Professional methods 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 spending on 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 definitely the constantly rising labour costs. Over the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and expenses linked to most sawing and cut to length machine, the speed in which the job is done has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator experimentation only bring about waste of time and money. Today, so that you can remain competitive, the contractors are under pressure to embrace more sophisticated types of concrete sawing & drilling.
“The marketplace for floor saws, wall saws and high powered drilling machines are in a nascent stage today but growing at about 40% per year as the fee for labor rises, the usage of machines to speed up work and increase productivity and quality of work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines have been 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 offers 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 cabability to cut heavily-reinforced concrete.
You will find very few organized players from the core cutting arena. The majority of them are extensions of worldwide manufacturers such as 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 priced, inferior machines from China with the objective of making quick money. These appliances, however, have no after sales support nor will be the machines suited and made 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 choose inferior Chinese makes but only wind up spending more on repairs.”
When it comes to manufacturing facilities in India, no more than 25% are created indigenously, the others imported as well as the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is applying it as being its manufacturing facility to further develop and expand the development facility for diamond tools and disks and 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 technologies have matured to your stage where even on residential sites, coring is definitely the preferred technology for fast, vibration-free penetrations. We currently 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 marketplace size of controlled concrete dismantling in India is in close proximity to INR 120 crores. Including branded and unbranded market too. TYROLIT has a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven EI 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, United statesA. and also other parts around the world. These machines have a manufacturing warranty of twelve months. Also these are typically quite sturdy machines and require suprisingly low mainte-nance. TYROLIT’s Unique Service Concept provides some of the service requirement at site to take care of 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 constructed in the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, long life and easy to maintain bearings, dust and water protected motors, bearings and all sorts of sliding and rotating parts. Most if not all fasteners are manufactured from either stainless-steel or rust proof and tensile steel. Apart from being user friendly, maintenance can also be very easy with an easy task to access grease and oil points.
“There can be a significant desire for education about controlled dismantling being a technology from the construction industry. Other challenges connect with acceptability and adaptability of your technology in a few of the major projects, drilling and sawing vis-à-vis the typical chisel and hammer, economics of the technology since this is expensive, application with illiterate labor and localized option of the technology.”
Selecting the most appropriate blade (for the saw, the information as well as the job) is a vital element in getting maximum performance. A number of 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 depending on end application requirement and job site requirements. The main 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 usually specified to cut precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible together with the wall saw. The wall saw is also a fantastic selection for creating precise openings in almost any concrete structure. Flat sawing is generally utilized to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are usually used to provide expansion joints, remove damaged pavement sections, clean and repair random cracks dexqpky76 repair, and remove concrete sections for demolition purposes. Core drilling techniques are used when precise, circular cuts are needed like openings for plumbing, electrical and HVAC installations, creating holes for routing cables or placing anchoring bolts, installing load carrying devices or dowel bars, or even for concrete sample analysis. Wire sawing can be used as removal of thick sections of concrete. It is great for removing large sections of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in locations where work space is fixed.
Often the decision of cutting wet or dry depends on ones preferences and job requirements. While many sawing or drilling is wet, conditions like 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 advisable to use saws which are laser welded or atleast have special reinforced brazing. Using such blades ensure that the extremely high heat generated during dry cutting fails to damage the blade which can also cause injury and cause accidents.”
In addition to the sort of cutting and dry or wet cutting, varieties of concrete also influence your decision in choosing a blade. The duration of curing time after concrete flows greatly affects the way in which a diamond blade will interact with it during cutting. Curing may be influenced by weather (temperature, moisture and season) and also the composition (admixtures, aggregate and sand). Cured concrete is generally set no less than 2 days. The sand is completely bonded using the mortar along with the concrete reaches full hardness. Concrete is normally within its green state for 6 to 48 hours after it is 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 inside the slurry, and produces far more abrasion on a diamond blade. Undercut protection is critical when cutting green concrete to prevent excessive wear about the steel core with the segment weld. Green concrete sawing is normal when taking care of new construction projects like; motorways, runways, driveways & industrial flooring.
The size and type of aggregate use a great impact on the entire hardness of concrete and the blade to decide on. The aggregate can make up as much as 75% from the total volume. Typically, larger aggregate has a tendency to create 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 can either be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you have to know where sand is produced by. Crushed sand and bank sand are generally sharp; river sand is usually round.
Choice for core drilling operation may also requires knowing the diameter in the final hole required, surface finish from the drilled hole, surface and accessibility of your drilling area.
“Tool horsepower, tool reliability and convenience will 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 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 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 will not 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.
Aside from saw speed, the simplicity of transport and installation is important in jobsites which may have single doors or window openings to be cut out or where saw must be constantly moved from a floor to the next. Some machines are employed in a modular system thus attracting certain advantages, since the single component can be easier transported and installed.
With regards to costs, this equipment is not very expensive machines and if regularly maintained, the price of maintenance may be kept as low as any machine a yearly spend of around 6% – 10% of the buying price of the machine.
The trend is clearly lighter, lesser, faster and more profitable. But what includes this development is a stronger demand that operators be trained effectively. Also, contractors should be made aware or there should be experts who can suggest the ideal techniques and equipment for the most efficient and cost-effective cutting at any stage of your 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 linked to training the dealers and customers’ maintenance personnel. They perform a crucial role within the daily operation of the company. “Akhil Jain, CEO, Prime Technologies.