Professional strategies for 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. Due to an elevated spending on 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 such sophisticated methods will be the constantly rising labour costs. In the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Given the high labor and overhead costs involved with most sawing and Core cutting machine, the speed with which the job is completed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator trial and error only cause waste of time and money. Today, to be able to remain competitive, the contractors are under pressure to embrace modern-day methods of concrete sawing & drilling.
“The marketplace for floor saws, wall saws and powered drilling machines happen to be in a nascent stage today but growing at about 40% yearly as the price of labor rises, the usage of machines to increase work and increase productivity superiority work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines have been in operation. Low Powered Hand Held Drilling and sawing happen to be in many thousands in fact it is hard 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. Some examples are reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
There are actually not many organized players within the core cutting arena. The majority of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. Like some other industry, the market is flooded with Chinese equipment and fly by night traders who sell inexpensive, low quality machines from China with the objective of making quick money. These machines, however, do not have post sales support nor would be the machines suited and created 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 get poor quality Chinese makes but only turn out spending more about repairs.”
Regarding manufacturing facilities in India, only about 25% are manufactured indigenously, the others imported and the bulk coming from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is utilizing it as its manufacturing facility to increase develop and expand the development 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 five to ten years, the technology has matured to some stage where even on residential sites, coring is definitely 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 industry size of controlled concrete dismantling in India is in close proximity to INR 120 crores. This can include branded and unbranded market as well. TYROLIT has a variety of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling up to 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven transformer core cutting machine highly ideal for 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 around the world. These appliances come with a manufacturing warranty of 1 year. Also these are typically quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides a number of the service requirement at site to deal with emergency Breakdowns.
Diabu Machines recently entered the Indian market. Designed remembering the Indian working conditions as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are designed on the platform of robust, rigid and productivity. Diabu uses good quality and right configuration steel, longevity and maintenance free bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not completely fasteners are made from either stainless or rust proof and tensile steel. Besides being user-friendly, maintenance is likewise very simple with easy to access grease and oil points.
“There is actually a significant necessity for education about controlled dismantling as being a technology from the construction industry. Other challenges relate with acceptability and adaptability from the technology in several of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics associated with the technology since this is expensive, application with illiterate labor and localized option of the technology.”
Choosing the proper blade (for your saw, the content along with the job) is the most important consider getting maximum performance. A number of other variables also affect blade performance. Changing any variable will have an effect on cutting speed and blade life.
Concrete cutting becoming an application oriented process, blades are supplied as per end application requirement and job site requirements. The principle concrete cutting tools that happen to be utilized range from 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 in addition to bevel cuts are possible with all the wall saw. The wall saw is also an excellent option for creating precise openings in virtually any concrete structure. Flat sawing is generally accustomed to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are normally used 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 used when precise, circular cuts are important 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 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 fixed.
Frequently the decision of cutting wet or dry depends on ones preferences and job requirements. While many sawing or drilling is wet, conditions such as water scarcity in sites, requirement to help keep the internet site clean water/slurry as a result of proximity with existing office/ factory /commercial/residential space, proximity to electrical or other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is usually preferable to use saws that are laser welded or atleast have special reinforced brazing. Using such blades ensure that the very high heat generated during dry cutting does not damage the blade which might also cause injury and cause accidents.”
Aside from the type of cutting and dry or wet cutting, varieties of concrete also influence the decision in selecting a blade. The duration of curing time after concrete flows greatly affects how a diamond blade will communicate with it during cutting. Curing might be afflicted with weather (temperature, moisture and season) and also the composition (admixtures, aggregate and sand). Cured concrete is usually set a minimum of 48 hours. The sand is entirely bonded together with the mortar as well as the concrete reaches full hardness. Concrete is generally within its green state for 6 to 48 hours after it is actually poured. With this early state, the sand will not be completely bonded with 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 considerably more abrasion on a diamond blade. Undercut protection is vital when cutting green concrete to prevent excessive wear around the steel core on the segment weld. Green concrete sawing is common when concentrating on new construction projects such as; motorways, runways, driveways & industrial flooring.
Both the size and kind of aggregate possess a great impact on the entire hardness of concrete and also the blade to pick. The aggregate will make up as much as 75% of your total volume. As a general rule, larger aggregate will make the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is portion 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 discover the sharpness of sand, you must know where sand originates from. Crushed sand and bank sand are generally sharp; river sand is generally round.
Choice for core drilling operation may also requires understanding the diameter of the final hole required, surface finish of your drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and simplicity may also be necessary for choosing the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter of your core, entire 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 considerable amounts of dust. While wet cutting or drilling operation is not going to generate dust since it uses water, the instance of dust is practically totally avoided. However, the slurry generated should be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Besides saw speed, the simplicity of transport and installation is necessary in jobsites that have single doors or window openings to become remove or the location where the saw has to be constantly moved from a single floor to the next. Some machines function in a modular system thus bringing in certain advantages, because the single component can be easier transported and installed.
Regarding costs, these machines are not too expensive machines and when regularly maintained, the cost of maintenance may be kept only any machine an annual spend of approximately 6% – 10% of the price tag on the machine.
The trend is clearly lighter, lesser, faster and much more profitable. But what comes with this development is actually a stronger demand that operators be trained effectively. Also, contractors should be made aware or there ought to be professionals who can suggest the very best techniques and equipment for the best efficient and price-effective cutting at any stage of the project.
“On the service front, Prime Technologies has 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 an important role in the everyday operation of our company. “Akhil Jain, CEO, Prime Technologies.