Professional strategies for concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it is still a young but growing industry. As a result of an elevated spending on infrastructure projects and residential & commercial construction, India holds tremendous potential in terms of diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of the 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. Because of the high labor and expenses linked to most sawing and cut to length machine, the rate that the task is done has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator testing only bring about waste of money and time. Today, to be able to remain competitive, the contractors are under pressure to embrace more sophisticated strategies for concrete sawing & drilling.
“The niche for floor saws, wall saws and powered drilling machines have been in a nascent stage today but growing at about 40% each year as the expense of labor rises, using machines to accelerate work and increase productivity and quality of work boosts phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines happen to be in operation. Low Powered Hand Held Drilling and sawing are in many thousands which is 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, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the cabability to cut heavily-reinforced concrete.
You will find very few organized players in the core cutting arena. The majority of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. As in any other industry, the industry is flooded with Chinese equipment and fly by night traders who sell low cost, poor quality machines from China with the aim of making quick money. These appliances, however, have no post sales support nor are definitely the machines suited and built to function 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 go for poor quality Chinese makes only end up spending more about repairs.”
When it comes to manufacturing facilities in India, only about 25% are made indigenously, the others imported and the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is employing it as its manufacturing facility to help develop and expand the development facility for diamond tools and disks and also to strengthen its position in the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past 5 to 10 years, the technology has matured to some 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 industry dimensions of controlled concrete dismantling in India is close to INR 120 crores. Including branded and unbranded market at the same time. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven Stack core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are produced in Switzerland, Austria, U.S.A. and also other parts around the world. These appliances feature a manufacturing warranty of twelve months. Also these are typically quite sturdy machines and require really low mainte-nance. TYROLIT’s Unique Service Concept provides some of the service requirement at site to deal with emergency Breakdowns.
Diabu Machines has recently entered the Indian market. Designed remembering the Indian working conditions and also the Indian operator, Diabu’s floor saws, wall saws and drilling machines are made around the platform of robust, rigid and high productivity. Diabu uses top quality and right configuration steel, extended life and easy to maintain bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not all fasteners are made from either stainless or rust proof and tensile steel. Aside from being simple to use, maintenance is additionally very easy with very easy to access grease and oil points.
“There is a significant need for education about controlled dismantling like a technology from the construction industry. Other challenges connect with acceptability and adaptability in the technology in several of the major projects, drilling and sawing vis-à-vis the typical chisel and hammer, economics linked to the technology as this is expensive, application with illiterate labor and localized availability of the technology.”
Choosing the right blade (for your saw, the material as well as the job) is a vital element in getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable can have an effect on cutting speed and blade life.
Concrete cutting as an application oriented process, blades are supplied based on end application requirement and job site requirements. The main concrete cutting tools that happen to be utilized range from the wall (or track) saw, the flat (or slab) saw, the core drill, and the wire saw. Wall sawing is typically 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 selection for creating precise openings in virtually any concrete structure. Flat sawing is generally utilized 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 required 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 perhaps for concrete sample analysis. Wire sawing can be used for 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 locations where work area is fixed.
Frequently the decision of cutting wet or dry depends on ones preferences and job requirements. While many sawing or drilling is wet, conditions including water scarcity in sites, requirement to maintain the website clean of water/slurry as a result 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 always preferable 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 is not going to damage the blade which can also cause injury and cause accidents.”
Besides the kind of cutting and dry or wet cutting, types of concrete also influence your decision in selecting a blade. The size of curing time after concrete flows greatly affects the way in which a diamond blade will connect to it during cutting. Curing may be affected by weather (temperature, moisture and season) and also the composition (admixtures, aggregate and sand). Cured concrete is normally set no less than 48 hours. The sand is entirely bonded using the mortar and also the concrete reaches full hardness. Concrete is usually within its green state for 6 to 48 hours after it can be poured. In this early state, the sand is 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 within the slurry, and produces a lot more abrasion on a diamond blade. Undercut protection is critical when cutting green concrete to prevent excessive wear in the steel core in the segment weld. Green concrete sawing is normal when working on new construction projects like; motorways, runways, driveways & industrial flooring.
Both size and type of aggregate possess a great impact on the entire hardness of concrete and also the blade to pick. The aggregate can certainly make up just as much as 75% of your total volume. For the most part, 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 normally sand. Sand either can be sharp (abrasive) or round (non-abrasive). To look for the sharpness of sand, you must know where the sand is from. Crushed sand and bank sand are usually sharp; river sand is generally round.
Selection for core drilling operation may also requires understanding the diameter of your final hole required, surface finish of your drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and ease of use are also important for choosing the proper tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter of your 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 for the project.”
Conventional concrete cutting and drilling methods generated considerable amounts of dust. While wet cutting or drilling operation does not generate dust because it uses water, the instance of dust is almost totally avoided. However, the slurry generated should be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
In addition to saw speed, the ease of transport and installation is needed in jobsites which have single doors or window openings being eliminate or where the saw has to be constantly moved from a single floor to the next. Some machines operate in a modular system thus bringing in certain advantages, as being the single component might be easier transported and installed.
With respect to costs, this equipment is not very expensive machines and if regularly maintained, the expense of maintenance might be kept as little as any machine an annual spend around 6% – 10% of the price of the appliance.
The craze is clearly lighter, lesser, faster and a lot 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 should be pros who can recommend the most effective techniques and equipment for the most efficient and expense-effective cutting at any stage of the project.
“On the service front, Prime Technologies features 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 linked to training the dealers and customers’ maintenance personnel. They perform a vital role from the daily operation of our own company. “Akhil Jain, CEO, Prime Technologies.