Professional types of concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it is still a young but growing industry. Because of an elevated shelling out for 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 those sophisticated methods is definitely the constantly rising labour costs. In the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Because of the high labor and expenses involved in most sawing and cut to length machine, the rate in which the task is performed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator learning from mistakes only result in waste of money and time. Today, as a way to remain competitive, the contractors are under pressure to embrace more sophisticated types of concrete sawing & drilling.
“The industry for floor saws, wall saws and high powered drilling machines will be in a nascent stage today but growing at about 40% each year as the expense of labor rises, the use of machines to quicken work and increase productivity and excellence of work increases phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines will be in operation. Low Powered Hand Held Drilling and sawing are in many thousands and it 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. Included in this are reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the opportunity to cut heavily-reinforced concrete.
You can find hardly any organized players from the core cutting arena. Most of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. Like almost every other industry, the current market is flooded with Chinese equipment and fly by night traders who sell low priced, poor machines from China with the goal of making quick money. These appliances, however, do not have post 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 choose poor Chinese makes only find yourself spending much more on repairs.”
With respect to manufacturing facilities in India, approximately 25% are made indigenously, the rest imported and also the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is employing it as being its manufacturing facility to further 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. Throughout the last maybe five or ten years, the technology has matured to some stage where even on residential sites, coring may be the preferred technology for fast, vibration-free penetrations. We currently see the market for coring at over 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the industry scale of controlled concrete dismantling in India is in close proximity to INR 120 crores. This includes branded and unbranded market at the same time. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines is capable of doing drilling around 1000 mm diameters. Its Ultimate Drilling Machine (UDM) can be a self-propelled gasoline driven EI core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units and its particular core cutting machines and drills are created in Switzerland, Austria, U.S.A. and other parts around the world. These machines have a manufacturing warranty of twelve months. Also these are generally quite sturdy machines and require extremely low mainte-nance. TYROLIT’s Unique Service Concept provides some of the service requirement at site to manage emergency Breakdowns.
Diabu Machines has recently entered the Indian market. Designed remembering the Indian working conditions along with the Indian operator, Diabu’s floor saws, wall saws and drilling machines are designed around the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, longevity and easy to maintain bearings, dust and water protected motors, bearings and all sliding and rotating parts. Most if not all fasteners are made of either stainless-steel or rust proof and high tensile steel. In addition to being user friendly, maintenance is likewise really easy with an easy task to access grease and oil points.
“There is actually a significant desire for education about controlled dismantling as a technology from the construction industry. Other challenges relate with acceptability and adaptability from the technology in a few of the major projects, drilling and sawing vis-à-vis the standard chisel and hammer, economics of the technology as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Selecting the most appropriate blade (for that saw, the content and also the job) is the most essential consider getting maximum performance. A number of other variables also affect blade performance. Changing any variable may have an effect on cutting speed and blade life.
Concrete cutting as an application oriented process, blades are supplied depending on end application requirement and job site requirements. The primary concrete cutting tools which are utilized add 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 as well as bevel cuts are possible with the wall saw. The wall saw is likewise a fantastic selection for creating precise openings in virtually any concrete structure. Flat sawing is normally used to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are typically accustomed to provide expansion joints, remove damaged pavement sections, clean and repair random cracks dexqpky76 repair, and take away concrete sections for demolition purposes. Core drilling techniques are employed when precise, circular cuts are needed 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 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.
Frequently the decision of cutting wet or dry depends upon ones preferences and job requirements. Some sawing or drilling is wet, conditions for example water scarcity in sites, requirement to help keep the site clean of water/slurry because 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 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 may also cause injury and cause accidents.”
Besides the kind of cutting and dry or wet cutting, varieties of concrete also influence the decision in selecting a blade. The size of curing time after concrete flows greatly affects how a diamond blade will connect to it during cutting. Curing can be afflicted with weather (temperature, moisture and time of year) as well as the composition (admixtures, aggregate and sand). Cured concrete is usually set at the very least 48 hrs. The sand is entirely bonded with all the mortar along with the concrete reaches full hardness. Concrete is typically in their green state for 6 to 48 hrs after it is actually poured. In this particular early state, the sand is not completely bonded together with 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 far more abrasion on a diamond blade. Undercut protection is essential when cutting green concrete to stop excessive wear around the steel core in the segment weld. Green concrete sawing is normal when concentrating on new construction projects such as; motorways, runways, driveways & industrial flooring.
The size and kind of aggregate have got a great influence on the entire hardness of concrete and the blade to decide on. The aggregate will make up up to 75% of your total volume. As a general rule, larger aggregate is likely to have the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is part 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 the location where the sand is from. Crushed sand and bank sand are usually sharp; river sand is generally round.
Selection for core drilling operation will even requires knowing the diameter in the final hole required, surface finish of your drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and simplicity of use are also essential for selecting the most appropriate tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter of your 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 for the project.”
Conventional concrete cutting and drilling methods generated considerable amounts of dust. While wet cutting or drilling operation does not generate dust since 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 ease of transport and installation is important in jobsites which may have single doors or window openings to become reduce or where saw has to be constantly moved from a floor to another. Some machines function in a modular system thus bringing in certain advantages, as the single component may be easier transported and installed.
Regarding costs, these machines are not so expensive machines of course, if regularly maintained, the price of maintenance may be kept only any machine an annual spend of approximately 6% – 10% of the price tag on the equipment.
The trend 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 needs to be made aware or there should be pros who can suggest the ideal techniques and equipment for efficient and cost-effective cutting at any stage in the project.
“On the service front, Prime Technologies has a band of service engineers that are always roaming and actively engage themselves in providing solutions and technical advice to clients. They are also linked to training the dealers and customers’ maintenance personnel. They perform an important role within the day-to-day operation of the company. “Akhil Jain, CEO, Prime Technologies.