Professional methods of 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 increased spending on 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 the 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. Given the high labor and expenses involved with most sawing and cut to length machine, the rate with which the job is performed has become vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator experimentation only cause waste of time and money. Today, so that you can remain competitive, the contractors are under pressure to embrace more sophisticated methods of concrete sawing & drilling.
“The niche for floor saws, wall saws and high powered drilling machines will be in a nascent stage today but growing at about 40% yearly as the price of labor rises, the use of machines to increase work and increase productivity and excellence of work will increase 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 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. Such as reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
There are not many organized players in the core cutting arena. The majority of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. As with any other industry, the industry is flooded with Chinese equipment and fly by night traders who sell inexpensive, inferior machines from China with the objective of making quick money. These appliances, however, have zero after sales support nor will be the machines suited and created 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 consider poor quality Chinese makes but only end up spending much more about repairs.”
When it comes to manufacturing facilities in India, no more than 25% are manufactured indigenously, the others imported and the bulk from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is utilizing it its manufacturing facility to help develop and expand the development facility for diamond tools and disks and to strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Throughout the last 5-10 years, the technology has matured into a stage where even on residential sites, coring may be the preferred technology for fast, vibration-free penetrations. Right now we see the marketplace for coring at a lot more than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the current market measurements of controlled concrete dismantling in India is near to INR 120 crores. This includes branded and unbranded market too. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines are capable of doing drilling as much as 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven EI core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units along with its core cutting machines and drills are manufactured in Switzerland, Austria, United statesA. along with other parts around the globe. These appliances have 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 care for emergency Breakdowns.
Diabu Machines has entered the Indian market. Designed keeping in mind the Indian working conditions and the Indian operator, Diabu’s floor saws, wall saws and drilling machines are built about the platform of robust, rigid and productivity. Diabu uses good quality and right configuration steel, longevity and maintenance free 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 tensile steel. Apart from being easy to use, maintenance is also quite simple with an easy task to access grease and oil points.
“There is really a significant necessity for education about controlled dismantling as being a technology in the construction industry. Other challenges correspond with acceptability and adaptability of the technology in a number of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics related to the technology because this is expensive, application with illiterate labor and localized accessibility of the technology.”
Selecting the right blade (for that saw, the content as well as the job) is an essential aspect in getting maximum performance. Many 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 key 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 usually specified to cut precise dimensional door, vent and window openings. Straight in addition to bevel cuts are possible together with the wall saw. The wall saw is also a fantastic option for creating precise openings in every concrete structure. Flat sawing is generally utilized to cut horizontal flat surfaces including floors, bridge decks, and pavement. Flat saws are generally employed to provide expansion joints, remove damaged pavement sections, clean and repair random cracks dexqpky76 repair, and remove concrete sections for demolition purposes. Core drilling techniques are utilized when precise, circular cuts are essential 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 for concrete sample analysis. Wire sawing can be used elimination of thick parts of concrete. It is fantastic for removing large parts of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in places that 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 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 usually is better to use saws which can be laser welded or atleast have special reinforced brazing. Using such blades ensure that the very high heat generated during dry cutting will not damage the blade which may also cause injury and cause accidents.”
Besides the form of cutting and dry or wet cutting, kinds of concrete also influence the choice in selecting a blade. The duration of curing time after concrete flows greatly affects how a diamond blade will connect to it during cutting. Curing might be influenced by weather (temperature, moisture and time of the year) and also the composition (admixtures, aggregate and sand). Cured concrete is typically set at the very least 2 days. The sand is completely bonded with the mortar and the concrete reaches full hardness. Concrete is usually within its green state for 6 to two days after it is actually poured. In this particular early state, the sand will not be completely bonded using 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 inside the slurry, and produces much more abrasion over a diamond blade. Undercut protection is essential when cutting green concrete in order to avoid excessive wear on the steel core at the segment weld. Green concrete sawing is common when concentrating on new construction projects including; motorways, runways, driveways & industrial flooring.
Both the size and kind of aggregate possess a great impact on the general hardness of concrete along with the blade to pick. The aggregate will make up around 75% of the total volume. For the most part, larger aggregate will 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 may either be sharp (abrasive) or round (non-abrasive). To ascertain the sharpness of sand, you need to know where the sand originates from. Crushed sand and bank sand tend to be sharp; river sand is usually round.
Selection for core drilling operation will even requires learning the diameter from the final hole required, surface finish in the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and ease of use are also required for selecting the most appropriate tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter from the core, length of the core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Silicon steel 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 because it uses water, the instance of dust is nearly totally avoided. However, the slurry generated has to be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Besides saw speed, the ease of transport and installation is important in jobsites which have single doors or window openings to be eliminate or in which the saw has to be constantly moved from a floor to the next. Some machines work in a modular system thus bringing in certain advantages, as being the single component can be easier transported and installed.
Regarding costs, this equipment is not so expensive machines of course, if regularly maintained, the fee for maintenance may be kept as little as any machine a yearly spend of about 6% – 10% of the price tag on the machine.
The trend is clearly lighter, lesser, faster plus more profitable. But what comes along with this development is really a stronger demand that operators be trained effectively. Also, contractors should be made aware or there has to be pros who can suggest the most effective techniques and equipment for the most efficient and expense-effective cutting at any stage of your project.
“On the service front, Prime Technologies includes a band of service engineers who definitely are always roaming and actively engage themselves in providing solutions and technical advice to clients. Also, they are involved in training the dealers and customers’ maintenance personnel. They perform a huge role in the everyday operation of the company. “Akhil Jain, CEO, Prime Technologies.