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. As a result of a higher spending on 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 such 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. Because of the high labor and expenses involved with most sawing and cut to length machine, the rate that the work is completed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator learning from mistakes only cause waste of time and money. Today, so that you can remain competitive, the contractors are under pressure to embrace more sophisticated strategies for concrete sawing & drilling.
“The market for floor saws, wall saws and high powered drilling machines happen to be in a nascent stage today but growing at about 40% yearly as the cost of labor rises, using machines to accelerate work and increase productivity superiority work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines happen to be in operation. Low Powered Handheld Drilling and sawing are in many thousands and is particularly tough 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, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the cabability to cut heavily-reinforced concrete.
You can find very few organized players in the core cutting arena. The majority of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. Like every other industry, the industry is flooded with Chinese equipment and fly by night traders who sell inexpensive, low quality machines from China with the aim of making quick money. These appliances, however, have no after sales support nor will be the machines suited and designed to operate 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 wind up spending more about repairs.”
With respect to manufacturing facilities in India, only about 25% are produced indigenously, others imported along with the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is utilizing it as being its manufacturing facility to advance develop and expand the production facility for diamond tools and disks as well as strengthen its position in the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past 5 to 10 years, the technologies have matured to some 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 greater than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the market scale of controlled concrete dismantling in India is near INR 120 crores. This includes 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 approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven transformer core cutting machine highly suited to drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are produced in Switzerland, Austria, U.S.A. along with other parts around the globe. These machines have a manufacturing warranty of one year. Also they are quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides some of the service requirement at site to take care of emergency Breakdowns.
Diabu Machines recently entered the Indian market. Designed bearing in mind the Indian working conditions as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are built about the platform of robust, rigid and high productivity. Diabu uses good 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 produced from either steel or rust proof and high tensile steel. Aside from being easy to use, maintenance is likewise really easy with easy to access grease and oil points.
“There is actually a significant requirement for education about controlled dismantling being a technology in 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 conventional chisel and hammer, economics of the technology since this is expensive, application with illiterate labor and localized availability of the technology.”
Selecting the most appropriate blade (for the saw, the content as well as the job) is the most important aspect 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 being an application oriented process, blades are supplied based on end application requirement and job site requirements. The main concrete cutting tools which are utilized add the wall (or track) saw, the flat (or slab) saw, the core drill, as well as the wire saw. Wall sawing is generally 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 a fantastic selection for creating precise openings in almost any concrete structure. Flat sawing is typically utilized to cut horizontal flat surfaces for example floors, bridge decks, and pavement. Flat saws are generally employed 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 required 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 perhaps for concrete sample analysis. Wire sawing can be used for removing of thick sections of concrete. It is great 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.
Often the decision of cutting wet or dry is dependent upon ones preferences and job requirements. Some sawing or drilling is wet, conditions such as water scarcity in sites, requirement to maintain the site clean water/slurry on account 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 preferable to use saws that happen to be 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 could also cause injury and cause accidents.”
Besides the sort of cutting and dry or wet cutting, varieties of concrete also influence the choice when choosing a blade. The length of curing time after concrete is poured greatly affects the way in which a diamond blade will connect with it during cutting. Curing can be affected by weather (temperature, moisture and time of the year) along with the composition (admixtures, aggregate and sand). Cured concrete is generally set no less than 48 hours. The sand is totally bonded with all the mortar and the concrete reaches full hardness. Concrete is typically in their green state for 6 to 48 hrs after it can be poured. In this particular early state, the sand is not really completely bonded using 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 from the slurry, and produces far more abrasion on a diamond blade. Undercut protection is essential when cutting green concrete to avoid excessive wear on the steel core in the segment weld. Green concrete sawing is usual when concentrating on new construction projects for example; motorways, runways, driveways & industrial flooring.
Both size and kind of aggregate possess a great effect on the complete hardness of concrete along with the blade to choose. The aggregate can certainly make up up to 75% of the total volume. Typically, 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 part of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is usually sand. Sand may either be sharp (abrasive) or round (non-abrasive). To discover the sharpness of sand, you have to know where sand is from. Crushed sand and bank sand are often sharp; river sand is usually round.
Selection for core drilling operation may also requires understanding the diameter of the final hole required, surface finish of your drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and convenience will 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, entire core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Silicon steel 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 huge amounts of dust. While wet cutting or drilling operation is not going to generate dust because it uses water, the instance of dust is practically 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 ease of transport and installation is necessary in jobsites which may have single doors or window openings to become cut out or where saw has to be constantly moved from one floor to the next. Some machines operate in a modular system thus bringing in certain advantages, since the single component might be easier transported and installed.
With regards to costs, these machines are not so expensive machines and if regularly maintained, the fee for maintenance can be kept only any machine a yearly spend of approximately 6% – 10% of the cost of the equipment.
The buzz is clearly lighter, lesser, faster and a lot more profitable. But what includes this development is a stronger demand that operators be trained effectively. Also, contractors ought to be made aware or there has to be pros who can recommend the best techniques and equipment for the best efficient and expense-effective cutting at any stage of 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 involved with training the dealers and customers’ maintenance personnel. They perform a vital role within the everyday operation of our own company. “Akhil Jain, CEO, Prime Technologies.