Professional ways of 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. On account of an increased shelling out for infrastructure projects and residential & commercial construction, India holds tremendous potential in terms of diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of these sophisticated methods may be the constantly rising labour costs. In the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and overhead costs linked to most sawing and cut to length machine, the pace in which the work is done has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies on guessing and operator trial and error only result in waste of time and money.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 niche for floor saws, wall saws and powered drilling machines have been in a nascent stage today but growing at about 40% per annum as the price of labor rises, the use of machines to increase work and increase productivity superiority work boosts phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines happen to be in operation. Low Powered Handheld Drilling and sawing are in many thousands and it is tough 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.
There are actually very few organized players from the core cutting arena. Most of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. Like in any other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell low priced, low quality machines from China with the objective of making quick money. These appliances, however, have zero post sales support nor would be 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 choose low quality Chinese makes only end up spending much more about repairs.”
When it comes to manufacturing facilities in India, no more than 25% are created indigenously, others imported and 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 development facility for diamond tools and disks as well as to strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Throughout the last maybe five or ten years, the technology has matured to a stage where even on residential sites, coring may 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 market measurements of controlled concrete dismantling in India is in close proximity to INR 120 crores. This consists of branded and unbranded market as well. TYROLIT has a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can perform drilling up to 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven transformer core cutting machine highly suitable for 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. along with other parts of the world. These machines feature a manufacturing warranty of one year. Also they are 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 entered the Indian market. Designed keeping in mind the Indian working conditions and the Indian operator, Diabu’s floor saws, wall saws and drilling machines are constructed around the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, longevity and maintenance free bearings, dust and water protected motors, bearings and all sliding and rotating parts. Most if not all fasteners are produced from either stainless-steel or rust proof and tensile steel. Aside from being user-friendly, maintenance is additionally very easy with an easy task to access grease and oil points.
“There is really a significant desire for education about controlled dismantling like a technology in the construction industry. Other challenges correspond with acceptability and adaptability of the technology in several of the major projects, drilling and sawing vis-à-vis the standard chisel and hammer, economics linked to the technology because this is expensive, application with illiterate labor and localized availability of the technology.”
Choosing the right blade (for your saw, the material and also the job) is the most important aspect in getting maximum performance. Various other variables also affect blade performance. Changing any variable will have an effect on cutting speed and blade life.
Concrete cutting being an application oriented process, blades are supplied according to end application requirement and job site requirements. The primary concrete cutting tools which are utilized range from the wall (or track) saw, the flat (or slab) saw, the core drill, and the wire saw. Wall sawing is normally specified to reduce precise dimensional door, vent and window openings. Straight along with bevel cuts are possible using the wall saw. The wall saw is also a fantastic choice for creating precise openings in any concrete structure. Flat sawing is typically used to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are normally 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 being used when precise, circular cuts are essential 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 removing of thick parts of concrete. It is great for removing large parts of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in locations where work space is restricted.
Often the decision of cutting wet or dry is determined by ones preferences and job requirements. While most sawing or drilling is wet, conditions for example water scarcity in sites, requirement to keep the internet site clean of water/slurry because of proximity with existing office/ factory /commercial/residential space, proximity to electrical or another 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 that happen to be laser welded or atleast have special reinforced brazing. Using such blades be sure that the very 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, kinds of concrete also influence your choice when choosing a blade. The length of curing time after concrete flows greatly affects the way in which a diamond blade will connect to it during cutting. Curing may be impacted by weather (temperature, moisture and season) as well as the composition (admixtures, aggregate and sand). Cured concrete is usually set a minimum of 2 days. The sand is totally bonded with all the mortar and also the concrete reaches full hardness. Concrete is usually in the green state for 6 to 48 hrs after it can be poured. In this early state, the sand will not be completely bonded with all the mortar along with the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely in the slurry, and produces a lot more abrasion on the diamond blade. Undercut protection is essential when cutting green concrete to prevent excessive wear around the steel core with the segment weld. Green concrete sawing is usual when working on new construction projects such as; motorways, runways, driveways & industrial flooring.
The two size and kind of aggregate have got a great effect on the complete hardness of concrete and the blade to decide on. The aggregate could make up around 75% from the total volume. For the most part, larger aggregate tends to make your 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 either can be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you need to know where sand comes from. Crushed sand and bank sand are generally sharp; river sand is often round.
Choice for core drilling operation will likely requires knowing the diameter of the final hole required, surface finish of your drilled hole, surface and accessibility of your drilling area.
“Tool horsepower, tool reliability and ease of use may also be necessary for choosing the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter of the 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 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 because it uses water, the instance of dust is nearly totally avoided. However, the slurry generated should be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Aside from saw speed, the ease of transport and installation comes into play in jobsites that have single doors or window openings to become reduce or in which the saw should be constantly moved from a floor to another. Some machines are employed in a modular system thus attracting certain advantages, since the single component might be easier transported and installed.
Regarding costs, these machines are not expensive machines of course, if regularly maintained, the price of maintenance may be kept as little as any machine an annual spend around 6% – 10% of the price of the machine.
The popularity 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 should be made aware or there has to be experts who can suggest the most effective techniques and equipment for efficient and cost-effective cutting at any stage from the project.
“On the service front, Prime Technologies has 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 from the daily operation of the company. “Akhil Jain, CEO, Prime Technologies.