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. Because of a heightened 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 these 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 expenses involved with most sawing and Core cutting machine, the pace with which the job is carried out is becoming vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies on guessing and operator learning from mistakes only cause waste of money and time.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 types of concrete sawing & drilling.
“The market for floor saws, wall saws and powered drilling machines have been in a nascent stage today but growing at about 40% yearly as the fee for labor rises, the application of machines to accelerate work and increase productivity and excellence of work boosts phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines are in operation. Low Powered Handheld Drilling and sawing happen to be 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 can offer 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 capability to cut heavily-reinforced concrete.
You will find hardly any organized players from the core cutting arena. A lot of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. As in almost every other industry, the industry is flooded with Chinese equipment and fly by night traders who sell inexpensive, poor quality machines from China with the aim of making quick money. These machines, however, do not have post sales support nor will be the machines suited and made 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 consider inferior Chinese makes but only turn out spending more about repairs.”
With regards to manufacturing facilities in India, just about 25% are produced indigenously, others imported as well as the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is employing it as a its manufacturing facility to advance 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. Throughout the last 5-10 years, the technologies have matured into a stage where even on residential sites, coring may be the preferred technology for fast, vibration-free penetrations. Right now we see the marketplace 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 current market scale of controlled concrete dismantling in India is close to INR 120 crores. This includes branded and unbranded market as well. TYROLIT has a wide array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines is capable of doing drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven Stack core cutting machine highly suitable for drilling at runways. TYROLIT has 27 Global Production Units and its particular core cutting machines and drills are manufactured in Switzerland, Austria, United statesA. and also other parts around the globe. These machines include a manufacturing warranty of twelve months. Also these are generally quite sturdy machines and require extremely low mainte-nance. TYROLIT’s Unique Service Concept provides several of the service requirement at site to deal with emergency Breakdowns.
Diabu Machines has entered the Indian market. Designed remembering 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 productivity. Diabu uses top quality and right configuration steel, longevity and maintenance free bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not all fasteners are made from either steel or rust proof and high tensile steel. Apart from being user-friendly, maintenance is likewise really easy with an easy task to access grease and oil points.
“There can be a significant desire for education about controlled dismantling as a technology inside the construction industry. Other challenges relate with acceptability and adaptability of 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 right blade (for that saw, the fabric and the job) is a vital factor in getting maximum performance. Many other variables also affect blade performance. Changing any variable will 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 main concrete cutting tools which are utilized add the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is usually specified to reduce precise dimensional door, vent and window openings. Straight along with bevel cuts are possible using the wall saw. The wall saw is also a great choice for creating precise openings in almost any concrete structure. Flat sawing is typically employed to cut horizontal flat surfaces including floors, bridge decks, and pavement. Flat saws are normally used to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and take off concrete sections for demolition purposes. Core drilling techniques are employed when precise, circular cuts are important 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 elimination of thick sections of concrete. It is fantastic for removing large sections of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in areas where work space is restricted.
Usually the decision of cutting wet or dry depends on ones preferences and job requirements. Some sawing or drilling is wet, conditions for example water scarcity in sites, requirement to maintain the website clean of water/slurry on account 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 usually advisable to use saws which can be 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.”
Aside from the form of cutting and dry or wet cutting, varieties of concrete also influence the decision in choosing a blade. The size of curing time after concrete is poured greatly affects the way in which a diamond blade will interact with it during cutting. Curing might be influenced by weather (temperature, moisture and season) and the composition (admixtures, aggregate and sand). Cured concrete is typically set a minimum of two days. The sand is totally bonded with the mortar as well as the concrete reaches full hardness. Concrete is generally in their green state for 6 to two days after it is actually poured. In this early state, the sand is just not completely bonded together with the mortar along with 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 considerably more abrasion over a diamond blade. Undercut protection is essential when cutting green concrete to prevent excessive wear on the steel core at the segment weld. Green concrete sawing is typical when working on new construction projects such as; motorways, runways, driveways & industrial flooring.
Both size and kind of aggregate have a great effect on the general hardness of concrete as well as the blade to select. The aggregate will make up up to 75% of your total volume. As a general rule, larger aggregate tends 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 normally sand. Sand either can be sharp (abrasive) or round (non-abrasive). To look for the sharpness of sand, you should know where sand is produced by. Crushed sand and bank sand tend to be sharp; river sand is generally round.
Selection for core drilling operation may also requires understanding the diameter in 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 required for choosing the proper tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter in the core, length of the core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Transformer 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 will not generate dust mainly because it uses water, the instance of dust is virtually totally avoided. However, the slurry generated needs to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Apart from saw speed, the simplicity of transport and installation comes into play in jobsites who have single doors or window openings to get cut out or the location where the saw has to be constantly moved from a floor to another. Some machines function in a modular system thus bringing in certain advantages, because the single component can be easier transported and installed.
When it comes to costs, these machines are not very expensive machines and in case regularly maintained, the fee for maintenance could be kept as low as any machine a yearly spend of about 6% – 10% of the price of the appliance.
The trend is clearly lighter, lesser, faster plus more profitable. But what comes with this development is a stronger demand that operators be trained effectively. Also, contractors needs to be made aware or there has to be professionals who can recommend the ideal techniques and equipment for efficient and cost-effective cutting at any stage of your 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 associated with training the dealers and customers’ maintenance personnel. They perform a huge role from the everyday operation of our company. “Akhil Jain, CEO, Prime Technologies.