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 such sophisticated methods is 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 cut to length machine, the pace with which the job is completed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator testing only lead to waste of money and time. Today, in order to remain competitive, the contractors are under pressure to embrace modern-day ways of concrete sawing & drilling.
“The niche for floor saws, wall saws and high powered drilling machines are in a nascent stage today but growing at about 40% per year as the fee for labor rises, the usage of machines to speed up work and increase productivity and quality of work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines have been in operation. Low Powered Handheld Drilling and sawing are in many thousands in fact it is hard 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 ability to cut heavily-reinforced concrete.
You will find very few organized players within the core cutting arena. Most of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. As in some other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell affordable, inferior machines from China with the purpose of making quick money. These machines, however, do not have post sales support nor are the machines suited and built 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 get low quality Chinese makes but only turn out spending much more on repairs.”
When it comes to manufacturing facilities in India, no more than 25% are made indigenously, the remainder imported as well as the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is applying it its manufacturing facility to further develop and expand the development 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. Over the last 5 to 10 years, the technologies have matured to your stage where even on residential sites, coring is the preferred technology for fast, vibration-free penetrations. Right now we see the marketplace for coring at 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 near to INR 120 crores. This includes 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 can do drilling as much as 1000 mm diameters. Its Ultimate Drilling Machine (UDM) can be a self-propelled gasoline driven transformer core cutting machine highly suited to drilling at runways. TYROLIT has 27 Global Production Units along with its core cutting machines and drills are made in Switzerland, Austria, United statesA. and other parts of the world. These machines come with a manufacturing warranty of one year. Also these are quite sturdy machines and require really low mainte-nance. TYROLIT’s Unique Service Concept provides a few 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 also the Indian operator, Diabu’s floor saws, wall saws and drilling machines are designed on the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, long life and easy to maintain bearings, dust and water protected motors, bearings and all sorts of sliding and rotating parts. Most if not completely fasteners are made from either stainless or rust proof and high tensile steel. Apart from being simple to use, maintenance is likewise very simple with very easy to access grease and oil points.
“There is a significant necessity 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 related to the technology because this is expensive, application with illiterate labor and localized option of the technology.”
Choosing the right blade (to the saw, the fabric as well as the job) is an essential aspect in getting maximum performance. Many other variables also affect blade performance. Changing any variable could have an impact on cutting speed and blade life.
Concrete cutting as an application oriented process, blades are supplied according to end application requirement and job site requirements. The primary concrete cutting tools that are utilized add the wall (or track) saw, the flat (or slab) saw, the core drill, along with the wire saw. Wall sawing is usually specified to slice precise dimensional door, vent and window openings. Straight along with bevel cuts are possible with all the wall saw. The wall saw is additionally a fantastic choice for creating precise openings in virtually any concrete structure. Flat sawing is generally accustomed to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are typically utilized 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 used when precise, circular cuts are essential 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 perhaps for concrete sample analysis. Wire sawing can be used removal of thick sections of concrete. It is fantastic for removing large parts of heavily reinforced concrete, for example piers, towers and bridge sections, and cutting concrete in locations where work space is restricted.
Most of the decision of cutting wet or dry depends on ones preferences and job requirements. While most sawing or drilling is wet, conditions such as water scarcity in sites, requirement to hold the internet 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 usually is 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 is not going to damage the blade which may also cause injury and cause accidents.”
Apart from the kind of cutting and dry or wet cutting, kinds of concrete also influence your decision in picking a blade. The size of curing time after concrete is poured greatly affects the way a diamond blade will interact with it during cutting. Curing can be influenced by weather (temperature, moisture and time of year) along with the composition (admixtures, aggregate and sand). Cured concrete is typically set a minimum of 2 days. The sand is completely bonded with all the mortar along with the concrete reaches full hardness. Concrete is typically in the green state for 6 to 2 days after it is actually poured. In this early state, the sand is not really completely bonded together with the mortar along with the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely inside the slurry, and produces a lot more abrasion over a diamond blade. Undercut protection is vital when cutting green concrete to stop excessive wear about the steel core at the segment weld. Green concrete sawing is common when taking care of new construction projects for example; motorways, runways, driveways & industrial flooring.
The size and type of aggregate have got a great influence on the overall hardness of concrete along with the blade to pick. The aggregate can make up just as much as 75% from the total volume. Typically, larger aggregate will 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 often sand. Sand either can 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 tend to be sharp; river sand is usually round.
Choice for core drilling operation will even requires learning the diameter in the final hole required, surface finish of your drilled hole, surface and accessibility of your drilling area.
“Tool horsepower, tool reliability and convenience will also be required for choosing the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter of the core, entire 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 for the project.”
Conventional concrete cutting and drilling methods generated considerable amounts of dust. While wet cutting or drilling operation is not going to generate dust mainly 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.
In addition to saw speed, the ease of transport and installation comes into play in jobsites who have single doors or window openings to become reduce or where the saw needs 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.
With regards to costs, this equipment is not expensive machines of course, if regularly maintained, the cost of maintenance can be kept as little as any machine a yearly spend of approximately 6% – 10% of the price of the device.
The popularity is clearly lighter, lesser, faster plus more profitable. But what comes with this development is actually a stronger demand that operators be trained effectively. Also, contractors must be made aware or there has to be experts who can recommend the most effective techniques and equipment for the best efficient and expense-effective cutting at any stage from the project.
“On the service front, Prime Technologies features a band of service engineers who happen to be 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 a vital role inside the day-to-day operation in our company. “Akhil Jain, CEO, Prime Technologies.