Professional methods 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. Because of a heightened spending on infrastructure projects and residential & commercial construction, India holds tremendous potential with regards to diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of those sophisticated methods will be the constantly rising labour costs. Within the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and overhead costs involved with most sawing and Core cutting machine, the speed which the job is performed is now vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator testing only bring about waste of time and money. Today, so that you can remain competitive, the contractors are under pressure to embrace more sophisticated types of concrete sawing & drilling.
“The niche 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 expense of labor rises, the application of machines to accelerate work and increase productivity superiority work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines happen to be in operation. Low Powered Handheld Drilling and sawing will be in many thousands in fact it is tough to give even an approximate number.” – M.Venkatesh, Executive Director, Diabu Diamond Tools
Professional diamond concrete cutting systems offers 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 ability to cut heavily-reinforced concrete.
There are actually hardly any organized players within the core cutting arena. Many of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. Like in almost every other industry, the current market 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 go for low quality Chinese makes only turn out spending much more about repairs.”
Regarding manufacturing facilities in India, approximately 25% are manufactured indigenously, the others imported as well as the bulk coming from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is utilizing it as being its manufacturing facility to increase develop and expand the production facility for diamond tools and disks as well as strengthen its position in the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the last 5 to 10 years, the technology has matured to your stage where even on residential sites, coring is the preferred technology for fast, vibration-free penetrations. Right now we see the market for coring at greater than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the marketplace scale of controlled concrete dismantling in India is close to INR 120 crores. This includes branded and unbranded market also. TYROLIT has a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling up to 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is a self-propelled gasoline driven EI core cutting machine highly suited to drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are created in Switzerland, Austria, U.S.A. and other parts of the world. These machines feature a manufacturing warranty of one year. Also they are quite sturdy machines and require extremely 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 as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are made on the platform of robust, rigid and productivity. Diabu uses top quality 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 from either stainless-steel or rust proof and tensile steel. Aside from being user-friendly, maintenance is likewise quite simple with simple to access grease and oil points.
“There is actually a significant need for education about controlled dismantling being a technology inside the construction industry. Other challenges relate with acceptability and adaptability in the technology in a number of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics associated with the technology because this is expensive, application with illiterate labor and localized accessibility to the technology.”
Selecting the right blade (for that saw, the content and also the job) is a vital aspect in getting maximum performance. Many other variables also affect blade performance. Changing any variable will 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 are utilized add the wall (or track) saw, the flat (or slab) saw, the core drill, along with the wire saw. Wall sawing is generally specified to reduce precise dimensional door, vent and window openings. Straight and also bevel cuts are possible with the wall saw. The wall saw is likewise a great option for creating precise openings in almost any concrete structure. Flat sawing is typically accustomed to cut horizontal flat surfaces for example floors, bridge decks, and pavement. Flat saws are normally accustomed 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 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 even for concrete sample analysis. Wire sawing can be used removal of thick sections of concrete. It is ideal for removing large sections of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in places that work area is restricted.
Most of 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 hold the site clean water/slurry as a result of proximity with existing office/ factory /commercial/residential space, proximity to electrical or any other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is usually better to use saws which can be laser welded or atleast have special reinforced brazing. Using such blades ensure that the very high heat generated during dry cutting will not damage the blade which may also cause injury and cause accidents.”
Besides the sort of cutting and dry or wet cutting, types of concrete also influence the choice in picking a blade. The length of curing time after concrete is poured greatly affects how a diamond blade will communicate with it during cutting. Curing can be influenced by 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 utterly bonded using the mortar and the concrete reaches full hardness. Concrete is normally in the green state for 6 to 48 hours after it really is poured. With this early state, the sand will not be completely bonded 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 with a diamond blade. Undercut protection is crucial when cutting green concrete to prevent excessive wear in the steel core on the segment weld. Green concrete sawing is typical when focusing on new construction projects including; motorways, runways, driveways & industrial flooring.
Both size and type of aggregate have a great influence on the overall hardness of concrete and also the blade to choose. The aggregate will make up up to 75% in the total volume. Typically, larger aggregate tends to make your 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 often sand. Sand may either be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you need to know where sand originates from. Crushed sand and bank sand are often sharp; river sand is often round.
Selection for core drilling operation will also requires learning the diameter of the final hole required, surface finish in the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and simplicity of use can also be important for selecting the most appropriate 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 assist in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated considerable amounts of dust. While wet cutting or drilling operation does not generate dust as it uses water, the instance of dust is almost 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 important in jobsites which may have single doors or window openings to get cut out or the location where the saw needs to be constantly moved from a single floor to the next. Some machines work in a modular system thus bringing in certain advantages, since the single component might be easier transported and installed.
With respect to costs, these machines are not very expensive machines and in case regularly maintained, the expense of maintenance might be kept as little as any machine an annual spend of about 6% – 10% of the cost of the equipment.
The buzz is clearly lighter, lesser, faster and more profitable. But what comes along with this development can be a stronger demand that operators be trained effectively. Also, contractors should be made aware or there should be pros who can recommend the ideal techniques and equipment for efficient and cost-effective cutting at any stage of your 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 involved in training the dealers and customers’ maintenance personnel. They perform a crucial role inside the daily operation in our company. “Akhil Jain, CEO, Prime Technologies.