Professional types 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 an elevated 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 the 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 expenses associated with most sawing and cut to length machine, the speed which the task is carried out 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 Using outdated cutting &drilling techniques and drilling equipment that heavily relies on guessing and operator trial and error only result in waste of money and time.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, in order to remain competitive, the contractors are under pressure to embrace more sophisticated types of concrete sawing & drilling.
“The niche for floor saws, wall saws and high powered drilling machines will be in a nascent stage today but growing at about 40% per year as the fee for labor rises, using machines to increase work and increase productivity superiority work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines will be in operation. Low Powered Hand Held Drilling and sawing are in many thousands and it 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. Included in this 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.
You will find very few organized players in the core cutting arena. A lot of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. As in almost every other industry, the market is flooded with Chinese equipment and fly by night traders who sell low cost, poor machines from China with the goal of making quick money. These machines, however, have zero after 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 go for low quality Chinese makes only wind up spending more about repairs.”
With respect to manufacturing facilities in India, no more than 25% are made indigenously, the rest imported and the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is applying it as a its manufacturing facility to advance develop and expand the development facility for diamond tools and disks as well as to strengthen its position inside the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past five to ten years, the technology has 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 dimensions of controlled concrete dismantling in India is in close proximity to INR 120 crores. This can include branded and unbranded market too. 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 actually a self-propelled gasoline driven EI core cutting machine highly suitable for 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 globe. These machines have a manufacturing warranty of 1 year. Also these are quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides a number of the service requirement at site to manage emergency Breakdowns.
Diabu Machines has 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 high productivity. Diabu uses excellent and right configuration steel, longevity and easy to maintain bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not all fasteners are manufactured from either stainless or rust proof and high tensile steel. In addition to being easy to use, maintenance is additionally quite simple with simple 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 a few of the major projects, drilling and sawing vis-à-vis the typical chisel and hammer, economics related to the technology because this is expensive, application with illiterate labor and localized accessibility of the technology.”
Choosing the right blade (for the saw, the information and also the job) is the most essential factor in getting maximum performance. Many other variables also affect blade performance. Changing any variable can have an impact 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 principle concrete cutting tools which can be utilized are 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 and also bevel cuts are possible together with the wall saw. The wall saw is also an outstanding option for creating precise openings in almost any concrete structure. Flat sawing is usually utilized to cut horizontal flat surfaces for example 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 remove concrete sections for demolition purposes. Core drilling techniques are being used when precise, circular cuts are needed such as 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 elimination of thick sections of concrete. It is fantastic for removing large sections of heavily reinforced concrete, for example piers, towers and bridge sections, and cutting concrete in places that work space is fixed.
Often the decision of cutting wet or dry depends upon ones preferences and job requirements. While most sawing or drilling is wet, conditions including water scarcity in sites, requirement to keep the site clean water/slurry because 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 always wise to use saws that happen to be laser welded or atleast have special reinforced brazing. Using such blades be sure that the extremely high heat generated during dry cutting fails to damage the blade which could also cause injury and cause accidents.”
Besides the form of cutting and dry or wet cutting, forms of concrete also influence the decision in picking a blade. The size of curing time after concrete flows greatly affects the way a diamond blade will connect to it during cutting. Curing may be afflicted with weather (temperature, moisture and period) as well as the composition (admixtures, aggregate and sand). Cured concrete is normally set no less than two days. The sand is completely bonded with the mortar and the concrete reaches full hardness. Concrete is usually in its green state for 6 to 48 hrs after it can be poured. With this early state, the sand is just not completely bonded using 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 considerably more abrasion on the diamond blade. Undercut protection is crucial when cutting green concrete in order to avoid excessive wear about the steel core at the segment weld. Green concrete sawing is common when concentrating on new construction projects for example; motorways, runways, driveways & industrial flooring.
The two size and kind of aggregate have got a great influence on the entire hardness of concrete along with the blade to decide on. The aggregate can make up around 75% from the total volume. Typically, larger aggregate will have the concrete act harder, slowing drilling process. Smaller aggregates make a blade cut faster. Sand is section of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is generally sand. Sand may either be sharp (abrasive) or round (non-abrasive). To look for the sharpness of sand, you should know where the sand originates from. Crushed sand and bank sand are often sharp; river sand is often round.
Choice for core drilling operation will also requires learning the diameter of your final hole required, surface finish of the drilled hole, surface and accessibility of your drilling area.
“Tool horsepower, tool reliability and convenience are also necessary for choosing the proper tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like 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 large amounts of dust. While wet cutting or drilling operation fails to generate dust since it uses water, the instance of dust is nearly 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 which have single doors or window openings to get cut out or where saw must be constantly moved from a floor to the next. Some machines function in a modular system thus attracting certain advantages, because the single component may be easier transported and installed.
Regarding costs, this equipment is not too expensive machines and if regularly maintained, the fee for maintenance could be kept as little as any machine a yearly spend around 6% – 10% of the buying price of the appliance.
The popularity is clearly lighter, lesser, faster and a lot 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 should be experts who can recommend the most effective techniques and equipment for efficient and expense-effective cutting at any stage in the project.
“On the service front, Prime Technologies includes 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 linked to training the dealers and customers’ maintenance personnel. They perform a vital role in the day-to-day operation of our company. “Akhil Jain, CEO, Prime Technologies.