Professional ways 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. Due to 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 the sophisticated methods is the constantly rising labour costs. During the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Given the high labor and overhead costs linked to most sawing and cut to length machine, the speed that the work is performed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies on guessing and operator testing only bring about waste of time and money. Today, to be able to remain competitive, the contractors are under pressure to embrace modern-day methods of concrete sawing & drilling.
“The market for floor saws, wall saws and powered drilling machines are in a nascent stage today but growing at about 40% per year as the price of labor rises, using machines to speed up work and increase productivity superiority work increases phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines will be in operation. Low Powered Handheld Drilling and sawing happen to be in many thousands and it is hard 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. These include reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
You will find not many organized players from the core cutting arena. The majority of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. Like in any other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell low priced, inferior machines from China with the aim of making quick money. These machines, however, do not have after sales support nor are the machines suited and designed 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 get poor quality Chinese makes but only end up spending much more on repairs.”
With regards to manufacturing facilities in India, approximately 25% are produced indigenously, the others imported along with the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is employing it its manufacturing facility to increase develop and expand the production facility for diamond tools and disks as well as to strengthen its position within the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past maybe five or ten years, the technology has matured into a stage where even on residential sites, coring will be the preferred technology for fast, vibration-free penetrations. Right now we 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 near INR 120 crores. This can include branded and unbranded market also. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines is capable of doing drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven transformer core cutting machine highly ideal for drilling at runways. TYROLIT has 27 Global Production Units and its core cutting machines and drills are produced in Switzerland, Austria, UsaA. as well as other parts around the globe. These machines feature a manufacturing warranty of twelve months. Also they are quite sturdy machines and require suprisingly low mainte-nance. TYROLIT’s Unique Service Concept provides a number of the service requirement at site to deal with emergency Breakdowns.
Diabu Machines has 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 made around the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, longevity and maintenance free bearings, dust and water protected motors, bearings and all sorts of sliding and rotating parts. Most if not completely fasteners are made from either stainless-steel or rust proof and high tensile steel. Besides being user friendly, maintenance is likewise very simple with very easy to access grease and oil points.
“There can be a significant requirement for education about controlled dismantling being a technology within the construction industry. Other challenges correspond with acceptability and adaptability of your technology in some 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 option of the technology.”
Choosing the right blade (for that saw, the material along with the job) is a vital element in getting maximum performance. Various other variables also affect blade performance. Changing any variable will have an impact 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 include the wall (or track) saw, the flat (or slab) saw, the core drill, along with the wire saw. Wall sawing is normally specified to reduce precise dimensional door, vent and window openings. Straight and also bevel cuts are possible with all the wall saw. The wall saw is also a fantastic choice for creating precise openings in almost any concrete structure. Flat sawing is typically used 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 remove concrete sections for demolition purposes. Core drilling techniques are being used when precise, circular cuts are essential for example 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 as removing of thick sections of concrete. It is ideal for removing large parts of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in areas where work area is fixed.
Usually the decision of cutting wet or dry is determined by ones preferences and job requirements. Some sawing or drilling is wet, conditions such as water scarcity in sites, requirement to keep the internet site 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 wise to use saws that happen to be laser welded or atleast have special reinforced brazing. Using such blades ensure that the extremely high heat generated during dry cutting will not damage the blade which might also cause injury and cause accidents.”
Besides the kind of cutting and dry or wet cutting, kinds of concrete also influence the choice in selecting a blade. The duration of curing time after concrete flows greatly affects how a diamond blade will interact with it during cutting. Curing might be influenced by weather (temperature, moisture and season) and the composition (admixtures, aggregate and sand). Cured concrete is usually set a minimum of 2 days. The sand is totally bonded with the mortar along with the concrete reaches full hardness. Concrete is normally within its green state for 6 to 48 hrs after it can be poured. In this particular early state, the sand is just not completely bonded with all 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 with a diamond blade. Undercut protection is essential when cutting green concrete to stop excessive wear around the steel core at the segment weld. Green concrete sawing is usual when concentrating on new construction projects including; motorways, runways, driveways & industrial flooring.
The size and kind of aggregate use a great effect on the entire hardness of concrete and the blade to select. The aggregate can certainly make up just as much as 75% of your total volume. As a general rule, larger aggregate is likely to make your concrete act harder, slowing drilling process. Smaller aggregates make a blade cut faster. Sand is portion of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is normally sand. Sand may either be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you must know where the sand is produced by. Crushed sand and bank sand tend to be sharp; river sand is often round.
Choice for core drilling operation will even requires understanding the diameter of the final hole required, surface finish in the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and convenience can also be important for selecting the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter of the 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 to use for the project.”
Conventional concrete cutting and drilling methods generated considerable amounts of dust. While wet cutting or drilling operation will not generate dust because it uses water, the instance of dust is practically totally avoided. However, the slurry generated has to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Aside from saw speed, the ease of transport and installation is needed in jobsites which may have single doors or window openings to be remove or in which the saw has to be constantly moved from a floor to the next. Some machines are employed in a modular system thus bringing in certain advantages, as being the single component could be easier transported and installed.
With regards to costs, these machines are not too expensive machines and if regularly maintained, the fee for maintenance can be kept as low as any machine a yearly spend of approximately 6% – 10% of the price tag on the appliance.
The popularity is clearly lighter, lesser, faster and a lot more profitable. But what includes this development is really a stronger demand that operators be trained effectively. Also, contractors should be made aware or there has to be experts who can suggest the best techniques and equipment for the best efficient and expense-effective cutting at any stage of the project.
“On the service front, Prime Technologies carries a band of service engineers who happen to be always roaming and actively engage themselves in providing solutions and technical advice to clients. Also, they are involved in training the dealers and customers’ maintenance personnel. They perform a huge role within the everyday operation of our company. “Akhil Jain, CEO, Prime Technologies.