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. As a result of an increased 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 these sophisticated methods is definitely the constantly rising labour costs. Within the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Given the high labor and expenses involved with most sawing and cut to length machine, the rate with which the task is completed is becoming vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator trial and error only cause waste of time and money. Today, to be able to remain competitive, the contractors are under pressure to embrace modern-day strategies for concrete sawing & drilling.
“The market for floor saws, wall saws and powered drilling machines have been in a nascent stage today but growing at about 40% yearly as the fee for labor rises, the application of machines to speed up work and increase productivity superiority work boosts phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines happen to be in operation. Low Powered Handheld Drilling and sawing have been in many thousands which is very difficult 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.
There are actually very few organized players from the core cutting arena. A lot of them are extensions of worldwide manufacturers including Hilti, TYROLIT, Husqvarna and Diabu. Like almost every other industry, the market is flooded with Chinese equipment and fly by night traders who sell inexpensive, poor quality machines from China with the objective of making quick money. These appliances, however, do not have post sales support nor are definitely 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 quality Chinese makes but only end up spending more on repairs.”
When it comes to manufacturing facilities in India, approximately 25% are created indigenously, the rest imported and the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is using it as being its manufacturing facility to advance develop and expand the production 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 5-10 years, the technology has matured to a stage where even on residential sites, coring may be the preferred technology for fast, vibration-free penetrations. We currently see the marketplace 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 near to INR 120 crores. This includes branded and unbranded market at the same time. TYROLIT has a variety of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can perform drilling up to 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven transformer core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units and its core cutting machines and drills are produced in Switzerland, Austria, United statesA. as well as other parts around the world. These machines come with a manufacturing warranty of 1 year. Also these are generally quite sturdy machines and require suprisingly low mainte-nance. TYROLIT’s Unique Service Concept provides some of the service requirement at site to care for emergency Breakdowns.
Diabu Machines has recently entered the Indian market. Designed remembering the Indian working conditions as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are made on the platform of robust, rigid and high productivity. Diabu uses good quality and right configuration steel, extended 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 produced from either stainless or rust proof and high tensile steel. In addition to being user friendly, maintenance is additionally quite simple with very easy to access grease and oil points.
“There is actually a significant desire for education about controlled dismantling as a technology in the construction industry. Other challenges connect with acceptability and adaptability from the technology in some of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics of the technology since this is expensive, application with illiterate labor and localized accessibility to the technology.”
Choosing the right blade (to the saw, the fabric along with the job) is the most important element in getting maximum performance. Many other variables also affect blade performance. Changing any variable can 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 key concrete cutting tools which are utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, and the wire saw. Wall sawing is typically specified to reduce precise dimensional door, vent and window openings. Straight and also bevel cuts are possible with all the wall saw. The wall saw is likewise an outstanding option for creating precise openings in virtually any concrete structure. Flat sawing is normally accustomed to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are generally utilized 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 required 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 elimination of thick sections of concrete. It is perfect for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in places that work area is restricted.
Frequently the decision of cutting wet or dry depends on ones preferences and job requirements. While many sawing or drilling is wet, conditions for example water scarcity in sites, requirement to help keep the website 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 usually is preferable to use saws which are laser welded or atleast have special reinforced brazing. Using such blades be sure that the very high heat generated during dry cutting does not damage the blade which may also cause injury and cause accidents.”
Besides the form of cutting and dry or wet cutting, varieties of concrete also influence the choice in picking a blade. The size of curing time after concrete flows greatly affects the way in which a diamond blade will interact with it during cutting. Curing can be afflicted with weather (temperature, moisture and time of the year) and also the composition (admixtures, aggregate and sand). Cured concrete is usually set at least two days. The sand is entirely bonded with all the mortar and the concrete reaches full hardness. Concrete is generally within its green state for 6 to two days after it really is poured. With this 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 from the slurry, and produces a lot more abrasion over a diamond blade. Undercut protection is critical when cutting green concrete to prevent excessive wear on the steel core on the segment weld. Green concrete sawing is normal when working on new construction projects like; motorways, runways, driveways & industrial flooring.
Both size and type of aggregate possess a great influence on the overall hardness of concrete and the blade to select. The aggregate will make up as much as 75% in the total volume. As a general rule, larger aggregate is likely to make your 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 usually sand. Sand may either be sharp (abrasive) or round (non-abrasive). To discover the sharpness of sand, you should know where the sand is produced by. Crushed sand and bank sand are generally sharp; river sand is normally round.
Choice for core drilling operation may also requires learning the diameter in the final hole required, surface finish of the drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and simplicity 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 from the core, length of the core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Transformer core cutting machine, anchor or vacuum fixation assistance in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated large amounts of dust. While wet cutting or drilling operation is not going to generate dust because it uses water, the instance of dust is almost 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 necessary in jobsites which have single doors or window openings to get remove or where saw should be constantly moved from a floor to the next. Some machines operate in a modular system thus bringing in certain advantages, because the single component could be easier transported and installed.
With respect to costs, this equipment is not too expensive machines of course, if regularly maintained, the fee for maintenance may be kept as low as any machine a yearly spend around 6% – 10% of the buying price of the equipment.
The buzz is clearly lighter, lesser, faster plus more profitable. But what comes along with this development is a stronger demand that operators be trained effectively. Also, contractors must be made aware or there must be professionals who can recommend the most effective techniques and equipment for the best efficient and expense-effective cutting at any stage in the project.
“On the service front, Prime Technologies features 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 involved with training the dealers and customers’ maintenance personnel. They perform an important role inside the everyday operation of our own company. “Akhil Jain, CEO, Prime Technologies.