Professional ways of 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. On account of an increased 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 the sophisticated methods is definitely 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 in most sawing and cut to length machine, the speed which the job is performed has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily depends on guessing and operator trial and error only result in waste of time and money. Today, in order to remain competitive, the contractors are under pressure to embrace modern-day methods of concrete sawing & drilling.
“The marketplace for floor saws, wall saws and high powered drilling machines happen to be in a nascent stage today but growing at about 40% per year as the price of labor rises, the use of machines to increase work and increase productivity superiority work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines happen to be in operation. Low Powered Handheld Drilling and sawing will be in many thousands in fact it is hard 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 ability to cut heavily-reinforced concrete.
There are actually very few organized players in the core cutting arena. Many of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. As with every other industry, the market is flooded with Chinese equipment and fly by night traders who sell inexpensive, inferior machines from China with the aim of making quick money. These machines, however, have zero after sales support nor would be the machines suited and made 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 choose poor quality Chinese makes only wind up spending more on repairs.”
Regarding manufacturing facilities in India, only about 25% are produced indigenously, the others imported along with the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is utilizing it as being its manufacturing facility to further develop and expand the development facility for diamond tools and disks and also to strengthen its position inside the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. During the last maybe five or ten years, the technology has matured to your stage where even on residential sites, coring is the preferred technology for fast, vibration-free penetrations. Right now we 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 current market size of controlled concrete dismantling in India is in close proximity to INR 120 crores. This includes branded and unbranded market at the same time. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can perform drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) can be a self-propelled gasoline driven transformer core cutting machine highly appropriate for drilling at runways. TYROLIT has 27 Global Production Units and its core cutting machines and drills are created in Switzerland, Austria, U.S.A. along with other parts on the planet. These machines feature a manufacturing warranty of 12 months. Also these are typically quite sturdy machines and require extremely low mainte-nance. TYROLIT’s Unique Service Concept provides a number of the service requirement at site to deal with emergency Breakdowns.
Diabu Machines recently 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 designed about the platform of robust, rigid and high productivity. Diabu uses top quality and right configuration steel, longevity and easy to maintain bearings, dust and water protected motors, bearings and all sorts of sliding and rotating parts. Most if not completely fasteners are manufactured from either stainless or rust proof and high tensile steel. Aside from being user friendly, maintenance is also very simple with very easy to access grease and oil points.
“There is a significant desire for education about controlled dismantling like a technology inside the construction industry. Other challenges connect with acceptability and adaptability from the technology in a few of the major projects, drilling and sawing vis-à-vis the typical chisel and hammer, economics associated with the technology because this is expensive, application with illiterate labor and localized accessibility of the technology.”
Choosing the proper blade (to the saw, the content and also the job) is an essential element in getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable could have an impact on cutting speed and blade life.
Concrete cutting as an application oriented process, blades are supplied according to end application requirement and job site requirements. The key concrete cutting tools which can be 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 slice precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible with the wall saw. The wall saw is additionally a great choice for creating precise openings in every concrete structure. Flat sawing is generally accustomed to cut horizontal flat surfaces for example 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 off concrete sections for demolition purposes. Core drilling techniques are 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 even for concrete sample analysis. Wire sawing can be used for elimination of thick sections of concrete. It is fantastic for removing large sections of heavily reinforced concrete, like piers, towers and bridge sections, and cutting concrete in locations where work space is fixed.
Usually 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 keep the internet site clean water/slurry on account of proximity with existing office/ factory /commercial/residential space, proximity to electrical or other such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it will always be preferable to use saws that are laser welded or atleast have special reinforced brazing. Using such blades be sure that the extremely high heat generated during dry cutting fails to damage the blade which may also cause injury and cause accidents.”
Aside from the form of cutting and dry or wet cutting, kinds of concrete also influence your choice in selecting a blade. The length of curing time after concrete flows greatly affects how a diamond blade will connect with it during cutting. Curing might be influenced by weather (temperature, moisture and period) and also the composition (admixtures, aggregate and sand). Cured concrete is typically set no less than 48 hours. The sand is totally bonded with all the mortar as well as the concrete reaches full hardness. Concrete is usually in their green state for 6 to 48 hours after it really is poured. With this early state, the sand is not really 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 much more abrasion over a diamond blade. Undercut protection is crucial when cutting green concrete to stop excessive wear on the steel core with the segment weld. Green concrete sawing is normal when concentrating on new construction projects such as; motorways, runways, driveways & industrial flooring.
The size and kind of aggregate have got a great effect on the entire hardness of concrete and also the blade to choose. The aggregate could make up just as much as 75% of the total volume. On the whole, larger aggregate tends to create the concrete act harder, slowing drilling process. Smaller aggregates tend to 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 discover the sharpness of sand, you need to know in which the sand originates from. Crushed sand and bank sand are generally sharp; river sand is normally round.
Selection for core drilling operation will likely requires knowing the diameter in the final hole required, surface finish of your drilled hole, surface and accessibility in the drilling area.
“Tool horsepower, tool reliability and simplicity of use are also essential 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 assist in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated considerable amounts of dust. While wet cutting or drilling operation is not going to generate dust since 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.
Apart from saw speed, the simplicity of transport and installation is important in jobsites who have single doors or window openings to be reduce or the location where the saw must be constantly moved in one floor to the next. Some machines work in a modular system thus attracting certain advantages, because the single component can be easier transported and installed.
With regards to costs, these machines are not expensive machines of course, if regularly maintained, the cost of maintenance can be kept as little as any machine a yearly spend around 6% – 10% of the price tag on the device.
The buzz is clearly lighter, lesser, faster and a lot more profitable. But what includes this development is a stronger demand that operators be trained effectively. Also, contractors should be made aware or there has to be experts who can suggest the most effective techniques and equipment for the most efficient and cost-effective cutting at any stage of the project.
“On the service front, Prime Technologies has 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 associated with training the dealers and customers’ maintenance personnel. They perform a crucial role within the everyday operation of the company. “Akhil Jain, CEO, Prime Technologies.