Professional methods 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. On account of an increased shelling out for infrastructure projects and residential & commercial construction, India holds tremendous potential in terms of 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. Due to the high labor and overhead costs associated with most sawing and Core cutting machine, the speed with which the work is done has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator experimentation only lead to waste of money and time. Today, in order to remain competitive, the contractors are under pressure to embrace more sophisticated types of concrete sawing & drilling.
“The marketplace for floor saws, wall saws and high powered drilling machines are in a nascent stage today but growing at about 40% each year as the expense of labor rises, the use of machines to quicken work and increase productivity and excellence of work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines have been in operation. Low Powered Hand Held Drilling and sawing have been 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 offers significant advantages over conventional concrete removal methods. Included in this are reduced downtime, precision cutting, repair of structural integrity, reduced noise, dust and debris, limited-access cutting, and the opportunity to cut heavily-reinforced concrete.
You can find very few organized players in the core cutting arena. The majority of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. Like almost every 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 goal of making quick money. These appliances, however, do not have post sales support nor will be the machines suited and designed 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 go for inferior Chinese makes but only find yourself spending more on repairs.”
Regarding manufacturing facilities in India, only about 25% are made indigenously, the others imported along with the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is employing it its manufacturing facility to further develop and expand the development facility for diamond tools and disks as well as to strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the last 5-10 years, the technologies have matured to your stage where even on residential sites, coring is definitely the preferred technology for fast, vibration-free penetrations. Right now we see the market 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 size of controlled concrete dismantling in India is close to INR 120 crores. This consists of branded and unbranded market also. TYROLIT has a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling around 1000 mm diameters. Its Ultimate Drilling Machine (UDM) can be a self-propelled gasoline driven Stack core cutting machine highly suitable for drilling at runways. TYROLIT has 27 Global Production Units along with its core cutting machines and drills are manufactured in Switzerland, Austria, UsaA. along with other parts on the planet. These machines include a manufacturing warranty of 1 year. Also these are 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 recently entered the Indian market. Designed remembering the Indian working conditions and also the Indian operator, Diabu’s floor saws, wall saws and drilling machines are built in the platform of robust, rigid and productivity. Diabu uses good quality and right configuration steel, extended life and maintenance free bearings, dust and water protected motors, bearings and all of sliding and rotating parts. Most if not completely fasteners are made from either steel or rust proof and tensile steel. Aside from being simple to use, maintenance can also be very simple with an easy task to access grease and oil points.
“There can be a significant need for education about controlled dismantling as being a technology inside the construction industry. Other challenges relate to acceptability and adaptability of your technology in some of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics of the technology because this is expensive, application with illiterate labor and localized option of the technology.”
Selecting the most appropriate blade (to the saw, the information as well as the job) is the most important element in getting maximum performance. A number of other variables also affect blade performance. Changing any variable can 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 are utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is normally specified to slice precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible together with the wall saw. The wall saw is additionally an excellent choice for creating precise openings in almost any concrete structure. Flat sawing is normally utilized 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, clean 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 like 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 for removal of thick sections of concrete. It is great for removing large sections of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in locations where work space is restricted.
Usually the decision of cutting wet or dry depends upon ones preferences and job requirements. While most sawing or drilling is wet, conditions such as water scarcity in sites, requirement to help keep the website clean of water/slurry due to 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 be sure that the very high heat generated during dry cutting is not going to damage the blade which could also cause injury and cause accidents.”
In addition to the kind of cutting and dry or wet cutting, types of concrete also influence the choice when choosing a blade. The length of curing time after concrete flows greatly affects how a diamond blade will communicate with it during cutting. Curing could be affected by weather (temperature, moisture and period) as well as the composition (admixtures, aggregate and sand). Cured concrete is normally set at least 48 hrs. The sand is completely bonded using the mortar along with the concrete reaches full hardness. Concrete is usually in their green state for 6 to 48 hours after it really is poured. In this early state, the sand will not be 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 from the slurry, and produces much more abrasion on the diamond blade. Undercut protection is vital when cutting green concrete in order to avoid excessive wear in the steel core with the segment weld. Green concrete sawing is common when focusing on new construction projects such as; motorways, runways, driveways & industrial flooring.
Both the size and type of aggregate use a great effect on the overall hardness of concrete as well as the blade to pick. The aggregate will make up just as much as 75% from the total volume. For the most part, larger aggregate will create 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 generally sand. Sand may either be sharp (abrasive) or round (non-abrasive). To discover the sharpness of sand, you must know where the sand is from. Crushed sand and bank sand are often sharp; river sand is generally round.
Selection for core drilling operation may also requires knowing the diameter of the final hole required, surface finish from the drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and simplicity of use will also be required for choosing the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter in 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 to use 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 since 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 ease of transport and installation comes into play in jobsites who have single doors or window openings to get reduce or in which the saw should be constantly moved from a floor to another. Some machines work in a modular system thus bringing in certain advantages, because the single component can be easier transported and installed.
With regards to costs, this equipment is not so expensive machines of course, if regularly maintained, the expense of maintenance may be kept as little as any machine a yearly spend of approximately 6% – 10% of the price of the machine.
The buzz is clearly lighter, lesser, faster plus more profitable. But what incorporates this development is really a stronger demand that operators be trained effectively. Also, contractors should be made aware or there must be experts who can suggest the most effective techniques and equipment for efficient and cost-effective cutting at any stage from the project.
“On the service front, Prime Technologies has a band of service engineers who are always roaming and actively engage themselves in providing solutions and technical advice to clients. They are also involved in training the dealers and customers’ maintenance personnel. They perform an important role in the daily operation of our company. “Akhil Jain, CEO, Prime Technologies.