Professional ways 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. As a result of an elevated shelling out for infrastructure projects and residential & commercial construction, India holds tremendous potential with regards to diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of those sophisticated methods will be the constantly rising labour costs. Within the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Because of the high labor and expenses associated with most sawing and Core cutting machine, the speed that the position is completed has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator trial and error only result in waste of time and money. Today, in order to remain competitive, the contractors are under pressure to embrace modern-day types of concrete sawing & drilling.
“The market for floor saws, wall saws and high powered drilling machines will be in a nascent stage today but growing at about 40% per year as the cost of labor rises, the usage of machines to accelerate work and increase productivity and excellence of work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines are in operation. Low Powered Handheld Drilling and sawing have been in many thousands and is particularly very difficult to give even an approximate number.” – M.Venkatesh, Executive Director, Diabu Diamond Tools
Professional diamond concrete cutting systems can provide 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 cabability to cut heavily-reinforced concrete.
You can find not many organized players inside the core cutting arena. The majority of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. As with almost every other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell low priced, poor machines from China with the aim of making quick money. These appliances, however, have no after sales support nor would be the machines suited and created 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 get poor Chinese makes only wind up spending much more about repairs.”
With respect to manufacturing facilities in India, approximately 25% are produced indigenously, the rest imported and the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is using it as its manufacturing facility to further develop and expand the development facility for diamond tools and disks as well as strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past five to ten years, the technologies have matured into a stage where even on residential sites, coring is the preferred technology for fast, vibration-free penetrations. Right now we see the market for coring at over 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the industry dimensions of controlled concrete dismantling in India is close to INR 120 crores. This consists of branded and unbranded market also. TYROLIT has a wide array 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 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 manufactured in Switzerland, Austria, U.S.A. and also other parts around the globe. These appliances include a manufacturing warranty of one year. Also these are typically quite sturdy machines and require suprisingly 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 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 excellent and right configuration steel, extended life and easy to maintain bearings, dust and water protected motors, bearings and all sorts of sliding and rotating parts. Most if not all fasteners are made of either steel or rust proof and tensile steel. Besides being simple to use, maintenance is additionally really easy with an easy task to access grease and oil points.
“There is really a significant need for education about controlled dismantling as a technology within the construction industry. Other challenges relate with acceptability and adaptability in the technology in several of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics related to the technology because this is expensive, application with illiterate labor and localized availability of the technology.”
Selecting the right blade (to the saw, the information and also the job) is the most important aspect in getting maximum performance. A number of other variables also affect blade performance. Changing any variable can have an impact on cutting speed and blade life.
Concrete cutting as an application oriented process, blades are supplied according to end application requirement and job site requirements. The key concrete cutting tools which can be utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is typically specified to cut precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible with the wall saw. The wall saw is likewise a great choice for creating precise openings in virtually any concrete structure. Flat sawing is generally utilized to cut horizontal flat surfaces including floors, bridge decks, and pavement. Flat saws are generally employed to provide expansion joints, remove damaged pavement sections, clean and repair random cracks dexqpky76 repair, and take off concrete sections for demolition purposes. Core drilling techniques are employed when precise, circular cuts are essential 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 perhaps for concrete sample analysis. Wire sawing can be used 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 areas where work space is restricted.
Frequently the decision of cutting wet or dry depends upon ones preferences and job requirements. While most sawing or drilling is wet, conditions for example water scarcity in sites, requirement to maintain the site clean water/slurry as a result 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 usually is wise to use saws which are laser welded or atleast have special reinforced brazing. Using such blades ensure that the extremely high heat generated during dry cutting is not going to damage the blade which could also cause injury and cause accidents.”
Aside from the sort of cutting and dry or wet cutting, varieties of concrete also influence your decision in picking a blade. The length of curing time after concrete flows greatly affects how a diamond blade will communicate with it during cutting. Curing might be influenced by weather (temperature, moisture and season) along with the composition (admixtures, aggregate and sand). Cured concrete is typically set no less than 2 days. The sand is entirely bonded together with the mortar as well as the concrete reaches full hardness. Concrete is typically within its green state for 6 to 48 hours after it is actually poured. In this particular early state, the sand is not 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 within the slurry, and produces a lot more abrasion with a diamond blade. Undercut protection is crucial when cutting green concrete in order to avoid excessive wear in the steel core with the segment weld. Green concrete sawing is normal when concentrating on new construction projects for example; motorways, runways, driveways & industrial flooring.
Both the size and type of aggregate possess a great impact on the overall hardness of concrete along with the blade to choose. The aggregate can make up around 75% in 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 area of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is usually sand. Sand may either be sharp (abrasive) or round (non-abrasive). To look for the sharpness of sand, you should know the location where the sand is produced by. Crushed sand and bank sand are often sharp; river sand is generally round.
Choice for core drilling operation will likely requires knowing the diameter from the final hole required, surface finish of your drilled hole, surface and accessibility of your drilling area.
“Tool horsepower, tool reliability and simplicity may also be necessary for selecting the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter of your 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 help 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 fails to generate dust since it uses water, the instance of dust is nearly totally avoided. However, the slurry generated has to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Besides saw speed, the ease of transport and installation is necessary in jobsites which may have single doors or window openings being eliminate or where the saw must be constantly moved from one floor to another. Some machines work in a modular system thus attracting certain advantages, as being the single component could be easier transported and installed.
When it comes to costs, this equipment is not very expensive machines and in case regularly maintained, the price of maintenance might be kept only any machine a yearly spend around 6% – 10% of the cost of the equipment.
The popularity is clearly lighter, lesser, faster plus more profitable. But what comes with this development is really a stronger demand that operators be trained effectively. Also, contractors should be made aware or there must be professionals who can recommend the most effective 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 happen to be always roaming and actively engage themselves in providing solutions and technical advice to clients. They are also linked to training the dealers and customers’ maintenance personnel. They perform a huge role inside the daily operation of our own company. “Akhil Jain, CEO, Prime Technologies.