Professional types of concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it really is still a young but growing industry. Because of an elevated shelling out for infrastructure projects and residential & commercial construction, India holds tremendous potential regarding 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. Because of the high labor and expenses linked to most sawing and cut to length machine, the speed in which the work is done has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator experimentation only lead to waste of money and time. Today, as a way to remain competitive, the contractors are under pressure to embrace more sophisticated methods of concrete sawing & drilling.
“The industry for floor saws, wall saws and high powered drilling machines have been in a nascent stage today but growing at about 40% per year as the expense of labor rises, the usage of machines to accelerate work and increase productivity and excellence of work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines are in operation. Low Powered Hand Held Drilling and sawing happen to be in many thousands and it 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. 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 can find hardly any organized players from the core cutting arena. The majority of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. As with any other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell low priced, low quality machines from China with the objective of making quick money. These appliances, however, do not have post sales support nor are definitely 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 consider poor quality Chinese makes only wind up spending more about repairs.”
With respect to manufacturing facilities in India, no more than 25% are produced indigenously, the others imported and the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is utilizing it its manufacturing facility to help develop and expand the production facility for diamond tools and disks as well as strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past five to ten years, the technology has matured to a 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 over 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the current market measurements of controlled concrete dismantling in India is near to INR 120 crores. This can include branded and unbranded market too. 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) is really a self-propelled gasoline driven Stack core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are manufactured in Switzerland, Austria, UsaA. and also other parts around the globe. These appliances have 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 manage emergency Breakdowns.
Diabu Machines has entered the Indian market. Designed remembering the Indian working conditions and the Indian operator, Diabu’s floor saws, wall saws and drilling machines are constructed about the platform of robust, rigid and productivity. Diabu uses good 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 all fasteners are manufactured from either stainless-steel or rust proof and high tensile steel. In addition to being user-friendly, maintenance is likewise quite simple with easy to access grease and oil points.
“There is actually a significant necessity for education about controlled dismantling as a technology within the construction industry. Other challenges correspond with acceptability and adaptability in the technology in several of the major projects, drilling and sawing vis-à-vis the standard chisel and hammer, economics of the technology since this is expensive, application with illiterate labor and localized accessibility of the technology.”
Selecting the most appropriate blade (for that saw, the fabric along with the job) is an essential element in getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable could 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 primary concrete cutting tools that are utilized range from the wall (or track) saw, the flat (or slab) saw, the core drill, along with the wire saw. Wall sawing is typically 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 can also be a great choice for creating precise openings in almost any concrete structure. Flat sawing is normally used to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are generally employed 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 important 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 parts of concrete. It is great for removing large sections of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in locations where work area is restricted.
Often the decision of cutting wet or dry depends upon ones preferences and job requirements. While most sawing or drilling is wet, conditions like water scarcity in sites, requirement to maintain the site clean of water/slurry on account 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 preferable to use saws that are laser welded or atleast have special reinforced brazing. Using such blades ensure that the extremely high heat generated during dry cutting fails to damage the blade which could also cause injury and cause accidents.”
Aside from the type of cutting and dry or wet cutting, forms of concrete also influence the decision in selecting a blade. The duration of curing time after concrete flows greatly affects the way a diamond blade will interact with it during cutting. Curing may be afflicted with weather (temperature, moisture and time of year) and also the composition (admixtures, aggregate and sand). Cured concrete is usually set at the very least 2 days. The sand is utterly bonded together with the mortar and the concrete reaches full hardness. Concrete is normally in its green state for 6 to two days after it really is poured. Within this early state, the sand is not really completely bonded together 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 from the slurry, and produces much more abrasion on a diamond blade. Undercut protection is vital when cutting green concrete to avoid excessive wear around the steel core with the segment weld. Green concrete sawing is normal when concentrating on new construction projects such as; motorways, runways, driveways & industrial flooring.
The size and kind of aggregate possess a great impact on the general hardness of concrete as well as the blade to pick. The aggregate can certainly make up as much as 75% from the total volume. On the whole, larger aggregate will create 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 often sand. Sand either can be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you should know where sand is produced by. Crushed sand and bank sand are generally sharp; river sand is normally round.
Selection for core drilling operation will also requires knowing the diameter from the final hole required, surface finish of your drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and ease of use are also essential for selecting 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 assistance 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 nearly totally avoided. However, the slurry generated has to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Besides saw speed, the simplicity of transport and installation comes into play in jobsites which have single doors or window openings to get eliminate or where saw has to be constantly moved in one floor to another. Some machines function in a modular system thus bringing in certain advantages, as the single component might be easier transported and installed.
When it comes to costs, this equipment is not so expensive machines of course, if regularly maintained, the cost of maintenance could be kept only any machine a yearly spend of approximately 6% – 10% of the buying price of the equipment.
The trend is clearly lighter, lesser, faster and more profitable. But what comes along with this development is really a stronger demand that operators be trained effectively. Also, contractors needs to be made aware or there ought to be pros who can recommend the ideal techniques and equipment for the most efficient and cost-effective cutting at any stage from the project.
“On the service front, Prime Technologies carries a band of service engineers who are always roaming and actively engage themselves in providing solutions and technical advice to clients. Also, they are linked to training the dealers and customers’ maintenance personnel. They perform a huge role in the everyday operation in our company. “Akhil Jain, CEO, Prime Technologies.