Professional strategies for concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it is actually 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 with regards to diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of such sophisticated methods may be the constantly rising labour costs. Over the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and expenses linked to most sawing and Core cutting machine, the rate in which the work is carried out has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator experimentation only result in waste of money and time. Today, to be able to remain competitive, the contractors are under pressure to embrace more sophisticated methods of concrete sawing & drilling.
“The niche for floor saws, wall saws and powered drilling machines have been in a nascent stage today but growing at about 40% yearly as the expense of labor rises, the application of machines to speed up work and increase productivity and excellence of work increases phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines are in operation. Low Powered Hand Held Drilling and sawing have been 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 can offer significant advantages over conventional concrete removal methods. These include reduced downtime, precision cutting, repair of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
You can find not many organized players from the core cutting arena. Many of them are extensions of worldwide manufacturers for example 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 affordable, low quality machines from China with the goal of making quick money. These appliances, however, have no post sales support nor are the machines suited and designed to work 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 low quality Chinese makes only end up spending more on repairs.”
Regarding manufacturing facilities in India, no more than 25% are made indigenously, others imported and also the bulk coming from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is applying it as its manufacturing facility to increase develop and expand the production facility for diamond tools and disks and to strengthen its position in 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 is the preferred technology for fast, vibration-free penetrations. We currently see the market for coring at greater 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 in close proximity to INR 120 crores. This can include branded and unbranded market at the same time. TYROLIT has a wide array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing drilling as much as 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is 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 also other parts around the globe. These machines come with a manufacturing warranty of 1 year. 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 care for emergency Breakdowns.
Diabu Machines has recently entered the Indian market. Designed remembering the Indian working conditions and the Indian operator, Diabu’s floor saws, wall saws and drilling machines are built around the platform of robust, rigid and high productivity. Diabu uses high quality and right configuration steel, longevity and easy to maintain bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not all fasteners are manufactured from either stainless or rust proof and tensile steel. In addition to being user friendly, maintenance can also be really easy with an easy task to access grease and oil points.
“There is really a significant requirement for education about controlled dismantling being a technology in the construction industry. Other challenges correspond with acceptability and adaptability in the technology in some of the major projects, drilling and sawing vis-à-vis the standard chisel and hammer, economics linked to the technology as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Selecting the most appropriate blade (for the saw, the fabric and the job) is the most essential consider getting maximum performance. A number of other variables also affect blade performance. Changing any variable can have an effect on cutting speed and blade life.
Concrete cutting becoming an application oriented process, blades are supplied based on end application requirement and job site requirements. The primary concrete cutting tools which are utilized are the wall (or track) saw, the flat (or slab) saw, the core drill, as well as the wire saw. Wall sawing is typically 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 additionally an excellent option for creating precise openings in virtually any concrete structure. Flat sawing is typically used to cut horizontal flat surfaces including floors, bridge decks, and pavement. Flat saws are usually accustomed to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and take away concrete sections for demolition purposes. Core drilling techniques are utilized 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 even for concrete sample analysis. Wire sawing can be used for removal of thick parts of concrete. It is perfect for removing large parts of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in locations where work area is fixed.
Often the decision of cutting wet or dry is determined by ones preferences and job requirements. Some sawing or drilling is wet, conditions like water scarcity in sites, requirement to help keep the web page 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 will always be better to use saws that happen to be laser welded or atleast have special reinforced brazing. Using such blades be sure that the extremely high heat generated during dry cutting will not damage the blade which can also cause injury and cause accidents.”
Apart from the sort of cutting and dry or wet cutting, types of concrete also influence your choice when choosing a blade. The length of curing time after concrete is poured greatly affects just how a diamond blade will connect to it during cutting. Curing may be afflicted with weather (temperature, moisture and period) as well as the composition (admixtures, aggregate and sand). Cured concrete is typically set a minimum of 2 days. The sand is completely bonded using the mortar along with the concrete reaches full hardness. Concrete is usually within its green state for 6 to 48 hours after it really is poured. In this particular early state, the sand is just not completely bonded 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 from the slurry, and produces a lot more abrasion with a diamond blade. Undercut protection is essential when cutting green concrete to stop excessive wear about the steel core on the segment weld. Green concrete sawing is normal when focusing on new construction projects including; motorways, runways, driveways & industrial flooring.
The size and type of aggregate use a great impact on the general hardness of concrete as well as the blade to pick. The aggregate can certainly make up around 75% from the total volume. On the whole, larger aggregate will create the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is section 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 is from. Crushed sand and bank sand are usually sharp; river sand is normally round.
Selection for core drilling operation will likely requires knowing the diameter of your final hole required, surface finish from the drilled hole, surface and accessibility of your drilling area.
“Tool horsepower, tool reliability and simplicity of use are also important 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, 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 to use for the project.”
Conventional concrete cutting and drilling methods generated a lot of dust. While wet cutting or drilling operation fails to 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 ease of transport and installation comes into play in jobsites who have single doors or window openings to be reduce or where the saw has to be constantly moved from a floor to the next. Some machines function in a modular system thus attracting certain advantages, as the single component might be easier transported and installed.
When it comes to costs, this equipment is not too expensive machines and when regularly maintained, the expense of maintenance can be kept only any machine an annual spend around 6% – 10% of the price tag on the device.
The craze is clearly lighter, lesser, faster plus more profitable. But what incorporates this development is a stronger demand that operators be trained effectively. Also, contractors needs to be made aware or there must be professionals who can suggest the very best techniques and equipment for efficient and expense-effective cutting at any stage of the project.
“On the service front, Prime Technologies has a band of service engineers who are always roaming and actively engage themselves in providing solutions and technical advice to clients. They are also involved with training the dealers and customers’ maintenance personnel. They perform a crucial role in the daily operation in our company. “Akhil Jain, CEO, Prime Technologies.