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. Due to a higher 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 such sophisticated methods is the constantly rising labour costs. During the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and overhead costs linked to most sawing and cut to length machine, the rate with which the work is done has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator learning from mistakes only cause waste of money and time. Today, as a way to remain competitive, the contractors are under pressure to embrace modern-day ways 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% yearly as the price of labor rises, the application of machines to increase work and increase productivity and quality of work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines happen to be 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 offers significant advantages over conventional concrete removal methods. Some examples 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.
You will find hardly any organized players inside the core cutting arena. Many of them are extensions of worldwide manufacturers for example 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 priced, low 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 designed 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 low quality Chinese makes only find yourself spending more on repairs.”
When it comes to manufacturing facilities in India, only about 25% are produced indigenously, others imported along with the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems during 2010 is applying it as being its manufacturing facility to further develop and expand the production facility for diamond tools and disks as well as to strengthen its position inside the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. During the last 5 to 10 years, the technologies have matured into a stage where even on residential sites, coring is definitely 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 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 a self-propelled gasoline driven EI core cutting machine highly suited to drilling at runways. TYROLIT has 27 Global Production Units along with its core cutting machines and drills are manufactured in Switzerland, Austria, U.S.A. and other parts on the planet. These appliances come with a manufacturing warranty of one year. Also these are quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides several of the service requirement at site to manage emergency Breakdowns.
Diabu Machines 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 designed on the platform of robust, rigid and productivity. Diabu uses excellent and right configuration steel, longevity and easy to maintain bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not all fasteners are produced from either stainless or rust proof and high tensile steel. In addition to being user friendly, maintenance is additionally really easy with an easy task to access grease and oil points.
“There is a significant desire for education about controlled dismantling as a technology in the construction industry. Other challenges correspond with acceptability and adaptability of your technology in some of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics associated with the technology because this is expensive, application with illiterate labor and localized availability of the technology.”
Selecting the right blade (for the saw, the fabric as well as the job) is an essential element in 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 being an application oriented process, blades are supplied based on end application requirement and job site requirements. The primary concrete cutting tools which are utilized are the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is typically specified to reduce precise dimensional door, vent and window openings. Straight in addition to bevel cuts are possible together with the wall saw. The wall saw is additionally a great selection for creating precise openings in virtually any concrete structure. Flat sawing is normally employed to cut horizontal flat surfaces including floors, bridge decks, and pavement. Flat saws are normally used 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 utilized when precise, circular cuts are important 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 perhaps 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, such as piers, towers and bridge sections, and cutting concrete in places that work area is fixed.
Most of the decision of cutting wet or dry depends on ones preferences and job requirements. While most sawing or drilling is wet, conditions such as water scarcity in sites, requirement to hold the website 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 usually is advisable to use saws which are laser welded or atleast have special reinforced brazing. Using such blades be sure that the very high heat generated during dry cutting does not damage the blade which can also cause injury and cause accidents.”
In addition to the kind of cutting and dry or wet cutting, types of concrete also influence the choice when choosing a blade. The size of curing time after concrete flows greatly affects the way in which a diamond blade will interact with it during cutting. Curing could be affected by weather (temperature, moisture and time of year) along with the composition (admixtures, aggregate and sand). Cured concrete is generally set at the very least 48 hrs. The sand is completely bonded with all the mortar and the concrete reaches full hardness. Concrete is generally in its green state for 6 to 48 hours after it is poured. With this early state, the sand is just not completely bonded using the mortar and 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 a lot more abrasion on the diamond blade. Undercut protection is crucial when cutting green concrete to prevent excessive wear in the steel core in the segment weld. Green concrete sawing is normal when focusing on new construction projects such as; motorways, runways, driveways & industrial flooring.
Both the size and kind of aggregate have a great influence on the complete hardness of concrete as well as the blade to pick. The aggregate will make up up to 75% from the total volume. For the most part, larger aggregate is likely to create 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 normally sand. Sand either can be sharp (abrasive) or round (non-abrasive). To discover the sharpness of sand, you should know where the sand is produced by. Crushed sand and bank sand tend to be sharp; river sand is normally round.
Selection for core drilling operation will also requires understanding the diameter of your final hole required, surface finish in the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and ease of use may also be required for selecting the most appropriate tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter of your core, entire core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Silicon steel core cutting machine, anchor or vacuum fixation assist 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 will not generate dust mainly because it uses water, the instance of dust is virtually totally avoided. However, the slurry generated should be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Aside from saw speed, the ease of transport and installation is needed in jobsites which may have single doors or window openings to be eliminate or in which the saw needs to be constantly moved from one floor to the next. Some machines are employed 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 fee for maintenance can be kept as low as any machine a yearly spend around 6% – 10% of the buying price of the machine.
The craze is clearly lighter, lesser, faster plus more profitable. But what includes this development is really a stronger demand that operators be trained effectively. Also, contractors must be made aware or there must be pros who can recommend the best techniques and equipment for the best efficient and price-effective cutting at any stage from the project.
“On the service front, Prime Technologies carries a band of service engineers who happen to be always roaming and actively engage themselves in providing solutions and technical advice to clients. They are also involved in training the dealers and customers’ maintenance personnel. They perform a crucial role inside the daily operation of our own company. “Akhil Jain, CEO, Prime Technologies.