Professional ways 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. Due to an elevated shelling out for 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 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 involved in most sawing and Core cutting machine, the speed which the job is done has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator learning from mistakes only cause waste of time and money. Today, to be able to remain competitive, the contractors are under pressure to embrace modern-day strategies for concrete sawing & drilling.
“The marketplace for floor saws, wall saws and powered drilling machines have been in a nascent stage today but growing at about 40% per year as the price of labor rises, the application of machines to quicken work and increase productivity superiority work boosts phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines will be in operation. Low Powered Handheld Drilling and sawing will be 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 provide significant advantages over conventional concrete removal methods. These include 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 hardly any organized players within the core cutting arena. The majority of them are extensions of worldwide manufacturers including Hilti, TYROLIT, Husqvarna and Diabu. As with some 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, do not have after sales support nor would be the machines suited and built 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 poor quality Chinese makes only end up spending more on repairs.”
When it comes to manufacturing facilities in India, approximately 25% are made indigenously, the others imported and also the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is employing it its manufacturing facility to increase develop and expand the development facility for diamond tools and disks and also to strengthen its position within the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the last 5-10 years, the technology has matured to some stage where even on residential sites, coring may be the preferred technology for fast, vibration-free penetrations. We currently see the market 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 marketplace scale of controlled concrete dismantling in India is in close proximity to INR 120 crores. This consists of branded and unbranded market also. TYROLIT has a wide array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing 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 and its core cutting machines and drills are created in Switzerland, Austria, United statesA. along with other parts around the world. These machines come with a manufacturing warranty of twelve months. Also these are typically 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 recently entered the Indian market. Designed keeping in mind the Indian working conditions along with the Indian operator, Diabu’s floor saws, wall saws and drilling machines are made in the platform of robust, rigid and productivity. Diabu uses high quality and right configuration steel, extended life and maintenance free bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not completely fasteners are manufactured from either stainless-steel or rust proof and high tensile steel. In addition to being simple to use, maintenance can also be really easy with an easy task to access grease and oil points.
“There is actually a significant desire 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 typical chisel and hammer, economics associated with the technology as this is expensive, application with illiterate labor and localized availability of the technology.”
Choosing the proper blade (for that saw, the fabric as well as the job) is a vital consider getting maximum performance. Many other variables also affect blade performance. Changing any variable may 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 primary concrete cutting tools that are utilized range from the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is typically specified to slice precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible with the wall saw. The wall saw is additionally an outstanding selection for creating precise openings in virtually any concrete structure. Flat sawing is generally employed 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, clean and repair random cracks dexqpky76 repair, and remove concrete sections for demolition purposes. Core drilling techniques are employed when precise, circular cuts are required 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 even for concrete sample analysis. Wire sawing can be used elimination of thick parts of concrete. It is fantastic for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in areas where work area is fixed.
Usually the decision of cutting wet or dry depends upon ones preferences and job requirements. While many sawing or drilling is wet, conditions including 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 will always be advisable to use saws which are laser welded or atleast have special reinforced brazing. Using such blades ensure that the extremely high heat generated during dry cutting will not damage the blade which can also cause injury and cause accidents.”
Aside from the form of cutting and dry or wet cutting, types of concrete also influence the decision in choosing a blade. The size of curing time after concrete flows greatly affects how a diamond blade will connect with it during cutting. Curing might be influenced by weather (temperature, moisture and time of year) along with the composition (admixtures, aggregate and sand). Cured concrete is usually set at least two days. The sand is entirely bonded with all the mortar along with the concrete reaches full hardness. Concrete is normally in their green state for 6 to 2 days after it is poured. In this early state, the sand is not completely bonded using the mortar and also 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 far more abrasion with a diamond blade. Undercut protection is critical when cutting green concrete to prevent excessive wear around the steel core at the segment weld. Green concrete sawing is common when concentrating on new construction projects such as; motorways, runways, driveways & industrial flooring.
Both the size and kind of aggregate use a great affect on the entire hardness of concrete along with the blade to decide on. The aggregate can certainly make up up to 75% from the total volume. For the most part, larger aggregate is likely to make the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is part 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 the location where the sand is produced by. Crushed sand and bank sand are generally sharp; river sand is normally round.
Choice for core drilling operation may also requires learning the diameter of the final hole required, surface finish in the drilled hole, surface and accessibility of your drilling area.
“Tool horsepower, tool reliability and simplicity will also be necessary for choosing the proper tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter of your 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 help 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 mainly because it uses water, the instance of dust is nearly totally avoided. However, the slurry generated must be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Apart from saw speed, the simplicity of transport and installation is important in jobsites which may have single doors or window openings to be cut out or where the saw has to be constantly moved from a floor to the next. Some machines function in a modular system thus attracting certain advantages, as being the single component could be easier transported and installed.
When it comes to costs, these machines are not very expensive machines and in case regularly maintained, the cost of maintenance can be kept as low as any machine an annual spend around 6% – 10% of the price tag on the equipment.
The buzz is clearly lighter, lesser, faster and a lot more profitable. But what comes along with this development is actually a stronger demand that operators be trained effectively. Also, contractors must be made aware or there must be pros who can suggest the best techniques and equipment for efficient and expense-effective cutting at any stage from the project.
“On the service front, Prime Technologies carries 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 from the day-to-day operation in our company. “Akhil Jain, CEO, Prime Technologies.