Professional ways 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. Due to a heightened spending on infrastructure projects and residential & commercial construction, India holds tremendous potential regarding 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. Given the high labor and overhead costs involved with most sawing and cut to length machine, the speed which the job is carried out has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator testing only cause waste of time and money. Today, so that you can remain competitive, the contractors are under pressure to embrace modern-day methods of concrete sawing & drilling.
“The niche for floor saws, wall saws and high powered drilling machines are in a nascent stage today but growing at about 40% each year as the cost of labor rises, the use of machines to speed up work and increase productivity and excellence of work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines are in operation. Low Powered Hand Held Drilling and sawing happen to be in many thousands in fact it is very difficult to give even an approximate number.” – M.Venkatesh, Executive Director, Diabu Diamond Tools
Professional diamond concrete cutting systems provides 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 capability to cut heavily-reinforced concrete.
There are actually very few organized players in the core cutting arena. The majority of them are extensions of worldwide manufacturers including Hilti, TYROLIT, Husqvarna and Diabu. As in any other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell low priced, poor machines from China with the purpose of making quick money. These appliances, however, have zero after sales support nor are the machines suited and created 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 inferior Chinese makes but only wind up spending much more about repairs.”
With regards to manufacturing facilities in India, no more than 25% are created indigenously, others imported and the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is utilizing it as being its manufacturing facility to advance develop and expand the development facility for diamond tools and disks as well as strengthen its position within the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. During the last 5-10 years, the technologies have matured into a 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 marketplace scale of controlled concrete dismantling in India is near to INR 120 crores. Including branded and unbranded market as well. TYROLIT has a variety of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing drilling as much as 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is a self-propelled gasoline driven EI core cutting machine highly ideal for drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are created in Switzerland, Austria, U.S.A. along with other parts on the planet. These appliances include a manufacturing warranty of twelve months. Also these are quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides some of the service requirement at site to care for emergency Breakdowns.
Diabu Machines recently entered the Indian market. Designed bearing 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 high quality and right configuration steel, longevity 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 produced from either stainless or rust proof and high tensile steel. Apart from being easy to use, maintenance is additionally quite simple with an easy task to access grease and oil points.
“There is really a significant need for education about controlled dismantling as a technology in the construction industry. Other challenges relate to acceptability and adaptability in the technology in a few of the major projects, drilling and sawing vis-à-vis the standard chisel and hammer, economics related to the technology because this is expensive, application with illiterate labor and localized accessibility of the technology.”
Choosing the proper blade (to the saw, the material as well as the job) is a vital element in getting maximum performance. Many other variables also affect blade performance. Changing any variable will 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 which are utilized range from 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 slice precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible together with the wall saw. The wall saw is additionally an outstanding choice for creating precise openings in every 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 off concrete sections for demolition purposes. Core drilling techniques are utilized when precise, circular cuts are essential 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 perhaps for concrete sample analysis. Wire sawing can be used elimination of thick sections of concrete. It is fantastic for removing large parts 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 is determined by ones preferences and job requirements. While many sawing or drilling is wet, conditions including water scarcity in sites, requirement to maintain the internet site clean water/slurry because 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 will always be better to use saws that are laser welded or atleast have special reinforced brazing. Using such blades be sure that the extremely high heat generated during dry cutting will not damage the blade which can also cause injury and cause accidents.”
Aside from the type of cutting and dry or wet cutting, forms of concrete also influence your decision in picking a blade. The duration of curing time after concrete is poured greatly affects the way a diamond blade will connect with it during cutting. Curing could be afflicted with weather (temperature, moisture and time of the year) and the composition (admixtures, aggregate and sand). Cured concrete is typically set at the very least two days. The sand is utterly bonded using the mortar and the concrete reaches full hardness. Concrete is normally in its green state for 6 to 2 days after it can be poured. In this particular early state, the sand is not completely bonded together with the mortar along with 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 much more abrasion on the diamond blade. Undercut protection is crucial when cutting green concrete to avoid excessive wear around the steel core in the segment weld. Green concrete sawing is usual when working on new construction projects for example; motorways, runways, driveways & industrial flooring.
Both size and type of aggregate possess a great influence on the overall hardness of concrete along with the blade to decide on. The aggregate can make up around 75% of the total volume. As a general rule, larger aggregate will create the concrete act harder, slowing drilling process. Smaller aggregates make a blade cut faster. Sand is part of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is often sand. Sand either can be sharp (abrasive) or round (non-abrasive). To look for the sharpness of sand, you have to know where sand is produced by. Crushed sand and bank sand tend to be sharp; river sand is normally round.
Selection for core drilling operation will also requires learning the diameter in the final hole required, surface finish in the drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and simplicity can also be essential 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, Silicon steel core cutting machine, anchor or vacuum fixation aid 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 will not generate dust mainly because it uses water, the instance of dust is practically totally avoided. However, the slurry generated needs to 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 necessary in jobsites that have single doors or window openings to be eliminate or where the saw must be constantly moved in one floor to another. Some machines work in a modular system thus bringing in certain advantages, as the single component can be easier transported and installed.
With respect to costs, this equipment is not expensive machines of course, if regularly maintained, the cost of maintenance might be kept as low as any machine a yearly spend around 6% – 10% of the cost of the device.
The craze is clearly lighter, lesser, faster plus more profitable. But what comes along with this development is really a stronger demand that operators be trained effectively. Also, contractors ought to be made aware or there ought to be experts who can suggest the very best techniques and equipment for efficient and cost-effective cutting at any stage of your project.
“On the service front, Prime Technologies carries a band of service engineers who definitely 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 huge role inside the everyday operation of the company. “Akhil Jain, CEO, Prime Technologies.