Professional methods 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. On account of a heightened 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 the sophisticated methods may be the constantly rising labour costs. During the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Given the high labor and overhead costs linked to most sawing and Core cutting machine, the speed in which the task is completed has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator learning from mistakes only cause waste of money and time. Today, so that you can 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 are in a nascent stage today but growing at about 40% each year as the cost of labor rises, the application of machines to quicken work and increase productivity and quality of work boosts phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines have been in operation. Low Powered Handheld Drilling and sawing have been 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 offer 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 will find not many organized players from the core cutting arena. Most of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. As in any other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell low cost, inferior machines from China with the goal of making quick money. These machines, however, have no post sales support nor would be the machines suited and built to function 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 only turn out spending more about repairs.”
With regards to manufacturing facilities in India, just about 25% are manufactured indigenously, the remainder imported along with the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is applying it its manufacturing facility to help develop and expand the development facility for diamond tools and disks as well as strengthen its position inside the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past 5-10 years, the technologies have matured to a stage where even on residential sites, coring will be the preferred technology for fast, vibration-free penetrations. We currently 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 near to INR 120 crores. This consists of branded and unbranded market as well. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling around 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is a self-propelled gasoline driven EI core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units along with its core cutting machines and drills are made in Switzerland, Austria, United statesA. and also other parts around the world. These machines feature a manufacturing warranty of 12 months. Also these are quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides some of the service requirement at site to care for emergency Breakdowns.
Diabu Machines recently entered the Indian market. Designed remembering the Indian working conditions as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are made on the platform of robust, rigid and high productivity. Diabu uses excellent and right configuration steel, extended life and maintenance free bearings, dust and water protected motors, bearings and all sliding and rotating parts. Most if not all fasteners are produced from either stainless or rust proof and high tensile steel. Besides being user-friendly, maintenance is also really easy with easy to access grease and oil points.
“There is actually a significant necessity for education about controlled dismantling like a technology within 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 traditional chisel and hammer, economics associated with the technology as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Choosing the right blade (to the saw, the content along with the job) is the most essential aspect in getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable can have an impact 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 principle concrete cutting tools which are utilized are the wall (or track) saw, the flat (or slab) saw, the core drill, and the wire saw. Wall sawing is generally specified to cut precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible together with the wall saw. The wall saw can also be a fantastic option for creating precise openings in any concrete structure. Flat sawing is typically employed to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are usually used 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 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 for concrete sample analysis. Wire sawing can be used as removing of thick parts of concrete. It is great for removing large parts of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in places that work area is restricted.
Most of the decision of cutting wet or dry depends on ones preferences and job requirements. While most sawing or drilling is wet, conditions for example water scarcity in sites, requirement to keep the website clean water/slurry because of proximity with existing office/ factory /commercial/residential space, proximity to electrical or other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is usually wise 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 could also cause injury and cause accidents.”
In addition to the kind of cutting and dry or wet cutting, varieties of concrete also influence the choice in picking a blade. The size of curing time after concrete flows greatly affects just how a diamond blade will connect with it during cutting. Curing may be impacted by weather (temperature, moisture and period) as well as the composition (admixtures, aggregate and sand). Cured concrete is generally set no less than 48 hours. The sand is completely bonded with the mortar and the concrete reaches full hardness. Concrete is usually in the green state for 6 to 48 hours after it is actually poured. In this particular early state, the sand will not be completely bonded using the mortar along with the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely in the slurry, and produces considerably more abrasion on the diamond blade. Undercut protection is critical when cutting green concrete to stop excessive wear about the steel core with the segment weld. Green concrete sawing is usual when concentrating on new construction projects including; motorways, runways, driveways & industrial flooring.
The two size and type of aggregate possess a great influence on the general hardness of concrete and the blade to decide on. The aggregate will make up as much as 75% of the total volume. For the most part, larger aggregate has a tendency to make the concrete act harder, slowing drilling process. Smaller aggregates make a blade cut faster. Sand is portion of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is usually sand. Sand either can be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you should know where the sand is from. Crushed sand and bank sand are often sharp; river sand is often round.
Choice for core drilling operation will likely requires understanding the diameter from the final hole required, surface finish in the drilled hole, surface and accessibility from 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 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 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 mainly because it uses water, the instance of dust is nearly totally avoided. However, the slurry generated needs to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
In addition to saw speed, the ease of transport and installation comes into play in jobsites that have single doors or window openings to be eliminate or where saw has to be constantly moved from a single floor to the next. Some machines are employed in a modular system thus bringing in certain advantages, as the single component could be easier transported and installed.
Regarding costs, this equipment is not expensive machines and in case regularly maintained, the price of maintenance could be kept only any machine an annual spend of about 6% – 10% of the price tag on the appliance.
The popularity is clearly lighter, lesser, faster and much more profitable. But what comes with this development is actually a stronger demand that operators be trained effectively. Also, contractors must be made aware or there has to be pros who can recommend the most effective techniques and equipment for efficient and cost-effective cutting at any stage of the project.
“On the service front, Prime Technologies includes 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 an important role from the day-to-day operation in our company. “Akhil Jain, CEO, Prime Technologies.