Professional ways of 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. On account of a heightened 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 these 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 in most sawing and Core cutting machine, the speed that the work is carried out is now vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator testing only cause waste of time and money. Today, so that you can remain competitive, the contractors are under pressure to embrace more sophisticated types of concrete sawing & drilling.
“The marketplace for floor saws, wall saws and high powered drilling machines are in a nascent stage today but growing at about 40% per annum as the expense of labor rises, the use of machines to quicken work and increase productivity and quality of work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines have been in operation. Low Powered Hand Held Drilling and sawing will be in many thousands and is particularly very difficult 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. Some examples are reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the capability to cut heavily-reinforced concrete.
There are actually only a few organized players within the core cutting arena. The majority of them are extensions of worldwide manufacturers including Hilti, TYROLIT, Husqvarna and Diabu. As with any other industry, the market is flooded with Chinese equipment and fly by night traders who sell low cost, poor machines from China with the purpose 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 choose low quality Chinese makes but only wind up spending much more on repairs.”
When it comes to manufacturing facilities in India, no more than 25% are manufactured indigenously, others imported and also the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is employing it its manufacturing facility to advance develop and expand the production facility for diamond tools and disks and also to strengthen its position within the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Throughout the last 5-10 years, the technology has matured to a stage where even on residential sites, coring may be the preferred technology for fast, vibration-free penetrations. We currently see the marketplace for coring at over 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the marketplace size of controlled concrete dismantling in India is in close proximity to INR 120 crores. Including branded and unbranded market also. TYROLIT has a wide range 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 Stack core cutting machine highly suited to drilling at runways. TYROLIT has 27 Global Production Units and its particular core cutting machines and drills are manufactured in Switzerland, Austria, UsaA. and also other parts on the planet. These appliances include a manufacturing warranty of 1 year. Also these are generally quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides a few 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 and also the Indian operator, Diabu’s floor saws, wall saws and drilling machines are constructed around the platform of robust, rigid and high productivity. Diabu uses top quality and right configuration steel, extended life and maintenance free bearings, dust and water protected motors, bearings and all sorts of sliding and rotating parts. Most if not all fasteners are made from either stainless or rust proof and tensile steel. Aside from being user-friendly, maintenance is additionally really easy with simple to access grease and oil points.
“There is really a significant desire for education about controlled dismantling being a technology in the construction industry. Other challenges correspond with acceptability and adaptability of the technology in a number of the major projects, drilling and sawing vis-à-vis the standard chisel and hammer, economics related to the technology since this is expensive, application with illiterate labor and localized option of the technology.”
Choosing the right blade (for your saw, the material as well as the job) is the most important aspect in getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable may have an effect on cutting speed and blade life.
Concrete cutting being an application oriented process, blades are supplied based on end application requirement and job site requirements. The key concrete cutting tools that are utilized range from 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 and also bevel cuts are possible using the wall saw. The wall saw is additionally an excellent option for creating precise openings in virtually any concrete structure. Flat sawing is usually used to cut horizontal flat surfaces for example floors, bridge decks, and pavement. Flat saws are typically 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 being used when precise, circular cuts are essential 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 for concrete sample analysis. Wire sawing can be used elimination of thick parts of concrete. It is great for removing large parts of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in places that work area is fixed.
Most of the decision of cutting wet or dry depends on ones preferences and job requirements. Some sawing or drilling is wet, conditions like water scarcity in sites, requirement to help keep the web page 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 is always better to use saws that are laser welded or atleast have special reinforced brazing. Using such blades ensure that the very high heat generated during dry cutting does not damage the blade which may also cause injury and cause accidents.”
Aside from the type of cutting and dry or wet cutting, types of concrete also influence your choice in selecting a blade. The length of curing time after concrete is poured greatly affects just how a diamond blade will connect with it during cutting. Curing can be impacted by weather (temperature, moisture and time of the year) and also the composition (admixtures, aggregate and sand). Cured concrete is generally set a minimum of 2 days. The sand is completely bonded with the mortar along with the concrete reaches full hardness. Concrete is usually in their green state for 6 to 2 days after it really is poured. Within this early state, the sand is not really 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 much more abrasion with a diamond blade. Undercut protection is crucial when cutting green concrete to stop excessive wear about the steel core in the segment weld. Green concrete sawing is typical when working on new construction projects including; motorways, runways, driveways & industrial flooring.
The two size and kind of aggregate possess a great affect on the overall hardness of concrete and the blade to pick. The aggregate can make up just as much as 75% of the total volume. Typically, larger aggregate has a tendency to make 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 normally sand. Sand can either be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you should know in which the sand is produced by. Crushed sand and bank sand are generally sharp; river sand is normally round.
Choice for core drilling operation will even requires knowing the diameter in the final hole required, surface finish of the drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and simplicity will also be important for selecting the most appropriate tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter in the core, length of the 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 to use for the project.”
Conventional concrete cutting and drilling methods generated large amounts of dust. While wet cutting or drilling operation will not generate dust as it uses water, the instance of dust is nearly totally avoided. However, the slurry generated should 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 important in jobsites which may have single doors or window openings to become eliminate or where the saw must be constantly moved in one floor to another. Some machines operate in a modular system thus attracting certain advantages, because the single component may be easier transported and installed.
Regarding costs, these machines are not very expensive machines and in case regularly maintained, the cost of maintenance might be kept as little as any machine an annual spend of approximately 6% – 10% of the cost of the device.
The craze is clearly lighter, lesser, faster and a lot more profitable. But what comes along with this development is actually a stronger demand that operators be trained effectively. Also, contractors must be made aware or there has to be pros who can recommend the very best techniques and equipment for efficient and cost-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 associated with training the dealers and customers’ maintenance personnel. They perform a vital role in the day-to-day operation of the company. “Akhil Jain, CEO, Prime Technologies.