Professional strategies for 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. As a result of a higher shelling out for infrastructure projects and residential & commercial construction, India holds tremendous potential with regards to diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of such sophisticated methods is definitely 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 linked to most sawing and Core cutting machine, the rate that the task is performed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator experimentation only bring about waste of time and money. Today, as a way to remain competitive, the contractors are under pressure to embrace modern-day ways of concrete sawing & drilling.
“The marketplace 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 price of labor rises, the application of machines to quicken work and increase productivity and quality of work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines are in operation. Low Powered Hand Held 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 can provide significant advantages over conventional concrete removal methods. Included in this are reduced downtime, precision cutting, repair of structural integrity, reduced noise, dust and debris, limited-access cutting, and the capability to cut heavily-reinforced concrete.
There are actually not many organized players within the core cutting arena. Many of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. Like in some other industry, the marketplace is flooded with Chinese equipment and fly by night traders who sell inexpensive, inferior machines from China with the purpose of making quick money. These appliances, however, have zero after sales support nor will be the machines suited and created 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 consider poor quality Chinese makes but only wind up spending much more on repairs.”
With respect to manufacturing facilities in India, no more than 25% are produced indigenously, the others imported along with the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is employing it as being its manufacturing facility to increase 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 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 market measurements of controlled concrete dismantling in India is near INR 120 crores. Including branded and unbranded market also. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can perform drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) can be a self-propelled gasoline driven transformer core cutting machine highly suited to drilling at runways. TYROLIT has 27 Global Production Units and its particular core cutting machines and drills are produced in Switzerland, Austria, United statesA. as well as other parts around the globe. These appliances include a manufacturing warranty of twelve months. Also these 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 manage emergency Breakdowns.
Diabu Machines has recently entered the Indian market. Designed keeping in mind the Indian working conditions as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are built around the platform of robust, rigid and high productivity. Diabu uses high quality and right configuration steel, extended 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 made of either stainless or rust proof and high tensile steel. Apart from being user friendly, maintenance is additionally really easy with an easy task to access grease and oil points.
“There is actually a significant requirement for education about controlled dismantling being a technology from the construction industry. Other challenges correspond with acceptability and adaptability of the technology in some of the major projects, drilling and sawing vis-à-vis the conventional chisel and hammer, economics associated with the technology as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Selecting the right blade (for your saw, the information as well as the job) is an essential factor 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 becoming an application oriented process, blades are supplied depending on end application requirement and job site requirements. The primary concrete cutting tools that are utilized are the wall (or track) saw, the flat (or slab) saw, the core drill, as well as the wire saw. Wall sawing is typically specified to cut precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible with the wall saw. The wall saw is also an outstanding option for creating precise openings in almost any concrete structure. Flat sawing is normally utilized to cut horizontal flat surfaces including floors, bridge decks, and pavement. Flat saws are normally employed to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and remove concrete sections for demolition purposes. Core drilling techniques are used when precise, circular cuts are important 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 for concrete sample analysis. Wire sawing can be used for removal of thick sections of concrete. It is great for removing large sections of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in areas where work area is restricted.
Often the decision of cutting wet or dry is determined by ones preferences and job requirements. Some sawing or drilling is wet, conditions like water scarcity in sites, requirement to keep the internet site clean of water/slurry because of proximity with existing office/ factory /commercial/residential space, proximity to electrical or some other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is always better to use saws which are 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.”
Apart from the kind of cutting and dry or wet cutting, types of concrete also influence your choice in picking a blade. The length of curing time after concrete is poured greatly affects the way a diamond blade will connect with it during cutting. Curing may be affected by weather (temperature, moisture and time of the year) and also the composition (admixtures, aggregate and sand). Cured concrete is generally set at least 48 hrs. The sand is utterly bonded together with the mortar and the concrete reaches full hardness. Concrete is typically within its green state for 6 to 2 days after it really is poured. Within this early state, the sand is not really completely bonded using the mortar and also 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 with a diamond blade. Undercut protection is critical when cutting green concrete to prevent excessive wear around the steel core in the segment weld. Green concrete sawing is common when working on new construction projects including; motorways, runways, driveways & industrial flooring.
Both the size and type of aggregate have a great affect on the entire hardness of concrete along with the blade to select. The aggregate could make up up to 75% of the total volume. As a general rule, larger aggregate will create the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is portion of the aggregate mix, and determines the abrasiveness of concrete. “Small aggregate” is often sand. Sand may either be sharp (abrasive) or round (non-abrasive). To look for the sharpness of sand, you should know the location where the sand originates from. Crushed sand and bank sand are often sharp; river sand is often round.
Choice for core drilling operation will even requires learning the diameter of your final hole required, surface finish of the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and ease of use will also be essential for choosing the proper 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, 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 fails to generate dust since it uses water, the instance of dust is almost 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 is important in jobsites who have single doors or window openings being remove or where the saw must be constantly moved from a single floor to another. Some machines function in a modular system thus bringing in certain advantages, because the single component may be easier transported and installed.
With respect to costs, these machines are not too expensive machines and if regularly maintained, the cost of maintenance might be kept as little as any machine a yearly spend around 6% – 10% of the cost of the equipment.
The craze 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 needs to be made aware or there ought to be pros who can suggest the ideal techniques and equipment for the best efficient and price-effective cutting at any stage of your project.
“On the service front, Prime Technologies includes a band of service engineers that are 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 huge role inside the everyday operation in our company. “Akhil Jain, CEO, Prime Technologies.