Professional ways of concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it can be still a young but growing industry. On account of an increased shelling out for infrastructure projects and residential & commercial construction, India holds tremendous potential when it comes to diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of these 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. Due to the high labor and overhead costs involved in most sawing and Core cutting machine, the speed that the job is carried out is becoming vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator trial and error only cause waste of money and time. Today, as a way to remain competitive, the contractors are under pressure to embrace more sophisticated types of concrete sawing & drilling.
“The marketplace 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 cost 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 High Powered Drilling Machines have been in operation. Low Powered Hand Held Drilling and sawing have been in many thousands and it is hard 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. Some examples are 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 only a few organized players from the core cutting arena. A lot of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. Like almost every 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 aim of making quick money. These appliances, however, have no post sales support nor are definitely the machines suited and made 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 get inferior Chinese makes but only wind up spending much more on repairs.”
With respect to manufacturing facilities in India, no more than 25% are manufactured indigenously, the rest imported as well as the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is utilizing it as being its manufacturing facility to further develop and expand the production facility for diamond tools and disks and to strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Throughout the last maybe five or ten years, the technologies have matured to some stage where even on residential sites, coring may be the preferred technology for fast, vibration-free penetrations. Right now we see the market for coring at over 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the market size of controlled concrete dismantling in India is near INR 120 crores. This consists of branded and unbranded market at the same time. TYROLIT has a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines is capable of doing drilling up to 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven EI core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units and its core cutting machines and drills are created in Switzerland, Austria, UsaA. as well as other parts around the globe. These appliances include a manufacturing warranty of one year. Also these are typically quite sturdy machines and require suprisingly low mainte-nance. TYROLIT’s Unique Service Concept provides several of the service requirement at site to take care of 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 built on the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, longevity and easy to maintain bearings, dust and water protected motors, bearings and all sliding and rotating parts. Most if not completely fasteners are produced from either stainless-steel or rust proof and high tensile steel. Aside from being easy to use, maintenance can also be very easy with easy to access grease and oil points.
“There is actually a significant necessity for education about controlled dismantling as a technology from the construction industry. Other challenges correspond 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 linked to the technology since this is expensive, application with illiterate labor and localized accessibility to the technology.”
Choosing the right blade (for the saw, the material and also the job) is the most essential factor in getting maximum performance. Various other variables also affect blade performance. Changing any variable may have an impact on cutting speed and blade life.
Concrete cutting being an application oriented process, blades are supplied according to end application requirement and job site requirements. The main concrete cutting tools which can be utilized add the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is generally specified to reduce precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible with all the wall saw. The wall saw is additionally an outstanding option for creating precise openings in every concrete structure. Flat sawing is usually utilized to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are generally used to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and take away concrete sections for demolition purposes. Core drilling techniques are employed 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 even for concrete sample analysis. Wire sawing can be used as removing of thick parts of concrete. It is ideal for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in places that work area is fixed.
Most of the decision of cutting wet or dry is dependent upon ones preferences and job requirements. While many sawing or drilling is wet, conditions for example water scarcity in sites, requirement to keep the web page clean 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 always preferable 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 is not going to damage the blade which can also cause injury and cause accidents.”
Apart from the kind of cutting and dry or wet cutting, types of concrete also influence the decision in picking a blade. The size of curing time after concrete flows greatly affects just how a diamond blade will connect to it during cutting. Curing might be affected by weather (temperature, moisture and time of the year) as well as the composition (admixtures, aggregate and sand). Cured concrete is generally set a minimum of two days. The sand is entirely bonded together with the mortar and the concrete reaches full hardness. Concrete is normally in the green state for 6 to 48 hrs after it really is poured. In this particular early state, the sand is just not completely bonded with all the mortar along with the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely within the slurry, and produces much more abrasion with a diamond blade. Undercut protection is vital when cutting green concrete to prevent excessive wear on the steel core with the segment weld. Green concrete sawing is common when taking care of new construction projects for example; motorways, runways, driveways & industrial flooring.
The two size and kind of aggregate use a great affect on the general hardness of concrete and the blade to choose. The aggregate will make up around 75% from the total volume. As a general rule, larger aggregate is likely to have 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 generally sand. Sand can either be sharp (abrasive) or round (non-abrasive). To discover the sharpness of sand, you should know the location where the sand comes from. Crushed sand and bank sand are often sharp; river sand is usually round.
Selection for core drilling operation may also requires knowing the diameter from the final hole required, surface finish from the drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and simplicity of use are also important for selecting the right 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, Straight core cutting machine, anchor or vacuum fixation help in deciding which concrete core cutter to use for the project.”
Conventional concrete cutting and drilling methods generated huge amounts of dust. While wet cutting or drilling operation fails to 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.
Besides saw speed, the ease of transport and installation is necessary in jobsites which may have single doors or window openings to get remove or in which the saw must be constantly moved in one floor to another. Some machines are employed in a modular system thus attracting certain advantages, because the single component can be easier transported and installed.
With respect to costs, this equipment is not too expensive machines and in case regularly maintained, the fee for maintenance can be kept only any machine a yearly spend of around 6% – 10% of the buying price of the appliance.
The trend is clearly lighter, lesser, faster plus more profitable. But what comes along with this development can be a stronger demand that operators be trained effectively. Also, contractors needs to be made aware or there ought to be experts who can suggest the very best techniques and equipment for the best efficient and price-effective cutting at any stage from the project.
“On the service front, Prime Technologies includes a band of service engineers that are always roaming and actively engage themselves in providing solutions and technical advice to clients. Also, they are associated with training the dealers and customers’ maintenance personnel. They perform an important role within the everyday operation of our own company. “Akhil Jain, CEO, Prime Technologies.