accessibility to the technology.”
Choosing the right blade (for the saw, the content as well as the job) is the most important element in getting maximum performance. Many 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 according to end application requirement and job site requirements. The main concrete cutting tools that happen to be utilized add the wall (or track) saw, the flat (or slab) saw, the core drill, and the wire saw. Wall sawing is normally specified to cut precise dimensional door, vent and window openings. Straight along with bevel cuts are possible using the wall saw. The wall saw is likewise an outstanding choice for creating precise openings in virtually any concrete structure. Flat sawing is generally used to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are generally utilized 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 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 concrete sample analysis. Wire sawing can be used as removing of thick parts of concrete. It is fantastic for removing large sections of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in areas where work area is restricted.
Most of the decision of cutting wet or dry is dependent upon ones preferences and job requirements. While many sawing or drilling is wet, conditions like water scarcity in sites, requirement to hold the website clean water/slurry on account of proximity with existing office/ factory /commercial/residential space, proximity to electrical or another such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it usually is better to use saws which can be laser welded or atleast have special reinforced brazing. Using such blades ensure that the extremely high heat generated during dry cutting does not damage the blade which can also cause injury and cause accidents.”
Besides the sort of cutting and dry or wet cutting, types of concrete also influence the decision in selecting a blade. The duration of curing time after concrete flows greatly affects the way a diamond blade will interact with it during cutting. Curing may be impacted by weather (temperature, moisture and season) along with the composition (admixtures, aggregate and sand). Cured concrete is typically set no less than 2 days. The sand is entirely bonded using the mortar and the concrete reaches full hardness. Concrete is normally in their green state for 6 to 48 hours after it really is poured. Within this early state, the sand is not completely bonded using the mortar and 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 a lot more abrasion on a diamond blade. Undercut protection is vital when cutting green concrete to avoid excessive wear about the steel core at the segment weld. Green concrete sawing is normal when focusing on new construction projects including; motorways, runways, driveways & industrial flooring.
The size and kind of aggregate have got a great impact on the overall hardness of concrete and the blade to decide on. The aggregate can make up as much as 75% in the total volume. On the whole, larger aggregate has a tendency to make your concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is part of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is usually sand. Sand either can be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you need to know where the sand comes from. Crushed sand and bank sand are often sharp; river sand is normally round.
Choice for core drilling operation may also requires knowing the diameter in the final hole required, surface finish from the drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and ease of use may also be essential for choosing the right 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, Transformer 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 a lot of dust. While wet cutting or drilling operation is not going to generate dust as it uses water, the instance of dust is practically totally avoided. However, the slurry generated needs 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 that have single doors or window openings to be remove or in which the saw needs to be constantly moved in one floor to another. Some machines are employed in a modular system thus bringing in certain advantages, as the single component can be easier transported and installed.
When it comes to costs, this equipment is not expensive machines of course, if regularly maintained, the price of maintenance can be kept as little as any machine an annual spend of approximately 6% – 10% of the cost of the machine.
The popularity is clearly lighter, lesser, faster and more profitable. But what comes with this development can be a stronger demand that operators be trained effectively. Also, contractors must be made aware or there must be pros who can recommend the ideal techniques and equipment for the most efficient and cost-effective cutting at any stage in the project.
“On the service front, Prime Technologies features 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 in the daily operation in our company. “Akhil Jain, CEO, Prime Technologies.