Professional methods of concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it really is still a young but growing industry. On account of a heightened 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 those 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. Due to the high labor and overhead costs linked to most sawing and Core cutting machine, the pace with which the work is carried out has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator experimentation only bring about waste of time and money. Today, so that you can remain competitive, the contractors are under pressure to embrace modern-day strategies for concrete sawing & drilling.
“The industry for floor saws, wall saws and powered drilling machines will be in a nascent stage today but growing at about 40% yearly as the fee for labor rises, the application of machines to accelerate work and increase productivity superiority work increases phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines will be in operation. Low Powered Hand Held Drilling and sawing have been in many thousands and it is very difficult 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, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the cabability to cut heavily-reinforced concrete.
You can find only a few organized players in the core cutting arena. Most of them are extensions of worldwide manufacturers including Hilti, TYROLIT, Husqvarna and Diabu. Like every other industry, the current market is flooded with Chinese equipment and fly by night traders who sell low cost, low quality machines from China with the purpose of making quick money. These appliances, however, have zero after sales support nor are 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 consider low quality Chinese makes only wind up spending more on repairs.”
With regards to manufacturing facilities in India, just about 25% are created indigenously, the remainder imported as well as the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is employing it as its manufacturing facility to increase develop and expand the production facility for diamond tools and disks and also to strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the last maybe five or ten years, the technology has matured to your 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 greater than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the marketplace size of controlled concrete dismantling in India is near INR 120 crores. This includes branded and unbranded market as well. TYROLIT has a variety 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) can be 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 produced in Switzerland, Austria, U.S.A. and also other parts on the planet. These appliances come with a manufacturing warranty of one year. Also these are generally quite sturdy machines and require extremely low mainte-nance. TYROLIT’s Unique Service Concept provides some of the service requirement at site to manage emergency Breakdowns.
Diabu Machines has entered the Indian market. Designed keeping in mind the Indian working conditions and also 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, extended life and maintenance free bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not all fasteners are manufactured from either steel or rust proof and high tensile steel. Besides being simple to use, maintenance is also very easy with easy to access grease and oil points.
“There is actually a significant desire for education about controlled dismantling as a technology inside 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 since this is expensive, application with illiterate labor and localized accessibility of the technology.”
Selecting the right blade (for that saw, the information along with the job) is an essential consider getting maximum performance. A number of other variables also affect blade performance. Changing any variable will have an impact on cutting speed and blade life.
Concrete cutting becoming an application oriented process, blades are supplied based on end application requirement and job site requirements. The principle concrete cutting tools which are utilized add the wall (or track) saw, the flat (or slab) saw, the core drill, and the wire saw. Wall sawing is typically specified to reduce precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible with all the wall saw. The wall saw is additionally a fantastic option for creating precise openings in virtually any concrete structure. Flat sawing is usually utilized to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are usually accustomed 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 employed 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 perhaps for concrete sample analysis. Wire sawing can be used removal of thick parts of concrete. It is ideal for removing large sections of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in locations where work space is restricted.
Often the decision of cutting wet or dry depends on ones preferences and job requirements. While many sawing or drilling is wet, conditions like water scarcity in sites, requirement to hold the web page clean water/slurry as a result 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 usually preferable to use saws that happen to be laser welded or atleast have special reinforced brazing. Using such blades be sure that the very high heat generated during dry cutting will not damage the blade which could also cause injury and cause accidents.”
Aside from the kind of cutting and dry or wet cutting, varieties of concrete also influence the decision in picking a blade. The length of curing time after concrete flows greatly affects the way a diamond blade will connect with it during cutting. Curing might be afflicted with weather (temperature, moisture and time of year) and also the composition (admixtures, aggregate and sand). Cured concrete is typically set a minimum of 48 hrs. The sand is completely bonded together with the mortar and the concrete reaches full hardness. Concrete is typically in their green state for 6 to 48 hours after it is actually poured. In this early state, the sand will not be completely bonded together with the mortar and 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 far more abrasion on the diamond blade. Undercut protection is critical when cutting green concrete in order to avoid excessive wear in the steel core on the segment weld. Green concrete sawing is common when focusing on new construction projects for example; motorways, runways, driveways & industrial flooring.
The two size and kind of aggregate use a great affect on the overall hardness of concrete and also the blade to pick. The aggregate could make up as much as 75% from the total volume. For the most part, larger aggregate will have 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 normally sand. Sand can either be sharp (abrasive) or round (non-abrasive). To discover the sharpness of sand, you need to know where the sand originates from. Crushed sand and bank sand are generally sharp; river sand is normally round.
Choice for core drilling operation will even requires understanding the diameter in the final hole required, surface finish of the drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and ease of use are also required for choosing the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter from 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 for the project.”
Conventional concrete cutting and drilling methods generated large amounts of dust. While wet cutting or drilling operation will not generate dust as 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.
In addition to saw speed, the ease of transport and installation is important in jobsites which have single doors or window openings to become eliminate or where saw must be constantly moved from one floor to another. Some machines work in a modular system thus attracting certain advantages, since the single component might be easier transported and installed.
With regards to costs, this equipment is not so expensive machines and when regularly maintained, the fee for maintenance might be kept as low as any machine an annual spend of about 6% – 10% of the price of the equipment.
The popularity is clearly lighter, lesser, faster and more profitable. But what incorporates this development is 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 includes 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 vital role in the day-to-day operation of our company. “Akhil Jain, CEO, Prime Technologies.