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. As a result of a higher 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 will be the constantly rising labour costs. Over the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Given the high labor and expenses involved with most sawing and cut to length machine, the speed that the task is completed is becoming vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator learning from mistakes only result in waste of time and money. Today, in order to remain competitive, the contractors are under pressure to embrace modern-day methods of concrete sawing & drilling.
“The industry for floor saws, wall saws and high powered drilling machines happen to be in a nascent stage today but growing at about 40% each year as the price of labor rises, using machines to speed up work and increase productivity and excellence of work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines will be in operation. Low Powered Handheld Drilling and sawing happen to be in many thousands which is very difficult 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. Such as 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 only a few organized players within the core cutting arena. Many of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. As with every other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell low priced, poor quality machines from China with the aim of making quick money. These machines, however, have no post sales support nor are the machines suited and created 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 Chinese makes but only find yourself spending much more about repairs.”
Regarding manufacturing facilities in India, just about 25% are made indigenously, others imported and also the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is employing it as a its manufacturing facility to further develop and expand the production facility for diamond tools and disks as well as to strengthen its position inside the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. During the last 5 to 10 years, the technology has matured to your stage where even on residential sites, coring is 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 dimensions of controlled concrete dismantling in India is near 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 can do drilling as much as 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven EI core cutting machine highly suited to drilling at runways. TYROLIT has 27 Global Production Units and its particular core cutting machines and drills are created in Switzerland, Austria, United statesA. and also other parts around the world. These appliances include a manufacturing warranty of twelve months. Also they are quite sturdy machines and require really 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 keeping in mind the Indian working conditions and also the Indian operator, Diabu’s floor saws, wall saws and drilling machines are built about the platform of robust, rigid and 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-steel or rust proof and high tensile steel. Aside from being easy to use, maintenance is additionally really easy with simple to access grease and oil points.
“There is really a significant desire for education about controlled dismantling like a technology within the construction industry. Other challenges connect with acceptability and adaptability in the technology in a number of the major projects, drilling and sawing vis-à-vis the typical chisel and hammer, economics associated with the technology as this is expensive, application with illiterate labor and localized option of the technology.”
Choosing the right blade (for the saw, the material and the job) is the most important factor in getting maximum performance. Many other variables also affect blade performance. Changing any variable could have an impact on cutting speed and blade life.
Concrete cutting being an application oriented process, blades are supplied depending on end application requirement and job site requirements. The principle concrete cutting tools which are utilized add the wall (or track) saw, the flat (or slab) saw, the core drill, and the wire saw. Wall sawing is generally specified to reduce precise dimensional door, vent and window openings. Straight along with bevel cuts are possible together with the wall saw. The wall saw is likewise an excellent selection for creating precise openings in every concrete structure. Flat sawing is usually used to cut horizontal flat surfaces like 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 being used when precise, circular cuts are needed for example 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 for removal of thick sections of concrete. It is perfect for removing large parts of heavily reinforced concrete, for example piers, towers and bridge sections, and cutting concrete in places that work space is fixed.
Most of the decision of cutting wet or dry depends on ones preferences and job requirements. Some sawing or drilling is wet, conditions including water scarcity in sites, requirement to maintain the website clean of water/slurry because 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 always advisable to use saws which can be laser welded or atleast have special reinforced brazing. Using such blades ensure that the very high heat generated during dry cutting fails to damage the blade which can also cause injury and cause accidents.”
Apart from the form of cutting and dry or wet cutting, kinds of concrete also influence the choice when choosing a blade. The duration of curing time after concrete flows greatly affects just how a diamond blade will connect with it during cutting. Curing might be affected by weather (temperature, moisture and time of the year) as well as the composition (admixtures, aggregate and sand). Cured concrete is usually set a minimum of 48 hours. The sand is entirely bonded with the mortar along with the concrete reaches full hardness. Concrete is usually in their green state for 6 to two days after it can be poured. In this early state, the sand will not be completely bonded together with the mortar and also 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 far more abrasion on the diamond blade. Undercut protection is critical when cutting green concrete in order to avoid excessive wear on the steel core on the segment weld. Green concrete sawing is common when concentrating on new construction projects like; motorways, runways, driveways & industrial flooring.
The size and type of aggregate have got a great influence on the entire hardness of concrete and also the blade to choose. The aggregate can certainly make up as much as 75% from the total volume. Typically, larger aggregate tends to make the concrete act harder, slowing drilling process. Smaller aggregates make a blade cut faster. Sand is section 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 look for the sharpness of sand, you have to know where sand originates from. Crushed sand and bank sand are often sharp; river sand is usually round.
Selection for core drilling operation will likely requires learning the diameter of the final hole required, surface finish from the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and convenience may also be necessary for selecting the most appropriate 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, Straight core cutting machine, anchor or vacuum fixation assist 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 will not generate dust mainly because it uses water, the instance of dust is virtually 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 simplicity of transport and installation is necessary in jobsites who have single doors or window openings to be eliminate or in which the saw must be constantly moved from a floor to another. Some machines are employed in a modular system thus attracting certain advantages, as being the single component may be easier transported and installed.
With respect to costs, these machines are not too expensive machines of course, if regularly maintained, the cost of maintenance could be kept only any machine a yearly spend around 6% – 10% of the price of the machine.
The buzz is clearly lighter, lesser, faster and much more profitable. But what includes this development is really a stronger demand that operators be trained effectively. Also, contractors should be made aware or there ought to be experts who can suggest the very best techniques and equipment for the most efficient and expense-effective cutting at any stage in the project.
“On the service front, Prime Technologies features a band of service engineers who definitely are always roaming and actively engage themselves in providing solutions and technical advice to clients. Also, they are involved with training the dealers and customers’ maintenance personnel. They perform a vital role inside the day-to-day operation of our company. “Akhil Jain, CEO, Prime Technologies.