Professional types 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. On account of a higher shelling out for infrastructure projects and residential & commercial construction, India holds tremendous potential when it comes to diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of such 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. Given the high labor and overhead costs associated with most sawing and cut to length machine, the pace in which the work is performed is becoming vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator experimentation only result in waste of money and time. Today, in order to remain competitive, the contractors are under pressure to embrace modern-day strategies for concrete sawing & drilling.
“The industry for floor saws, wall saws and powered drilling machines have been in a nascent stage today but growing at about 40% per annum as the expense of labor rises, the usage of machines to quicken work and increase productivity and excellence of 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 happen to be in many thousands which is tough 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. Such as reduced downtime, precision cutting, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the cabability to cut heavily-reinforced concrete.
You will find very few organized players within the core cutting arena. The majority of them are extensions of worldwide manufacturers including Hilti, TYROLIT, Husqvarna and Diabu. As in any other industry, the market is flooded with Chinese equipment and fly by night traders who sell low cost, low quality machines from China with the objective of making quick money. These appliances, however, have zero post 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 get poor quality Chinese makes only turn out spending much more about repairs.”
With respect to manufacturing facilities in India, approximately 25% are created indigenously, the remainder imported as well as the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is employing it as a its manufacturing facility to help develop and expand the production facility for diamond tools and disks as well as to strengthen its position in the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Throughout the last five to ten years, the technology has matured into a 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 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 includes 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 as much as 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven transformer core cutting machine highly ideal for drilling at runways. TYROLIT has 27 Global Production Units along with its core cutting machines and drills are produced in Switzerland, Austria, U.S.A. and also other parts around the world. These machines come with a manufacturing warranty of one year. Also these are typically quite sturdy machines and require suprisingly 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 bearing in mind the Indian working conditions along with the Indian operator, Diabu’s floor saws, wall saws and drilling machines are built in the platform of robust, rigid and high productivity. Diabu uses excellent and right configuration steel, longevity and maintenance free bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not completely fasteners are made from either stainless steel or rust proof and tensile steel. In addition to being user-friendly, maintenance is likewise quite simple with easy to access grease and oil points.
“There is really a significant necessity for education about controlled dismantling being a technology within the construction industry. Other challenges relate to acceptability and adaptability in 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 as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Choosing the proper blade (to the saw, the fabric as well as the job) is a vital consider getting maximum performance. A number of other variables also affect blade performance. Changing any variable may have an effect on cutting speed and blade life.
Concrete cutting becoming 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, along with the wire saw. Wall sawing is usually specified to cut precise dimensional door, vent and window openings. Straight and also bevel cuts are possible with all the wall saw. The wall saw is also an excellent choice for creating precise openings in almost any concrete structure. Flat sawing is normally employed to cut horizontal flat surfaces for example floors, bridge decks, and pavement. Flat saws are typically 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 required 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 concrete sample analysis. Wire sawing can be used removing of thick sections of concrete. It is perfect for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in locations where work area is fixed.
Frequently the decision of cutting wet or dry depends on ones preferences and job requirements. While many sawing or drilling is wet, conditions such as water scarcity in sites, requirement to help keep the website 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 better to use saws which are laser welded or atleast have special reinforced brazing. Using such blades be sure that the very high heat generated during dry cutting fails to damage the blade which may also cause injury and cause accidents.”
Aside from the sort of cutting and dry or wet cutting, types of concrete also influence the decision in picking a blade. The duration of curing time after concrete is poured greatly affects just how a diamond blade will connect to it during cutting. Curing could be affected by weather (temperature, moisture and season) as well as the composition (admixtures, aggregate and sand). Cured concrete is generally set a minimum of 48 hours. The sand is completely bonded together with the mortar and the concrete reaches full hardness. Concrete is usually in the green state for 6 to 48 hrs after it can be poured. In this early state, the sand is not completely bonded with all 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 inside the slurry, and produces far more abrasion with a diamond blade. Undercut protection is vital when cutting green concrete in order to avoid excessive wear in the steel core at the segment weld. Green concrete sawing is usual when focusing on new construction projects including; motorways, runways, driveways & industrial flooring.
The two size and type of aggregate possess a great effect on the overall hardness of concrete along with the blade to decide on. The aggregate can certainly make up as much as 75% of your total volume. On the whole, 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 can either be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you have to know where sand is produced by. Crushed sand and bank sand are often sharp; river sand is usually round.
Choice for core drilling operation will even requires knowing the diameter from the final hole required, surface finish in the drilled hole, surface and accessibility of your drilling area.
“Tool horsepower, tool reliability and convenience are also important 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, Straight 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 will not generate dust since it uses water, the instance of dust is practically totally avoided. However, the slurry generated must be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Besides saw speed, the simplicity of transport and installation is important in jobsites who have single doors or window openings being eliminate or in which the saw must be constantly moved from one floor to the next. Some machines are employed in a modular system thus attracting certain advantages, since the single component might be easier transported and installed.
With respect to costs, these machines are not too expensive machines of course, if regularly maintained, the price of maintenance could be kept as little as any machine a yearly spend of approximately 6% – 10% of the cost of the device.
The trend is clearly lighter, lesser, faster plus more profitable. But what incorporates this development can be a stronger demand that operators be trained effectively. Also, contractors needs to be made aware or there must be experts who can recommend the best techniques and equipment for efficient and cost-effective cutting at any stage in the project.
“On the service front, Prime Technologies features a band of service engineers who definitely are 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 vital role inside the daily operation of our own company. “Akhil Jain, CEO, Prime Technologies.