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 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 these sophisticated methods is definitely the constantly rising labour costs. Within 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 linked to most sawing and Core cutting machine, the speed with which the position is performed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator trial and error only cause waste of time and money.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 powered drilling machines have been in a nascent stage today but growing at about 40% per annum as the expense of labor rises, using machines to accelerate work and increase productivity and quality 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 will be in many thousands which 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 capability to cut heavily-reinforced concrete.
There are hardly any organized players inside the core cutting arena. Many of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. As with some other industry, the current market is flooded with Chinese equipment and fly by night traders who sell low cost, poor quality machines from China with the purpose of making quick money. These machines, however, have zero post sales support nor are the machines suited and built 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 get poor quality Chinese makes only wind up spending more on repairs.”
When it comes to manufacturing facilities in India, just about 25% are made indigenously, the others imported and also the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is utilizing it as its manufacturing facility to advance 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. Throughout the last five to ten years, the technologies have matured to some stage where even on residential sites, coring is the preferred technology for fast, vibration-free penetrations. We currently see the marketplace for coring at greater than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the market scale of controlled concrete dismantling in India is near INR 120 crores. Including branded and unbranded market as well. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling up to 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually a self-propelled gasoline driven EI core cutting machine highly ideal for drilling at runways. TYROLIT has 27 Global Production Units and its particular core cutting machines and drills are manufactured in Switzerland, Austria, U.S.A. as well as other parts around the world. These machines have a manufacturing warranty of 1 year. Also these are generally quite sturdy machines and require really low mainte-nance. TYROLIT’s Unique Service Concept provides several of the service requirement at site to deal with 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 around the platform of robust, rigid and productivity. Diabu uses high quality and right configuration steel, long life and maintenance free bearings, dust and water protected motors, bearings and all of sliding and rotating parts. Most if not completely fasteners are manufactured from either stainless-steel or rust proof and tensile steel. Aside from being user-friendly, maintenance is likewise very simple with easy to access grease and oil points.
“There can be a significant need for education about controlled dismantling as a technology in 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 standard chisel and hammer, economics associated with the technology as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Choosing the proper blade (for your saw, the content along with the job) is an essential consider 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 as per end application requirement and job site requirements. The key concrete cutting tools which can be 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 typically specified to cut precise dimensional door, vent and window openings. Straight in addition to bevel cuts are possible with the wall saw. The wall saw can also be an excellent choice for creating precise openings in almost any concrete structure. Flat sawing is usually accustomed to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are usually employed to provide expansion joints, remove damaged pavement sections, clean 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 for example 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 elimination of thick parts of concrete. It is fantastic for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in places that work area is restricted.
Often the decision of cutting wet or dry depends on ones preferences and job requirements. Some sawing or drilling is wet, conditions like water scarcity in sites, requirement to help keep the 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 will always be better 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.”
Apart from the form of cutting and dry or wet cutting, kinds of concrete also influence your decision when choosing a blade. The duration of curing time after concrete is poured greatly affects the way a diamond blade will interact with it during cutting. Curing might be impacted by weather (temperature, moisture and period) as well as the composition (admixtures, aggregate and sand). Cured concrete is generally set a minimum of 2 days. The sand is completely bonded with the mortar along with the concrete reaches full hardness. Concrete is usually in its green state for 6 to two days after it can be poured. In this particular early state, the sand is just not completely bonded together with the mortar as well as the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely within the slurry, and produces considerably more abrasion over a diamond blade. Undercut protection is crucial when cutting green concrete in order to avoid excessive wear on the steel core with the segment weld. Green concrete sawing is normal when taking care of new construction projects such as; motorways, runways, driveways & industrial flooring.
The size and kind of aggregate possess a great influence on the entire hardness of concrete as well as the blade to decide on. The aggregate can make up around 75% in the total volume. Typically, larger aggregate is likely to have the concrete act harder, slowing drilling process. Smaller aggregates make a blade cut faster. Sand is section 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 discover the sharpness of sand, you must know in which the sand is produced by. Crushed sand and bank sand tend to be sharp; river sand is usually round.
Selection for core drilling operation will also requires knowing the diameter in the final hole required, surface finish of the drilled hole, surface and accessibility of your drilling area.
“Tool horsepower, tool reliability and simplicity of use can also be important 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, Transformer 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 a lot 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.
Apart from saw speed, the simplicity of transport and installation is necessary in jobsites which may have single doors or window openings to be remove or in which the saw must be constantly moved from a floor to the next. Some machines function in a modular system thus bringing in certain advantages, because the single component might be easier transported and installed.
When it comes to costs, this equipment is not too expensive machines and when regularly maintained, the fee for maintenance can be kept only any machine a yearly spend of approximately 6% – 10% of the cost of the equipment.
The craze is clearly lighter, lesser, faster and much more profitable. But what includes this development can be a stronger demand that operators be trained effectively. Also, contractors ought to be made aware or there ought to be professionals who can recommend the best techniques and equipment for efficient and price-effective cutting at any stage of the project.
“On the service front, Prime Technologies features a band of service engineers who happen to be 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 crucial role in the day-to-day operation in our company. “Akhil Jain, CEO, Prime Technologies.