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. Due to an increased 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 definitely the constantly rising labour costs. Over 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 Core cutting machine, the rate in which the task is carried out is now vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator learning from mistakes only lead to waste of time and money. Today, to be able to remain competitive, the contractors are under pressure to embrace more sophisticated ways of concrete sawing & drilling.
“The industry for floor saws, wall saws and high powered drilling machines have been in a nascent stage today but growing at about 40% each year as the price of labor rises, using machines to increase work and increase productivity and excellence of work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines have been in operation. Low Powered Hand Held Drilling and sawing have been in many thousands in fact 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. Some examples are reduced downtime, precision cutting, repair of structural integrity, reduced noise, dust and debris, limited-access cutting, and the capability to cut heavily-reinforced concrete.
You will find not many organized players within the core cutting arena. Most of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. As in almost every other industry, the current market is flooded with Chinese equipment and fly by night traders who sell low cost, low quality machines from China with the goal of making quick money. These machines, however, have zero post sales support nor will be the machines suited and created to work 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 only end up spending more on repairs.”
With regards to manufacturing facilities in India, just about 25% are made indigenously, the rest imported as well as the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is using it its manufacturing facility to help develop and expand the development facility for diamond tools and disks and to strengthen its position within the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the last 5 to 10 years, the technology has matured to your stage where even on residential sites, coring is definitely 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 marketplace size of controlled concrete dismantling in India is near INR 120 crores. Including branded and unbranded market too. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling up to 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven Stack core cutting machine highly ideal for drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are created in Switzerland, Austria, UsaA. along with other parts of the world. These appliances have a manufacturing warranty of twelve months. Also these are typically quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides several of the service requirement at site to take care of emergency Breakdowns.
Diabu Machines recently entered the Indian market. Designed remembering the Indian working conditions as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are constructed in the platform of robust, rigid and productivity. Diabu uses high quality and right configuration steel, extended life and maintenance free bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not completely fasteners are made from either stainless or rust proof and high tensile steel. Aside from being simple to use, maintenance can also be really easy with easy to access grease and oil points.
“There can be a significant desire for education about controlled dismantling as a technology inside the construction industry. Other challenges correspond with acceptability and adaptability of the technology in a few of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics of the technology because this is expensive, application with illiterate labor and localized availability of the technology.”
Selecting the most appropriate blade (to the saw, the material as well as the job) is a vital consider 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 becoming an application oriented process, blades are supplied as per end application requirement and job site requirements. The primary concrete cutting tools which can be utilized range from 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 is additionally a fantastic option for creating precise openings in virtually any concrete structure. Flat sawing is usually employed to cut horizontal flat surfaces for example floors, bridge decks, and pavement. Flat saws are normally accustomed 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 important 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 for removal of thick parts of concrete. It is ideal for removing large sections of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in places that work space is fixed.
Most of the decision of cutting wet or dry is determined by ones preferences and job requirements. While most sawing or drilling is wet, conditions for example water scarcity in sites, requirement to help keep the site clean water/slurry due to 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 usually better to use saws which are laser welded or atleast have special reinforced brazing. Using such blades be sure that the very high heat generated during dry cutting does not damage the blade which can also cause injury and cause accidents.”
In addition to the kind of cutting and dry or wet cutting, kinds of concrete also influence the choice when choosing a blade. The duration of curing time after concrete flows greatly affects just how a diamond blade will connect with it during cutting. Curing may be influenced by weather (temperature, moisture and period) and the composition (admixtures, aggregate and sand). Cured concrete is typically set at the very least 48 hours. The sand is completely bonded together with the mortar along with the concrete reaches full hardness. Concrete is usually in its green state for 6 to 2 days after it is actually poured. With this early state, the sand is just not completely bonded using 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 inside the slurry, and produces much more abrasion over a diamond blade. Undercut protection is crucial when cutting green concrete in order to avoid excessive wear on the steel core with the segment weld. Green concrete sawing is typical when concentrating on new construction projects like; motorways, runways, driveways & industrial flooring.
The two size and type of aggregate have got a great effect on the overall hardness of concrete along with the blade to pick. The aggregate could make up around 75% in the total volume. Typically, larger aggregate is likely to have the 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 usually sand. Sand may either be sharp (abrasive) or round (non-abrasive). To discover the sharpness of sand, you need to know the location where the sand is produced by. Crushed sand and bank sand tend to be sharp; river sand is often round.
Selection for core drilling operation will also requires learning the diameter from the final hole required, surface finish of your drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and ease of use can also be necessary for choosing the proper tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter from the core, length of the core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Transformer core cutting machine, anchor or vacuum fixation assist in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated considerable amounts of dust. While wet cutting or drilling operation is not going to generate dust because 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.
Apart from saw speed, the simplicity of transport and installation comes into play in jobsites which have single doors or window openings to become reduce or in which the saw has to be constantly moved in one floor to the next. Some machines work in a modular system thus attracting certain advantages, since the single component might be easier transported and installed.
With regards to costs, this equipment is not expensive machines and when regularly maintained, the fee for maintenance might be kept only any machine an annual spend of about 6% – 10% of the price of the device.
The popularity is clearly lighter, lesser, faster plus more profitable. But what includes this development is really a stronger demand that operators be trained effectively. Also, contractors must be made aware or there ought to be experts who can suggest the ideal techniques and equipment for efficient and cost-effective cutting at any stage from the project.
“On the service front, Prime Technologies features a band of service engineers who 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 day-to-day operation of the company. “Akhil Jain, CEO, Prime Technologies.