Professional strategies for concrete sawing and drilling are prevalent in countries like USA, Japan, Australia and Europe. In India, it can be still a young but growing industry. Because of an elevated spending on infrastructure projects and residential & commercial construction, India holds tremendous potential regarding diamond tools and concrete sawing and drilling.
Another critical factor inducing the adoption of such sophisticated methods will be the constantly rising labour costs. During 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 associated with most sawing and Core cutting machine, the speed which the task is completed has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily will depend on guessing and operator trial and error only bring about waste of money and time. Today, to be able to remain competitive, the contractors are under pressure to embrace modern-day methods of concrete sawing & drilling.
“The niche for floor saws, wall saws and high powered drilling machines have been in a nascent stage today but growing at about 40% yearly as the cost of labor rises, using machines to increase work and increase productivity superiority work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines will be in operation. Low Powered Handheld Drilling and sawing are in many thousands in fact it is tough 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. Included in this are reduced downtime, precision cutting, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
You can find not many organized players within the core cutting arena. Many of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. As with some other industry, the industry is flooded with Chinese equipment and fly by night traders who sell affordable, low quality machines from China with the goal of making quick money. These appliances, however, have zero post sales support nor would be the machines suited and built 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 go for poor Chinese makes only find yourself spending more on repairs.”
With regards to manufacturing facilities in India, just about 25% are manufactured indigenously, others imported along with the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is utilizing it its manufacturing facility to increase develop and expand the development facility for diamond tools and disks and also to strengthen its position in the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Throughout the last 5-10 years, the technologies have matured into a stage where even on residential sites, coring is definitely the preferred technology for fast, vibration-free penetrations. Right now we see the marketplace for coring at more than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the industry scale of controlled concrete dismantling in India is near INR 120 crores. Including branded and unbranded market also. TYROLIT has a variety 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 a self-propelled gasoline driven EI core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are made in Switzerland, Austria, UsaA. along with other parts around the globe. These appliances feature a manufacturing warranty of 1 year. Also they are quite sturdy machines and require extremely 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 bearing in mind the Indian working conditions and also the Indian operator, Diabu’s floor saws, wall saws and drilling machines are constructed around the platform of robust, rigid and productivity. Diabu uses good quality and right configuration steel, extended life and easy to maintain bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not completely fasteners are made of either stainless or rust proof and high tensile steel. Apart from being easy to use, maintenance is additionally quite simple with easy to access grease and oil points.
“There is really a significant need for education about controlled dismantling like a technology from the construction industry. Other challenges relate with acceptability and adaptability in the technology in several of the major projects, drilling and sawing vis-à-vis the traditional chisel and hammer, economics associated with the technology since this is expensive, application with illiterate labor and localized option of the technology.”
Selecting the most appropriate blade (to the saw, the fabric as well as the job) is a vital consider getting maximum performance. Many other variables also affect blade performance. Changing any variable can have an impact on cutting speed and blade life.
Concrete cutting being an application oriented process, blades are supplied depending on end application requirement and job site requirements. The primary concrete cutting tools which can be utilized are the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is generally specified to slice precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible with the wall saw. The wall saw is likewise a great choice for creating precise openings in virtually any concrete structure. Flat sawing is usually employed to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are usually accustomed 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 being used 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 concrete sample analysis. Wire sawing can be used removing of thick sections of concrete. It is fantastic for removing large parts of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in areas where work space is fixed.
Most of the decision of cutting wet or dry is determined by ones preferences and job requirements. While most sawing or drilling is wet, conditions including water scarcity in sites, requirement to maintain the site 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 always wise to use saws that happen to be laser welded or atleast have special reinforced brazing. Using such blades be sure that the extremely high heat generated during dry cutting does not damage the blade which could also cause injury and cause accidents.”
In addition to the type of cutting and dry or wet cutting, varieties of concrete also influence your choice in choosing a blade. The length of curing time after concrete flows greatly affects the way a diamond blade will communicate with it during cutting. Curing may be influenced by weather (temperature, moisture and time of the year) along with the composition (admixtures, aggregate and sand). Cured concrete is usually set at least 2 days. The sand is completely bonded using the mortar and the concrete reaches full hardness. Concrete is generally in their green state for 6 to 48 hours after it is actually poured. In this early state, the sand is not completely bonded with the mortar along with the concrete doesn’t reach full hardness. When cutting green concrete, the sand loosens more readily, and flows more freely from the slurry, and produces much more abrasion with a diamond blade. Undercut protection is essential when cutting green concrete to stop excessive wear on the steel core in the segment weld. Green concrete sawing is normal when focusing on new construction projects like; motorways, runways, driveways & industrial flooring.
Both size and type of aggregate use a great affect on the overall hardness of concrete and the blade to pick. The aggregate could make up just as much as 75% from the total volume. For the most part, larger aggregate is likely to have the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is part 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 ascertain the sharpness of sand, you must know where the sand is from. Crushed sand and bank sand are often sharp; river sand is usually round.
Selection for core drilling operation may also requires learning the diameter from the final hole required, surface finish in the drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and convenience are also necessary for selecting the most appropriate tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter in the core, length of the core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Straight core cutting machine, anchor or vacuum fixation assistance in deciding which concrete core cutter to use for the project.”
Conventional concrete cutting and drilling methods generated considerable amounts of dust. While wet cutting or drilling operation does not generate dust mainly because it uses water, the instance of dust is almost totally avoided. However, the slurry generated must be cleaned regularly. For dry cutting, most manufacturers have dust extraction systems as accessories.
Aside from saw speed, the simplicity of transport and installation is important in jobsites which may have single doors or window openings to get cut out or where saw must be constantly moved in one floor to the next. Some machines function in a modular system thus attracting certain advantages, since the single component may be easier transported and installed.
When it comes to costs, these machines are not very expensive machines and when regularly maintained, the price of maintenance might be kept as little as any machine an annual spend of around 6% – 10% of the buying price of the appliance.
The trend is clearly lighter, lesser, faster and more profitable. But what incorporates this development can be a stronger demand that operators be trained effectively. Also, contractors ought to be made aware or there has to be professionals who can suggest the most effective techniques and equipment for efficient and price-effective cutting at any stage of your 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 linked to 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.