Professional methods 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. Because of 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 is definitely the constantly rising labour costs. During the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and overhead costs associated with most sawing and cut to length machine, the rate which the job is carried out is now vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies on guessing and operator testing only cause waste of money and time. Today, as a way to remain competitive, the contractors are under pressure to embrace more sophisticated ways of concrete sawing & drilling.
“The market for floor saws, wall saws and powered drilling machines are in a nascent stage today but growing at about 40% per year as the price of labor rises, the usage of machines to accelerate work and increase productivity and excellence of work increases 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 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. Included in this are reduced downtime, precision cutting, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
There are actually not many organized players in the core cutting arena. The majority of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. As in any other industry, the industry is flooded with Chinese equipment and fly by night traders who sell inexpensive, low quality machines from China with the aim of making quick money. These appliances, however, have no post sales support nor will be the machines suited and created to work 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 poor Chinese makes only find yourself spending much more on repairs.”
With regards to manufacturing facilities in India, only about 25% are produced indigenously, others imported along with the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is utilizing it its manufacturing facility to further 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. Throughout the last five to ten years, the technologies have matured into a stage where even on residential sites, coring will be the preferred technology for fast, vibration-free penetrations. Right now we see the marketplace 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 industry measurements of controlled concrete dismantling in India is near to INR 120 crores. This consists of 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 approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is a self-propelled gasoline driven EI core cutting machine highly suitable for drilling at runways. TYROLIT has 27 Global Production Units and its particular core cutting machines and drills are manufactured in Switzerland, Austria, United statesA. and also other parts of the world. These machines come with a manufacturing warranty of twelve months. Also these are quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides several of the service requirement at site to manage emergency Breakdowns.
Diabu Machines has entered the Indian market. Designed remembering the Indian working conditions and the Indian operator, Diabu’s floor saws, wall saws and drilling machines are designed in the platform of robust, rigid and productivity. Diabu uses excellent and right configuration steel, longevity and maintenance free bearings, dust and water protected motors, bearings and all of sliding and rotating parts. Most if not all fasteners are made of either steel or rust proof and high tensile steel. Apart from being user friendly, maintenance is likewise very simple with simple to access grease and oil points.
“There can be a significant requirement for education about controlled dismantling like a technology inside the construction industry. Other challenges relate with acceptability and adaptability of the technology in a number of the major projects, drilling and sawing vis-à-vis the typical chisel and hammer, economics linked to the technology since this is expensive, application with illiterate labor and localized accessibility of the technology.”
Selecting the right blade (for that saw, the fabric as well as the job) is the most essential factor in getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable can 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 are the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is normally specified to reduce precise dimensional door, vent and window openings. Straight in addition to bevel cuts are possible together with the wall saw. The wall saw is likewise an excellent choice for creating precise openings in virtually any concrete structure. Flat sawing is generally employed to cut horizontal flat surfaces for example floors, bridge decks, and pavement. Flat saws are usually 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 used when precise, circular cuts are essential 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 perhaps for concrete sample analysis. Wire sawing can be used elimination of thick parts of concrete. It is great for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in places that work area is fixed.
Often the decision of cutting wet or dry depends on ones preferences and job requirements. While most sawing or drilling is wet, conditions for example water scarcity in sites, requirement to maintain the web page clean water/slurry as a result 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 is always preferable to use saws which can be laser welded or atleast have special reinforced brazing. Using such blades be sure that the extremely high heat generated during dry cutting does not damage the blade which might also cause injury and cause accidents.”
Aside from the kind of cutting and dry or wet cutting, varieties of concrete also influence your choice in selecting a blade. The length of curing time after concrete is poured greatly affects how a diamond blade will connect to it during cutting. Curing can be impacted by weather (temperature, moisture and season) and also the composition (admixtures, aggregate and sand). Cured concrete is usually set at least 48 hrs. The sand is totally bonded using the mortar and also the concrete reaches full hardness. Concrete is typically within its green state for 6 to 2 days after it is actually poured. With this early state, the sand is not really 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 within the slurry, and produces much more abrasion on the diamond blade. Undercut protection is vital when cutting green concrete to stop 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 possess a great affect on the general hardness of concrete along with the blade to pick. The aggregate can certainly make up as much as 75% from the total volume. Typically, larger aggregate has a tendency to make the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is area of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is normally sand. Sand can either be sharp (abrasive) or round (non-abrasive). To determine the sharpness of sand, you need to know where the sand comes from. Crushed sand and bank sand are often sharp; river sand is usually round.
Choice for core drilling operation may also requires learning the diameter of your final hole required, surface finish in the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and ease of use are also necessary for choosing the proper 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 assist 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 mainly because it uses water, the instance of dust is nearly 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 simplicity of transport and installation is necessary in jobsites who have single doors or window openings to be eliminate or the location where the saw has to be constantly moved from a floor to the next. Some machines operate in a modular system thus attracting certain advantages, as being the single component can be easier transported and installed.
Regarding costs, this equipment is not very expensive machines and in case regularly maintained, the expense of maintenance can be kept as low as any machine an annual spend of about 6% – 10% of the cost of the appliance.
The buzz is clearly lighter, lesser, faster and much more profitable. But what includes this development is really a stronger demand that operators be trained effectively. Also, contractors must be made aware or there must be experts who can suggest the most effective techniques and equipment for efficient and expense-effective cutting at any stage of your 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. Also, they are involved with training the dealers and customers’ maintenance personnel. They perform a vital role within the day-to-day operation of our own company. “Akhil Jain, CEO, Prime Technologies.