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 a heightened spending on 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 these sophisticated methods will be the constantly rising labour costs. In 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 associated with most sawing and Core cutting machine, the pace that the work is carried out has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator testing only result in waste of time and money.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 have been in a nascent stage today but growing at about 40% each year as the price of labor rises, the application of machines to speed up work and increase productivity and quality of work increases phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines have been in operation. Low Powered Handheld Drilling and sawing will 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 provides significant advantages over conventional concrete removal methods. Such as reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the opportunity to cut heavily-reinforced concrete.
You can find not many organized players from the core cutting arena. Many of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. Like any other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell inexpensive, poor quality machines from China with the goal of making quick money. These machines, however, do not have after sales support nor will be the machines suited and made to function 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 consider poor quality Chinese makes only wind up spending much more about repairs.”
With regards to manufacturing facilities in India, only about 25% are produced indigenously, the others imported along with the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is employing it as its manufacturing facility to advance develop and expand the production facility for diamond tools and disks and to strengthen its position from 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 into a stage where even on residential sites, coring is the preferred technology for fast, vibration-free penetrations. We currently see the marketplace 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 market measurements of controlled concrete dismantling in India is near to INR 120 crores. This consists of branded and unbranded market also. TYROLIT has an array 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 Stack core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units and its particular core cutting machines and drills are made in Switzerland, Austria, UsaA. as well as other parts around the world. These appliances include a manufacturing warranty of twelve months. Also these are typically quite sturdy machines and require very 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 keeping in mind the Indian working conditions along with the Indian operator, Diabu’s floor saws, wall saws and drilling machines are built around the platform of robust, rigid and productivity. Diabu uses excellent and right configuration steel, extended life and maintenance free bearings, dust and water protected motors, bearings and all sorts of sliding and rotating parts. Most if not completely fasteners are made of either steel or rust proof and tensile steel. Apart from being user-friendly, maintenance is also very easy with easy to access grease and oil points.
“There is a significant requirement for education about controlled dismantling like a technology within the construction industry. Other challenges correspond with acceptability and adaptability in the technology in several of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics related to the technology since this is expensive, application with illiterate labor and localized availability of the technology.”
Choosing the right blade (for the saw, the fabric and also the job) is the most important aspect in getting maximum performance. A number of other variables also affect blade performance. Changing any variable can 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 are utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, and the wire saw. Wall sawing is usually specified to slice precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible with the wall saw. The wall saw is likewise a great choice for creating precise openings in virtually any concrete structure. Flat sawing is normally used to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are generally utilized 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 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 for removing of thick sections of concrete. It is great for removing large parts of heavily reinforced concrete, for example piers, towers and bridge sections, and cutting concrete in areas where work area is restricted.
Frequently the decision of cutting wet or dry depends on ones preferences and job requirements. While many sawing or drilling is wet, conditions such as water scarcity in sites, requirement to keep the web page clean of water/slurry on account of proximity with existing office/ factory /commercial/residential space, proximity to electrical or other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is usually wise to use saws which can be laser welded or atleast have special reinforced brazing. Using such blades be sure that the extremely high heat generated during dry cutting does not damage the blade which could also cause injury and cause accidents.”
Apart from the sort of cutting and dry or wet cutting, kinds of concrete also influence your decision in selecting a blade. The length of curing time after concrete flows greatly affects the way a diamond blade will communicate with it during cutting. Curing could be influenced by weather (temperature, moisture and season) and also the composition (admixtures, aggregate and sand). Cured concrete is generally set no less than two days. The sand is completely bonded using the mortar as well as the concrete reaches full hardness. Concrete is typically in its green state for 6 to 2 days after it is poured. In this early state, the sand is not completely bonded with all the mortar and also the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely inside the slurry, and produces considerably more abrasion with a diamond blade. Undercut protection is essential when cutting green concrete in order to avoid excessive wear in the steel core with the segment weld. Green concrete sawing is normal when working on new construction projects such as; motorways, runways, driveways & industrial flooring.
Both size and type of aggregate possess a great affect on the overall hardness of concrete along with the blade to select. The aggregate can certainly make up around 75% in the total volume. As a general rule, larger aggregate will make the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is section 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 look for the sharpness of sand, you need to know the location where the sand originates from. Crushed sand and bank sand tend to be sharp; river sand is normally round.
Choice for core drilling operation may also requires understanding the diameter from the final hole required, surface finish from the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and convenience can also be important for selecting the most appropriate 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, Transformer core cutting machine, anchor or vacuum fixation assistance in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated a lot of dust. While wet cutting or drilling operation will not generate dust since it uses water, the instance of dust is virtually totally avoided. However, the slurry generated needs to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
In addition to saw speed, the ease of transport and installation comes into play in jobsites which may have single doors or window openings to be cut out or the location where the saw should be constantly moved from a floor to another. Some machines function in a modular system thus attracting certain advantages, as the single component can be easier transported and installed.
When it comes to costs, these machines are not so expensive machines and when regularly maintained, the fee for maintenance can be kept as low as any machine a yearly spend of around 6% – 10% of the price of the device.
The buzz 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 professionals who can suggest the very best techniques and equipment for the most efficient and cost-effective cutting at any stage in the project.
“On the service front, Prime Technologies carries a band of service engineers who are always roaming and actively engage themselves in providing solutions and technical advice to clients. They are also associated with training the dealers and customers’ maintenance personnel. They perform a crucial role from the everyday operation of the company. “Akhil Jain, CEO, Prime Technologies.