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. Because of a higher shelling out for 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 such 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. Given the high labor and overhead costs involved in most sawing and cut to length machine, the rate with which the task is done has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies on guessing and operator trial and error only result in waste of money and time. Today, to be able to remain competitive, the contractors are under pressure to embrace more sophisticated types of concrete sawing & drilling.
“The market for floor saws, wall saws and powered drilling machines happen to be in a nascent stage today but growing at about 40% per annum as the price of labor rises, the application of machines to speed up work and increase productivity and excellence of work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines will be in operation. Low Powered Handheld Drilling and sawing will be in many thousands which is hard 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. Such as reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the cabability to cut heavily-reinforced concrete.
There are actually not many organized players from the core cutting arena. Most of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. As in any other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell affordable, inferior machines from China with the goal of making quick money. These machines, however, do not have after sales support nor would be the machines suited and created to are employed 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 but only turn out spending more about repairs.”
Regarding manufacturing facilities in India, just about 25% are created indigenously, the rest imported as well as the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is applying it as its manufacturing facility to advance 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 five to ten years, the technologies have matured to some stage where even on residential sites, coring will be 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 industry dimensions of controlled concrete dismantling in India is near to INR 120 crores. This can include branded and unbranded market as well. TYROLIT has a variety of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can perform drilling as much as 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven Stack core cutting machine highly suited to drilling at runways. TYROLIT has 27 Global Production Units and its core cutting machines and drills are manufactured in Switzerland, Austria, United statesA. and other parts around the world. These appliances feature a manufacturing warranty of 12 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 take care of 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 high quality and right configuration steel, long life and easy to maintain bearings, dust and water protected motors, bearings and all of sliding and rotating parts. Most if not all fasteners are produced from either steel or rust proof and tensile steel. Apart from being easy to use, maintenance is also really easy with easy to access grease and oil points.
“There is a significant desire for education about controlled dismantling as being a technology within the construction industry. Other challenges connect with acceptability and adaptability in the technology in some of the major projects, drilling and sawing vis-à-vis the standard chisel and hammer, economics related to the technology since this is expensive, application with illiterate labor and localized option of the technology.”
Choosing the right blade (to the saw, the information along with the job) is an essential element in getting maximum performance. Various other variables also affect blade performance. Changing any variable can have an impact 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 main concrete cutting tools that are utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is usually specified to reduce precise dimensional door, vent and window openings. Straight along with bevel cuts are possible with the wall saw. The wall saw is additionally an outstanding choice for creating precise openings in almost any concrete structure. Flat sawing is typically employed to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are usually utilized to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and remove concrete sections for demolition purposes. Core drilling techniques are utilized when precise, circular cuts are essential for example openings for plumbing, electrical and HVAC installations, creating holes for routing cables or placing anchoring bolts, installing load carrying devices or dowel bars, or concrete sample analysis. Wire sawing can be used for elimination of thick parts of concrete. It is fantastic for removing large sections of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in places that work area is restricted.
Frequently the decision of cutting wet or dry is dependent upon ones preferences and job requirements. Some sawing or drilling is wet, conditions for example water scarcity in sites, requirement to keep the website clean of water/slurry as a result of proximity with existing office/ factory /commercial/residential space, proximity to electrical or other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is usually 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 might also cause injury and cause accidents.”
Besides the form of cutting and dry or wet cutting, forms of concrete also influence the decision in selecting a blade. The length of curing time after concrete is poured greatly affects how a diamond blade will connect with it during cutting. Curing could be affected by weather (temperature, moisture and period) along with the composition (admixtures, aggregate and sand). Cured concrete is generally set no less than 2 days. The sand is entirely bonded with all the mortar and also the concrete reaches full hardness. Concrete is normally in its green state for 6 to 2 days after it really is poured. Within this early state, the sand is not completely bonded using the mortar and also the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely in the slurry, and produces a lot more abrasion on the diamond blade. Undercut protection is essential when cutting green concrete to prevent excessive wear about the steel core in the segment weld. Green concrete sawing is typical when focusing on new construction projects like; motorways, runways, driveways & industrial flooring.
The two size and type of aggregate have a great impact on the entire hardness of concrete along with the blade to decide on. The aggregate can make up up to 75% in the total volume. On the whole, larger aggregate is likely to make the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is portion 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 determine the sharpness of sand, you have to know in which the sand is produced by. Crushed sand and bank sand are usually sharp; river sand is often round.
Selection for core drilling operation will even requires knowing the diameter of the final hole required, surface finish of the drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and simplicity of use will also be essential for choosing the proper tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter from the 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 aid 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 will not generate dust mainly because it uses water, the instance of dust is virtually 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 who have single doors or window openings to be reduce or where saw needs to be constantly moved from a single floor to another. Some machines operate in a modular system thus attracting certain advantages, because the single component could be easier transported and installed.
Regarding costs, this equipment is not expensive machines and if regularly maintained, the cost of maintenance can be kept as little as any machine a yearly spend of approximately 6% – 10% of the cost of the device.
The buzz is clearly lighter, lesser, faster and much more profitable. But what comes along with this development is actually a stronger demand that operators be trained effectively. Also, contractors should be made aware or there must be experts who can suggest the best techniques and equipment for the most efficient and expense-effective cutting at any stage in the project.
“On the service front, Prime Technologies carries a band of service engineers who 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 vital role from the day-to-day operation of the company. “Akhil Jain, CEO, Prime Technologies.