Professional types 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 spending on infrastructure projects and residential & commercial construction, India holds tremendous potential when it comes to diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of the sophisticated methods is definitely the constantly rising labour costs. Over the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Due to the high labor and overhead costs linked to most sawing and Core cutting machine, the rate which the work is done is now vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator trial and error only lead to waste of money and time. Today, in order to remain competitive, the contractors are under pressure to embrace modern-day ways of concrete sawing & drilling.
“The industry for floor saws, wall saws and powered drilling machines are in a nascent stage today but growing at about 40% each year as the cost of labor rises, the usage of machines to speed up work and increase productivity superiority work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines have been in operation. Low Powered Handheld Drilling and sawing will 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 can provide significant advantages over conventional concrete removal methods. These include reduced downtime, precision cutting, upkeep 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. The majority of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. As in almost every other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell inexpensive, low quality machines from China with the purpose of making quick money. These appliances, however, have zero after sales support nor will 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 choose poor Chinese makes but only turn out spending much more on repairs.”
When it comes to manufacturing facilities in India, approximately 25% are manufactured indigenously, the rest imported and the bulk coming from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is applying it as being its manufacturing facility to advance develop and expand the production facility for diamond tools and disks and to strengthen its position within the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past 5 to 10 years, the technology has matured into a stage where even on residential sites, coring will be the preferred technology for fast, vibration-free penetrations. Right now we see the market for coring at a lot more than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the marketplace dimensions of controlled concrete dismantling in India is near to INR 120 crores. Including branded and unbranded market also. TYROLIT has a variety of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven EI 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, United statesA. along with other parts around the world. These appliances feature a manufacturing warranty of twelve months. Also these are typically quite sturdy machines and require suprisingly low mainte-nance. TYROLIT’s Unique Service Concept provides a few of the service requirement at site to take care of emergency Breakdowns.
Diabu Machines has 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 made about the platform of robust, rigid and productivity. Diabu uses good quality and right configuration steel, long life and maintenance free bearings, dust and water protected motors, bearings and all of sliding and rotating parts. Most if not completely fasteners are made of either stainless-steel or rust proof and high tensile steel. Aside from being simple to use, maintenance is likewise really easy with simple to access grease and oil points.
“There is really a significant requirement for education about controlled dismantling as being a technology in the construction industry. Other challenges correspond with acceptability and adaptability from the technology in some of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics linked to the technology since this is expensive, application with illiterate labor and localized accessibility of the technology.”
Choosing the proper blade (for that saw, the content and also the job) is the most important element in getting maximum performance. Various other variables also affect blade performance. Changing any variable will 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 primary concrete cutting tools which can 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 generally specified to slice precise dimensional door, vent and window openings. Straight along with bevel cuts are possible with all the wall saw. The wall saw is also an excellent choice for creating precise openings in virtually any concrete structure. Flat sawing is usually accustomed to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are usually used to provide expansion joints, remove damaged pavement sections, clean and repair random cracks dexqpky76 repair, and remove concrete sections for demolition purposes. Core drilling techniques are being used when precise, circular cuts are required 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 concrete sample analysis. Wire sawing can be used for removing of thick parts of concrete. It is great for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in places that work space is fixed.
Often the decision of cutting wet or dry depends on ones preferences and job requirements. While many sawing or drilling is wet, conditions for example water scarcity in sites, requirement to hold the website clean water/slurry on account 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 will always be wise to use saws which can be laser welded or atleast have special reinforced brazing. Using such blades be sure that the very high heat generated during dry cutting does not damage the blade which could also cause injury and cause accidents.”
Apart from the type 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 connect to it during cutting. Curing may be influenced by weather (temperature, moisture and season) as well as the composition (admixtures, aggregate and sand). Cured concrete is usually set a minimum of two days. The sand is entirely bonded together with the mortar as well as the concrete reaches full hardness. Concrete is usually in its green state for 6 to 48 hours after it is poured. In this particular early state, the sand is not really completely bonded together with the mortar as well as 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 far more abrasion on the diamond blade. Undercut protection is critical when cutting green concrete to stop excessive wear in the steel core with the segment weld. Green concrete sawing is typical when concentrating on new construction projects for example; motorways, runways, driveways & industrial flooring.
Both size and type of aggregate use a great impact on the entire hardness of concrete and the blade to select. The aggregate will make up just as much as 75% in the total volume. As a general rule, 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 either can be sharp (abrasive) or round (non-abrasive). To determine the sharpness of sand, you have to know where sand comes from. Crushed sand and bank sand are usually sharp; river sand is usually round.
Choice for core drilling operation may also requires learning the diameter from the final hole required, surface finish of the drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and simplicity 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 in the core, entire core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Straight core cutting machine, anchor or vacuum fixation assistance in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated large amounts of dust. While wet cutting or drilling operation does not generate dust since it uses water, the instance of dust is nearly totally avoided. However, the slurry generated needs to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Besides saw speed, the simplicity of transport and installation is important in jobsites who have single doors or window openings to get cut out or where saw needs to be constantly moved in one floor to another. Some machines function in a modular system thus bringing in certain advantages, as the single component could be easier transported and installed.
Regarding costs, these machines are not too expensive machines and in case regularly maintained, the expense of maintenance could be kept only any machine an annual spend around 6% – 10% of the cost of the machine.
The popularity is clearly lighter, lesser, faster and a lot 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 has to be professionals who can recommend the very best techniques and equipment for efficient and expense-effective cutting at any stage from the project.
“On the service front, Prime Technologies features 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 in training the dealers and customers’ maintenance personnel. They perform a crucial role in the daily operation of our company. “Akhil Jain, CEO, Prime Technologies.