Professional methods 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 a heightened 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 these sophisticated methods will be the constantly rising labour costs. Over the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Given the high labor and expenses associated with most sawing and Core cutting machine, the rate that the position is completed has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies on guessing and operator testing only cause waste of time and money. Today, in order to remain competitive, the contractors are under pressure to embrace more sophisticated methods of concrete sawing & drilling.
“The marketplace for floor saws, wall saws and powered drilling machines are in a nascent stage today but growing at about 40% each year as the fee for labor rises, the use of machines to speed up work and increase productivity superiority work increases phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines are in operation. Low Powered Hand Held Drilling and sawing will 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 offer significant advantages over conventional concrete removal methods. Such as reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
There are actually not many organized players from the core cutting arena. A lot of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. As in some 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 machines, however, have no after sales support nor would be 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 choose low quality Chinese makes but only find yourself spending much more on repairs.”
With respect to manufacturing facilities in India, no more than 25% are created indigenously, the remainder imported and the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is utilizing it as being its manufacturing facility to further 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 technologies have matured to some stage where even on residential sites, coring is definitely the preferred technology for fast, vibration-free penetrations. We currently see the market for coring at a lot more than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the current market dimensions of controlled concrete dismantling in India is in close proximity to INR 120 crores. This consists of branded and unbranded market also. TYROLIT has a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can perform drilling around 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven transformer core cutting machine highly suited to drilling at runways. TYROLIT has 27 Global Production Units and its core cutting machines and drills are produced in Switzerland, Austria, UsaA. along with other parts around the globe. These machines feature a manufacturing warranty of 1 year. Also these are generally quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides a few of the service requirement at site to manage emergency Breakdowns.
Diabu Machines has recently 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 constructed around the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, long life and maintenance free bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not completely fasteners are manufactured from either stainless steel or rust proof and high tensile steel. In addition to being easy to use, maintenance is also very easy with simple to access grease and oil points.
“There is 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 several of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics of the technology as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Choosing the right blade (for the saw, the content along with the job) is the most important 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 becoming an application oriented process, blades are supplied as per end application requirement and job site requirements. The principle concrete cutting tools that are utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, as well as the wire saw. Wall sawing is typically specified to reduce precise dimensional door, vent and window openings. Straight in addition to bevel cuts are possible with all the wall saw. The wall saw is likewise an outstanding option for creating precise openings in any concrete structure. Flat sawing is normally accustomed to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are usually 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 utilized when precise, circular cuts are needed including 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 removing of thick parts of concrete. It is perfect for removing large sections of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in locations where work space is restricted.
Often the decision of cutting wet or dry depends upon ones preferences and job requirements. While many sawing or drilling is wet, conditions like water scarcity in sites, requirement to hold the internet site clean water/slurry as a result of proximity with existing office/ factory /commercial/residential space, proximity to electrical or some other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is usually wise to use saws that 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 may also cause injury and cause accidents.”
Aside from the type of cutting and dry or wet cutting, varieties of concrete also influence your decision when choosing a blade. The duration of curing time after concrete flows greatly affects just how a diamond blade will communicate with it during cutting. Curing can be afflicted with weather (temperature, moisture and time of the year) and the composition (admixtures, aggregate and sand). Cured concrete is generally set at the very least two days. The sand is totally bonded together with the mortar and also the concrete reaches full hardness. Concrete is typically within its green state for 6 to two days after it can be poured. Within this early state, the sand is just not completely bonded with all 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 from the slurry, and produces far more abrasion with a diamond blade. Undercut protection is critical when cutting green concrete to prevent excessive wear about the steel core on the segment weld. Green concrete sawing is usual when concentrating on new construction projects such as; motorways, runways, driveways & industrial flooring.
Both size and type of aggregate use a great influence on the complete hardness of concrete and the blade to decide on. The aggregate can certainly make up around 75% of the 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 area 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 have to know the location where the sand is produced by. Crushed sand and bank sand are often sharp; river sand is generally round.
Choice for core drilling operation will even requires understanding the diameter in the final hole required, surface finish from the drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and simplicity 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 such as diameter in the core, length of the core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Straight core cutting machine, anchor or vacuum fixation assistance in deciding which concrete core cutter to use for the project.”
Conventional concrete cutting and drilling methods generated large amounts of dust. While wet cutting or drilling operation fails to generate dust because it uses water, the instance of dust is nearly totally avoided. However, the slurry generated has to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
In addition to saw speed, the simplicity of transport and installation is necessary in jobsites which may have single doors or window openings being remove or where saw should be constantly moved from a floor to the next. Some machines operate in a modular system thus attracting certain advantages, as the single component might be easier transported and installed.
With respect to costs, these machines are not so expensive machines and when regularly maintained, the fee for maintenance can be kept only any machine a yearly spend around 6% – 10% of the price of the equipment.
The trend is clearly lighter, lesser, faster and much more profitable. But what comes with this development is really a stronger demand that operators be trained effectively. Also, contractors must be made aware or there must be experts who can suggest the most effective techniques and equipment for the most efficient and price-effective cutting at any stage from 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 associated with training the dealers and customers’ maintenance personnel. They perform a crucial role from the everyday operation of our own company. “Akhil Jain, CEO, Prime Technologies.