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 an increased 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 these sophisticated methods will be the constantly rising labour costs. During the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Because of the high labor and overhead costs linked to most sawing and Core cutting machine, the pace in which the work is done has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator testing only result in waste of time and money. Today, in order to remain competitive, the contractors are under pressure to embrace more sophisticated ways of concrete sawing & drilling.
“The industry for floor saws, wall saws and powered drilling machines will be in a nascent stage today but growing at about 40% each year as the expense of labor rises, using machines to increase 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 are in many thousands and is particularly hard to give even an approximate number.” – M.Venkatesh, Executive Director, Diabu Diamond Tools
Professional diamond concrete cutting systems provides 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 cabability to cut heavily-reinforced concrete.
You will find hardly any organized players in the core cutting arena. Many 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, low quality machines from China with the goal of making quick money. These appliances, however, have zero after sales support nor will be the machines suited and made 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 get poor quality Chinese makes but only end up spending much more on repairs.”
With respect to manufacturing facilities in India, just about 25% are created indigenously, the rest imported and the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is utilizing it as its manufacturing facility to increase develop and expand the production 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. Right now we see the marketplace 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 dimensions of controlled concrete dismantling in India is near to INR 120 crores. This can include branded and unbranded market as well. TYROLIT has a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven Stack core cutting machine highly suited to drilling at runways. TYROLIT has 27 Global Production Units and its particular core cutting machines and drills are made in Switzerland, Austria, United statesA. and other parts on the planet. These machines have a manufacturing warranty of 12 months. Also they are quite sturdy machines and require suprisingly low mainte-nance. TYROLIT’s Unique Service Concept provides a few of the service requirement at site to manage emergency Breakdowns.
Diabu Machines has recently entered the Indian market. Designed bearing in mind the Indian working conditions as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are made about the platform of robust, rigid and high productivity. Diabu uses top quality and right configuration steel, extended life and easy to maintain bearings, dust and water protected motors, bearings and all of sliding and rotating parts. Most if not all fasteners are made from either stainless steel or rust proof and high tensile steel. Apart from being user friendly, maintenance is likewise very easy with an easy task to access grease and oil points.
“There can be a significant need for education about controlled dismantling being a technology from the construction industry. Other challenges correspond with acceptability and adaptability in the technology in a number of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics associated with the technology as this is expensive, application with illiterate labor and localized accessibility to the technology.”
Selecting the most appropriate blade (for your saw, the information and the job) is an essential aspect in getting maximum performance. A number of other variables also affect blade performance. Changing any variable could have an effect on cutting speed and blade life.
Concrete cutting being an application oriented process, blades are supplied as per end application requirement and job site requirements. The primary 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 cut precise dimensional door, vent and window openings. Straight along with bevel cuts are possible with the wall saw. The wall saw is also a great option for creating precise openings in every concrete structure. Flat sawing is usually utilized to cut horizontal flat surfaces like 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 remove concrete sections for demolition purposes. Core drilling techniques are being used when precise, circular cuts are needed 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 removing of thick sections of concrete. It is fantastic for removing large parts of heavily reinforced concrete, for example piers, towers and bridge sections, and cutting concrete in locations where work area is restricted.
Usually the decision of cutting wet or dry is determined by ones preferences and job requirements. Some sawing or drilling is wet, conditions for example water scarcity in sites, requirement to keep the website clean of water/slurry due to proximity with existing office/ factory /commercial/residential space, proximity to electrical or another 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 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 may also cause injury and cause accidents.”
Aside from the sort of cutting and dry or wet cutting, types of concrete also influence the choice in choosing a blade. The size of curing time after concrete flows greatly affects the way a diamond blade will communicate with it during cutting. Curing could be influenced by weather (temperature, moisture and time of year) as well as the composition (admixtures, aggregate and sand). Cured concrete is normally set at least 2 days. The sand is entirely bonded together with the mortar and also the concrete reaches full hardness. Concrete is normally in the green state for 6 to 2 days after it is actually poured. In this early state, the sand is just not completely bonded using the mortar and 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 a lot more abrasion on a diamond blade. Undercut protection is vital when cutting green concrete to stop excessive wear about the steel core with the segment weld. Green concrete sawing is common when working on new construction projects for example; motorways, runways, driveways & industrial flooring.
The size and type of aggregate have a great impact on the overall hardness of concrete and the blade to pick. The aggregate can certainly make up just as much as 75% from the total volume. Typically, larger aggregate tends to make your concrete act harder, slowing drilling process. Smaller aggregates make a blade cut faster. Sand is area 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 discover the sharpness of sand, you should know where the sand originates from. Crushed sand and bank sand are usually sharp; river sand is normally round.
Choice for core drilling operation will likely requires knowing the diameter in the final hole required, surface finish of your drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and simplicity will also be essential for selecting the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter from 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 assistance in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated huge amounts of dust. While wet cutting or drilling operation does not generate dust as it uses water, the instance of dust is practically 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 is important in jobsites who have single doors or window openings to become eliminate or where the saw must be constantly moved from one floor to the next. Some machines work in a modular system thus attracting certain advantages, as the single component could be easier transported and installed.
With regards to costs, this equipment is not expensive machines and when regularly maintained, the expense of maintenance might be kept as little as any machine an annual spend of about 6% – 10% of the price tag on the machine.
The trend is clearly lighter, lesser, faster and more profitable. But what comes with this development is a stronger demand that operators be trained effectively. Also, contractors must be made aware or there must be experts who can suggest the best techniques and equipment for efficient and expense-effective cutting at any stage in the project.
“On the service front, Prime Technologies has a band of service engineers that are always roaming and actively engage themselves in providing solutions and technical advice to clients. Also, they are involved in training the dealers and customers’ maintenance personnel. They perform a crucial role within the day-to-day operation of our company. “Akhil Jain, CEO, Prime Technologies.