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 spending on 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 such sophisticated methods is 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 linked to most sawing and cut to length machine, the rate in which the work is completed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator testing only cause waste of time and money.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 powered drilling machines happen to be in a nascent stage today but growing at about 40% per annum as the fee for labor rises, the use of machines to accelerate work and increase productivity and quality of work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines will be in operation. Low Powered Hand Held 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 provide significant advantages over conventional concrete removal methods. Such as reduced downtime, precision cutting, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
There are very few organized players inside the core cutting arena. A lot of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. Like in some other industry, the industry 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 appliances, however, have zero after sales support nor are definitely the machines suited and built 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 consider poor quality Chinese makes but only turn out spending much more about repairs.”
Regarding manufacturing facilities in India, just about 25% are made indigenously, others imported along with the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is using it as a its manufacturing facility to advance develop and expand the production facility for diamond tools and disks and also to strengthen its position inside the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Throughout the last 5 to 10 years, the technology has matured into a stage where even on residential sites, coring is definitely the preferred technology for fast, vibration-free penetrations. Right now we see the marketplace for coring at more 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 as well. TYROLIT has a variety of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines is capable of doing drilling as much as 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven transformer 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, U.S.A. and other parts around the world. These appliances have a manufacturing warranty of 1 year. Also they are quite sturdy machines and require really low mainte-nance. TYROLIT’s Unique Service Concept provides a few of the service requirement at site to manage 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 built about the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, extended life and easy to maintain bearings, dust and water protected motors, bearings and all sorts of sliding and rotating parts. Most if not completely fasteners are made of either stainless steel or rust proof and high tensile steel. Aside from being simple to use, maintenance is additionally really easy with very easy to access grease and oil points.
“There is actually a significant necessity for education about controlled dismantling like a technology inside the construction industry. Other challenges relate with acceptability and adaptability in the technology in some of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics associated with the technology because this is expensive, application with illiterate labor and localized accessibility to the technology.”
Selecting the most appropriate blade (for your saw, the fabric and the job) is the most essential element in getting maximum performance. Various 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 main concrete cutting tools that are utilized are 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 and also bevel cuts are possible with the wall saw. The wall saw is likewise a great selection for creating precise openings in every concrete structure. Flat sawing is typically used to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are usually utilized to provide expansion joints, remove damaged pavement sections, clean and repair random cracks dexqpky76 repair, and take off concrete sections for demolition purposes. Core drilling techniques are employed 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 as elimination of thick parts of concrete. It is ideal for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in places that work space is fixed.
Frequently the decision of cutting wet or dry is dependent upon ones preferences and job requirements. While most sawing or drilling is wet, conditions such as water scarcity in sites, requirement to hold the internet site clean of water/slurry on account of proximity with existing office/ factory /commercial/residential space, proximity to electrical or any other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is usually preferable to use saws which can be laser welded or atleast have special reinforced brazing. Using such blades ensure that the very high heat generated during dry cutting is not going to damage the blade which could also cause injury and cause accidents.”
Besides the form of cutting and dry or wet cutting, varieties of concrete also influence the choice in picking a blade. The size of curing time after concrete flows greatly affects just how a diamond blade will communicate with it during cutting. Curing might be afflicted with weather (temperature, moisture and period) and also the composition (admixtures, aggregate and sand). Cured concrete is generally set at the very least two days. The sand is entirely bonded with all the mortar as well as the concrete reaches full hardness. Concrete is usually in their green state for 6 to 2 days after it is poured. In this 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 within the slurry, and produces much more abrasion on the diamond blade. Undercut protection is critical when cutting green concrete to prevent excessive wear on the steel core on the segment weld. Green concrete sawing is typical when taking care of new construction projects like; motorways, runways, driveways & industrial flooring.
Both the size and type of aggregate use a great impact on the overall hardness of concrete and also the blade to decide on. The aggregate can make up just as much as 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 portion of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is usually sand. Sand can either be sharp (abrasive) or round (non-abrasive). To discover the sharpness of sand, you need to know where sand is from. Crushed sand and bank sand are generally sharp; river sand is often round.
Choice for core drilling operation will even 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 convenience may also be necessary for selecting the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter of your 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 help 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 fails to generate dust mainly because it uses water, the instance of dust is virtually 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 necessary in jobsites that have single doors or window openings being cut out 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, this equipment is not very expensive machines and if regularly maintained, the expense of maintenance might be kept as low as any machine an annual spend around 6% – 10% of the buying price of the device.
The buzz is clearly lighter, lesser, faster plus more profitable. But what incorporates this development is really a stronger demand that operators be trained effectively. Also, contractors must be made aware or there has to be experts who can suggest the ideal techniques and equipment for efficient and price-effective cutting at any stage of the project.
“On the service front, Prime Technologies carries 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 crucial role in the everyday operation of our own company. “Akhil Jain, CEO, Prime Technologies.