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. As a result of an elevated shelling out for 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 these sophisticated methods will be the constantly rising labour costs. Within 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 cut to length machine, the pace with which the position is performed is now vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator testing only cause waste of time and money. Today, to be able to remain competitive, the contractors are under pressure to embrace more sophisticated types of 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% per year as the price of labor rises, the usage of machines to increase work and increase productivity and quality of work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines have been in operation. Low Powered Handheld Drilling and sawing are in many thousands and is particularly very difficult 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. Some examples are reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
You can find not many organized players in the core cutting arena. A lot of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. As with some other industry, the industry is flooded with Chinese equipment and fly by night traders who sell low cost, poor machines from China with the aim of making quick money. These appliances, however, have zero after sales support nor will be the machines suited and made to are employed 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 go for low quality Chinese makes only turn out spending much more about repairs.”
Regarding manufacturing facilities in India, just about 25% are created indigenously, the remainder imported and also the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is applying it as a its manufacturing facility to further develop and expand the production facility for diamond tools and disks as well as 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 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 over 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the marketplace measurements of controlled concrete dismantling in India is near INR 120 crores. This can include branded and unbranded market also. TYROLIT has a wide array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines is capable of doing drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven transformer core cutting machine highly appropriate 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 other parts around the world. These appliances have a manufacturing warranty of twelve months. 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 manage emergency Breakdowns.
Diabu Machines recently entered the Indian market. Designed remembering the Indian working conditions along with the Indian operator, Diabu’s floor saws, wall saws and drilling machines are constructed about the platform of robust, rigid and productivity. Diabu uses top quality and right configuration steel, longevity and easy to maintain bearings, dust and water protected motors, bearings and all of sliding and rotating parts. Most if not all fasteners are produced from either steel or rust proof and tensile steel. Aside from being simple to use, maintenance is additionally very simple with simple to access grease and oil points.
“There is a significant need for education about controlled dismantling as a technology in the construction industry. Other challenges connect with acceptability and adaptability of your technology in a number of the major projects, drilling and sawing vis-à-vis the typical chisel and hammer, economics linked to the technology as this is expensive, application with illiterate labor and localized availability of the technology.”
Choosing the proper blade (for that saw, the information and the job) is an essential consider getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable could have an effect on cutting speed and blade life.
Concrete cutting becoming an application oriented process, blades are supplied as per end application requirement and job site requirements. The primary concrete cutting tools that are utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, as well as 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 using the wall saw. The wall saw can also be a great option for creating precise openings in almost any concrete structure. Flat sawing is usually accustomed to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are typically 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 needed such as 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 elimination of thick parts of concrete. It is ideal for removing large sections of heavily reinforced concrete, for example piers, towers and bridge sections, and cutting concrete in places that work space is restricted.
Frequently the decision of cutting wet or dry depends upon ones preferences and job requirements. Some sawing or drilling is wet, conditions for example water scarcity in sites, requirement to keep 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 will always be better to use saws that happen to 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 might also cause injury and cause accidents.”
In addition to the kind of cutting and dry or wet cutting, kinds of concrete also influence your choice in selecting a blade. The length of curing time after concrete flows greatly affects the way a diamond blade will connect to it during cutting. Curing might be affected by weather (temperature, moisture and period) and also the composition (admixtures, aggregate and sand). Cured concrete is normally set a minimum of two days. The sand is utterly bonded using the mortar as well as the concrete reaches full hardness. Concrete is typically in the green state for 6 to 2 days after it really is poured. With this early state, the sand will not be completely bonded using the mortar along with 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 a lot more abrasion with a diamond blade. Undercut protection is crucial when cutting green concrete to prevent excessive wear around the steel core on the segment weld. Green concrete sawing is usual when taking care of new construction projects for example; motorways, runways, driveways & industrial flooring.
The size and kind of aggregate use a great influence on the overall hardness of concrete as well as the blade to select. The aggregate will make up up to 75% in the total volume. Typically, 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 generally sand. Sand either can be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you have to know where the sand is from. Crushed sand and bank sand are often sharp; river sand is normally round.
Selection for core drilling operation will also requires understanding the diameter from the final hole required, surface finish in the drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and simplicity of use can also be essential for selecting the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors like diameter of your core, length of the 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 a lot of dust. While wet cutting or drilling operation will not generate dust mainly because it uses water, the instance of dust is nearly 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 simplicity of transport and installation is important in jobsites which have single doors or window openings being cut out or where the saw has to be constantly moved in one floor to another. Some machines function in a modular system thus bringing in certain advantages, as being the single component can be easier transported and installed.
When it comes to costs, this equipment is not too expensive machines and if regularly maintained, the fee for maintenance may be kept as low as any machine an annual spend of around 6% – 10% of the cost of the equipment.
The popularity is clearly lighter, lesser, faster and more profitable. But what incorporates this development is actually a stronger demand that operators be trained effectively. Also, contractors needs to be made aware or there must be experts who can recommend the best techniques and equipment for efficient and cost-effective cutting at any stage from 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. Also, they are linked to training the dealers and customers’ maintenance personnel. They perform a crucial role in the everyday operation of the company. “Akhil Jain, CEO, Prime Technologies.