Professional types 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. On account of a higher spending on 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 these sophisticated methods is the constantly rising labour costs. Within the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and expenses involved in most sawing and Core cutting machine, the speed in which the work is performed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator testing only cause waste of time and money. Today, as a way to remain competitive, the contractors are under pressure to embrace modern-day ways of concrete sawing & drilling.
“The market for floor saws, wall saws and high powered drilling machines have been in a nascent stage today but growing at about 40% yearly as the price of labor rises, the use of machines to increase work and increase productivity and quality of work increases phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines are in operation. Low Powered Handheld Drilling and sawing are in many thousands which is 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, 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 within the core cutting arena. A lot of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. As in some other industry, the market is flooded with Chinese equipment and fly by night traders who sell affordable, poor quality machines from China with the goal of making quick money. These machines, however, do not have post sales support nor are definitely the machines suited and made 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 poor quality Chinese makes but only end up spending much more about repairs.”
Regarding manufacturing facilities in India, only about 25% are manufactured indigenously, others imported along with the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is applying 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 in the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past maybe five or ten years, the technologies have matured to your stage where even on residential sites, coring will be 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 measurements of controlled concrete dismantling in India is near to INR 120 crores. This includes branded and unbranded market at the same time. TYROLIT has a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing drilling up to 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven Stack core cutting machine highly ideal for drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are produced in Switzerland, Austria, UsaA. along with other parts of the world. These appliances come with a manufacturing warranty of 1 year. 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 recently entered the Indian market. Designed keeping in mind the Indian working conditions as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are constructed about the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, extended life and easy to maintain bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not completely fasteners are manufactured from either stainless steel or rust proof and tensile steel. In addition to being user-friendly, maintenance is likewise very simple with easy to access grease and oil points.
“There is actually a significant requirement for education about controlled dismantling as being a technology within the construction industry. Other challenges connect with acceptability and adaptability from the technology in a number of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics of the technology since this is expensive, application with illiterate labor and localized availability of the technology.”
Selecting the right blade (for the saw, the fabric as well as the job) is the most important element in getting maximum performance. Many other variables also affect blade performance. Changing any variable will have an effect on cutting speed and blade life.
Concrete cutting as an application oriented process, blades are supplied as per end application requirement and job site requirements. The main concrete cutting tools which can be utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, along with the wire saw. Wall sawing is normally specified to reduce precise dimensional door, vent and window openings. Straight and also bevel cuts are possible with all the wall saw. The wall saw is additionally a great choice for creating precise openings in almost any concrete structure. Flat sawing is generally employed to cut horizontal flat surfaces including floors, bridge decks, and pavement. Flat saws are usually used to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and remove concrete sections for demolition purposes. Core drilling techniques are used when precise, circular cuts are required 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 perhaps for concrete sample analysis. Wire sawing can be used elimination of thick parts of concrete. It is ideal for removing large parts of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in locations where work area is restricted.
Frequently the decision of cutting wet or dry is determined by ones preferences and job requirements. While most sawing or drilling is wet, conditions such as water scarcity in sites, requirement to help keep the site clean water/slurry due to 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 usually is preferable 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 fails to damage the blade which might also cause injury and cause accidents.”
In addition to the sort of cutting and dry or wet cutting, varieties of concrete also influence the decision in choosing a blade. The length of curing time after concrete is poured greatly affects how a diamond blade will interact with it during cutting. Curing could be afflicted with weather (temperature, moisture and season) as well as the composition (admixtures, aggregate and sand). Cured concrete is usually set at the very least 48 hrs. The sand is totally bonded together with the mortar and the concrete reaches full hardness. Concrete is generally within its green state for 6 to 48 hrs after it can be poured. Within this early state, the sand is not really completely bonded using 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 on the diamond blade. Undercut protection is crucial when cutting green concrete to prevent excessive wear on the steel core at the segment weld. Green concrete sawing is typical when focusing on new construction projects like; motorways, runways, driveways & industrial flooring.
Both size and type of aggregate possess a great affect on the general hardness of concrete along with the blade to choose. The aggregate can make up around 75% of the total volume. For the most part, larger aggregate has a tendency to make the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is area of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is often sand. Sand may either be sharp (abrasive) or round (non-abrasive). To look for the sharpness of sand, you should know where sand originates from. Crushed sand and bank sand are generally sharp; river sand is usually round.
Choice for core drilling operation will likely requires knowing the diameter of your final hole required, surface finish of your drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and ease of use are also necessary 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, Silicon steel 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 is not going 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 is important in jobsites which may have single doors or window openings to get reduce or in which the saw needs to be constantly moved from one floor to another. Some machines operate in a modular system thus bringing in certain advantages, since the single component may be easier transported and installed.
When it comes to costs, these machines are not expensive machines and if regularly maintained, the expense of maintenance might be kept as little as any machine an annual spend of around 6% – 10% of the buying price of the equipment.
The buzz is clearly lighter, lesser, faster plus more profitable. But what comes along with this development is really a stronger demand that operators be trained effectively. Also, contractors must be made aware or there ought to be experts who can recommend the ideal techniques and equipment for the best efficient and expense-effective cutting at any stage in the project.
“On the service front, Prime Technologies includes a band of service engineers who 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 from the everyday operation of the company. “Akhil Jain, CEO, Prime Technologies.