Professional types of concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it is actually still a young but growing industry. Because 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 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. Given the high labor and expenses involved with most sawing and Core cutting machine, the pace with which the task is done has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator trial and error only result in waste of time and money. Today, to be able to remain competitive, the contractors are under pressure to embrace more sophisticated methods of concrete sawing & drilling.
“The market for floor saws, wall saws and powered drilling machines happen to be in a nascent stage today but growing at about 40% per annum as the expense of labor rises, the application of machines to accelerate work and increase productivity and excellence of work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines are in operation. Low Powered Handheld Drilling and sawing happen to be in many thousands in fact 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. Some examples are reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the cabability to cut heavily-reinforced concrete.
There are actually not many organized players in the core cutting arena. Most of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. Like any other industry, the industry is flooded with Chinese equipment and fly by night traders who sell inexpensive, poor quality machines from China with the aim of making quick money. These appliances, however, do not have post sales support nor are definitely 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 only end up spending much more on repairs.”
Regarding manufacturing facilities in India, approximately 25% are produced indigenously, the others imported as well as the bulk provided by 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 and to strengthen its position in the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. During the last maybe five or ten years, the technology has matured to a 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 over 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 near INR 120 crores. This can include branded and unbranded market as well. TYROLIT has a wide array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing drilling around 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is a self-propelled gasoline driven Stack core cutting machine highly suitable for drilling at runways. TYROLIT has 27 Global Production Units along with its core cutting machines and drills are created in Switzerland, Austria, United statesA. and also other parts of the world. These machines come with a manufacturing warranty of one year. Also they are quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides a number of the service requirement at site to care for 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 built about the platform of robust, rigid and productivity. Diabu uses excellent and right configuration steel, long life and easy to maintain bearings, dust and water protected motors, bearings and all sorts of sliding and rotating parts. Most if not all fasteners are produced from either stainless steel or rust proof and high tensile steel. Aside from being simple to use, maintenance is likewise quite simple with an easy task to access grease and oil points.
“There is really a significant need for education about controlled dismantling being a technology within the construction industry. Other challenges relate with acceptability and adaptability in the technology in a few of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics of the technology as 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 essential aspect in getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable can have an impact on cutting speed and blade life.
Concrete cutting becoming an application oriented process, blades are supplied depending on end application requirement and job site requirements. The principle concrete cutting tools that are utilized add the wall (or track) saw, the flat (or slab) saw, the core drill, along with the wire saw. Wall sawing is usually specified to reduce precise dimensional door, vent and window openings. Straight and also bevel cuts are possible together with the wall saw. The wall saw can also be a great selection for creating precise openings in virtually any concrete structure. Flat sawing is normally utilized to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are normally employed 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 utilized 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 even for concrete sample analysis. Wire sawing can be used as removal of thick parts of concrete. It is perfect for removing large sections of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in areas where work area is restricted.
Often the decision of cutting wet or dry depends upon ones preferences and job requirements. While most sawing or drilling is wet, conditions like water scarcity in sites, requirement to hold the site clean of water/slurry because 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 is always advisable to use saws that are 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 may also cause injury and cause accidents.”
In addition to the kind of cutting and dry or wet cutting, varieties of concrete also influence the choice in picking a blade. The duration of curing time after concrete is poured greatly affects how a diamond blade will interact with it during cutting. Curing could be influenced by weather (temperature, moisture and season) as well as the composition (admixtures, aggregate and sand). Cured concrete is usually set at the very least two days. The sand is utterly bonded with all the mortar along with the concrete reaches full hardness. Concrete is normally in their green state for 6 to 48 hours after it is poured. In 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 from the slurry, and produces far more abrasion on a diamond blade. Undercut protection is critical when cutting green concrete to avoid excessive wear around the steel core on the segment weld. Green concrete sawing is usual when focusing on new construction projects such as; motorways, runways, driveways & industrial flooring.
The two size and type of aggregate possess a great effect on the overall hardness of concrete and also the blade to pick. The aggregate could make up as much as 75% of the total volume. As a general rule, larger aggregate will make the concrete act harder, slowing drilling process. Smaller aggregates make a blade cut faster. Sand is portion 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 discover the sharpness of sand, you should know where the sand is produced by. Crushed sand and bank sand are generally sharp; river sand is often round.
Selection for core drilling operation may also requires understanding the diameter in 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 essential for selecting the most appropriate tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter from the core, length of the core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Silicon steel 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 huge amounts of dust. While wet cutting or drilling operation will not 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.
Aside from saw speed, the simplicity of transport and installation is important in jobsites who have single doors or window openings to get eliminate or where the saw should be constantly moved in one floor to the next. Some machines are employed in a modular system thus bringing in certain advantages, since the single component can be easier transported and installed.
When it comes to costs, this equipment is not so expensive machines and in case regularly maintained, the fee for maintenance may be kept as little as any machine an annual spend around 6% – 10% of the buying price of the device.
The trend is clearly lighter, lesser, faster and more profitable. But what incorporates this development is really a stronger demand that operators be trained effectively. Also, contractors must be made aware or there should be pros who can recommend the ideal techniques and equipment for the most efficient and expense-effective cutting at any stage from the project.
“On the service front, Prime Technologies features 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 associated with training the dealers and customers’ maintenance personnel. They perform a vital role from the day-to-day operation in our company. “Akhil Jain, CEO, Prime Technologies.