Professional strategies for concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it is still a young but growing industry. On account of an elevated shelling out for 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 the sophisticated methods may be the constantly rising labour costs. Over the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and expenses associated with most sawing and Core cutting machine, the rate in which the task is carried out is becoming vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator testing only bring about waste of money and time. 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 high powered drilling machines have been in a nascent stage today but growing at about 40% each year as the cost of labor rises, the application of machines to speed up work and increase productivity superiority work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines will be in operation. Low Powered Handheld Drilling and sawing happen to be 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 offers significant advantages over conventional concrete removal methods. Some examples are reduced downtime, precision cutting, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the opportunity to cut heavily-reinforced concrete.
You can find hardly any organized players inside the core cutting arena. Many 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, poor machines from China with the aim of making quick money. These machines, however, have zero after sales support nor will be the machines suited and made 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 inferior Chinese makes but only find yourself spending much more about repairs.”
Regarding manufacturing facilities in India, just about 25% are made indigenously, the remainder imported and the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is applying it its manufacturing facility to further develop and expand the production facility for diamond tools and disks as well as strengthen its position within 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 technology has matured into a stage where even on residential sites, coring is the preferred technology for fast, vibration-free penetrations. We currently 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 current market dimensions of controlled concrete dismantling in India is close to INR 120 crores. This includes branded and unbranded market at the same time. TYROLIT has a variety of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines is 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 appropriate for drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are created in Switzerland, Austria, U.S.A. and other parts of the world. These appliances have a manufacturing warranty of one year. Also these are generally quite sturdy machines and require extremely low mainte-nance. TYROLIT’s Unique Service Concept provides several 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 and the Indian operator, Diabu’s floor saws, wall saws and drilling machines are made in the platform of robust, rigid and high productivity. Diabu uses high quality and right configuration steel, longevity and easy to maintain bearings, dust and water protected motors, bearings and all sliding and rotating parts. Most if not all fasteners are manufactured from either stainless steel or rust proof and high tensile steel. Besides being user friendly, maintenance is also really easy with very easy to access grease and oil points.
“There can be a significant desire for education about controlled dismantling like a technology in the construction industry. Other challenges correspond with acceptability and adaptability in the technology in a number of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics associated with the technology because this is expensive, application with illiterate labor and localized accessibility to the technology.”
Choosing the proper blade (for that saw, the material as well as the job) is a vital aspect in getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable may have an effect on cutting speed and blade life.
Concrete cutting becoming an application oriented process, blades are supplied according to end application requirement and job site requirements. The primary concrete cutting tools that are utilized range from the wall (or track) saw, the flat (or slab) saw, the core drill, as well as the wire saw. Wall sawing is normally 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 a great option for creating precise openings in virtually any concrete structure. Flat sawing is usually utilized to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are typically accustomed to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and take off concrete sections for demolition purposes. Core drilling techniques are used when precise, circular cuts are needed 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 concrete sample analysis. Wire sawing can be used as elimination of thick parts of concrete. It is perfect for removing large parts of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in locations where work space is fixed.
Most of the decision of cutting wet or dry is determined by ones preferences and job requirements. While most sawing or drilling is wet, conditions including water scarcity in sites, requirement to help keep the internet site clean of water/slurry as a result 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 usually is wise 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 does not damage the blade which may also cause injury and cause accidents.”
In addition to the sort of cutting and dry or wet cutting, kinds of concrete also influence your decision in choosing a blade. The duration of curing time after concrete is poured greatly affects just how a diamond blade will communicate with it during cutting. Curing could be impacted by weather (temperature, moisture and period) and the composition (admixtures, aggregate and sand). Cured concrete is usually set at the very least 48 hours. The sand is completely bonded together with the mortar and also the concrete reaches full hardness. Concrete is normally within its green state for 6 to 48 hrs after it really is poured. In this early state, the sand is just not completely bonded together with the mortar and 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 considerably more abrasion on a diamond blade. Undercut protection is critical when cutting green concrete to stop excessive wear about the steel core in the segment weld. Green concrete sawing is typical when taking care of new construction projects for example; motorways, runways, driveways & industrial flooring.
The size and kind of aggregate possess a great impact on the complete hardness of concrete and the blade to choose. The aggregate can make up up to 75% from the total volume. Typically, larger aggregate is likely 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 can either be sharp (abrasive) or round (non-abrasive). To discover the sharpness of sand, you have to know where the sand originates from. Crushed sand and bank sand tend to be sharp; river sand is usually round.
Choice for core drilling operation will likely 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 of use are also necessary for selecting the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter of 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 aid in deciding which concrete core cutter to use for the project.”
Conventional concrete cutting and drilling methods generated large amounts of dust. While wet cutting or drilling operation will not 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 who have single doors or window openings being cut out or in which the saw has to be constantly moved from a single floor to the next. Some machines operate in a modular system thus bringing in certain advantages, as the single component could be easier transported and installed.
When it comes to costs, these machines are not too expensive machines and when regularly maintained, the price of maintenance may be kept as little as any machine a yearly spend of around 6% – 10% of the price of the machine.
The popularity is clearly lighter, lesser, faster and much more profitable. But what comes along with this development is actually a stronger demand that operators be trained effectively. Also, contractors must be made aware or there has to be professionals who can recommend the ideal techniques and equipment for efficient and price-effective cutting at any stage of your 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 in training the dealers and customers’ maintenance personnel. They perform a huge role in the day-to-day operation of our company. “Akhil Jain, CEO, Prime Technologies.