Professional strategies for concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it is still a young but growing industry. On account 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 is definitely the constantly rising labour costs. Within the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Due to the high labor and expenses associated with most sawing and Core cutting machine, the rate with which the task is carried out has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator learning from mistakes only cause waste of money and time. Today, to be able to remain competitive, the contractors are under pressure to embrace more sophisticated strategies for concrete sawing & drilling.
“The market for floor saws, wall saws and high powered drilling machines are in a nascent stage today but growing at about 40% yearly as the fee for 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 High Powered Drilling Machines happen to be 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 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 only a few organized players inside the core cutting arena. Many of them are extensions of worldwide manufacturers including Hilti, TYROLIT, Husqvarna and Diabu. As with every other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell inexpensive, poor machines from China with the objective of making quick money. These machines, however, have zero after sales support nor are the machines suited and built 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 choose poor quality Chinese makes but only turn out spending much more on repairs.”
With respect to manufacturing facilities in India, just about 25% are made indigenously, the remainder imported as well as the bulk coming from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is employing it as its manufacturing facility to increase develop and expand the production facility for diamond tools and disks as well as to strengthen its position within the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the last five to ten years, the technologies have matured to some stage where even on residential sites, coring will 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 marketplace dimensions of controlled concrete dismantling in India is close to INR 120 crores. This consists of branded and unbranded market also. TYROLIT has a variety of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing drilling around 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven transformer core cutting machine highly suitable for drilling at runways. TYROLIT has 27 Global Production Units and its core cutting machines and drills are created in Switzerland, Austria, UsaA. along with other parts around the globe. These appliances feature a manufacturing warranty of 12 months. Also these are quite sturdy machines and require suprisingly low mainte-nance. TYROLIT’s Unique Service Concept provides a few 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 designed about 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 manufactured from either steel or rust proof and high tensile steel. Aside from being user-friendly, maintenance is also really easy with very easy to access grease and oil points.
“There is a significant desire for education about controlled dismantling as being a technology from the construction industry. Other challenges relate to acceptability and adaptability from the technology in a number of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics related to the technology as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Choosing the right blade (for your saw, the material and also the job) is a vital factor in getting maximum performance. A number of other variables also affect blade performance. Changing any variable will have an effect on cutting speed and blade life.
Concrete cutting being an application oriented process, blades are supplied based on end application requirement and job site requirements. The main concrete cutting tools that are utilized add 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 reduce precise dimensional door, vent and window openings. Straight in addition to bevel cuts are possible with the wall saw. The wall saw is also a great choice for creating precise openings in every concrete structure. Flat sawing is usually used to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are normally utilized to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and remove concrete sections for demolition purposes. Core drilling techniques are being 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 for concrete sample analysis. Wire sawing can be used elimination of thick sections of concrete. It is perfect for removing large parts of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in places that work area is restricted.
Frequently the decision of cutting wet or dry depends upon ones preferences and job requirements. Some sawing or drilling is wet, conditions such as water scarcity in sites, requirement to hold the site clean of water/slurry due to 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 usually better to use saws that happen to be 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.”
Besides the type of cutting and dry or wet cutting, varieties of concrete also influence the decision in picking a blade. The size of curing time after concrete is poured greatly affects the way in which a diamond blade will connect to it during cutting. Curing could be affected by weather (temperature, moisture and season) and the composition (admixtures, aggregate and sand). Cured concrete is normally set no less than 2 days. The sand is completely bonded with all the mortar and also the concrete reaches full hardness. Concrete is typically in their green state for 6 to 48 hrs after it is poured. In this early state, the sand is not completely bonded together with the mortar and 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 considerably more abrasion on a diamond blade. Undercut protection is crucial when cutting green concrete to stop excessive wear around the steel core with the segment weld. Green concrete sawing is usual when working on new construction projects including; motorways, runways, driveways & industrial flooring.
The two size and type of aggregate use a great impact on the entire hardness of concrete along with the blade to choose. The aggregate can make up up to 75% of your total volume. As a general rule, larger aggregate has a tendency to have the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is section 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 must know where the sand comes from. Crushed sand and bank sand are generally sharp; river sand is usually round.
Selection for core drilling operation will even requires learning the diameter of your final hole required, surface finish in the drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and simplicity can also be required for choosing the proper tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter in 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 assistance in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated a lot of dust. While wet cutting or drilling operation fails to generate dust mainly because it uses water, the instance of dust is virtually totally avoided. However, the slurry generated has to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Aside from saw speed, the ease of transport and installation is important in jobsites which may have single doors or window openings to become cut out or where saw must be constantly moved from a single floor to another. Some machines function in a modular system thus bringing in certain advantages, since the single component may be easier transported and installed.
When it comes to costs, these machines are not very expensive machines and in case regularly maintained, the expense of maintenance may be kept as low as any machine a yearly spend of about 6% – 10% of the price tag on the device.
The popularity is clearly lighter, lesser, faster and a lot more profitable. But what comes with this development is actually a stronger demand that operators be trained effectively. Also, contractors needs to be made aware or there should be professionals who can suggest the best techniques and equipment for the most efficient and cost-effective cutting at any stage from the project.
“On the service front, Prime Technologies includes a band of service engineers who happen to be 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 a crucial role from the day-to-day operation of our company. “Akhil Jain, CEO, Prime Technologies.