Professional ways 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. Because of a higher 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 is the constantly rising labour costs. In the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and overhead costs associated with most sawing and cut to length machine, the pace that the job is done is becoming vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator testing only lead to waste of money and time. Today, as a way to remain competitive, the contractors are under pressure to embrace more sophisticated strategies for concrete sawing & drilling.
“The niche for floor saws, wall saws and high powered drilling machines are in a nascent stage today but growing at about 40% per year as the fee for labor rises, the application of machines to accelerate work and increase productivity and quality of work boosts phenomenally. Presently about 600 machines Floor Saws, Wall Saws and Powered Drilling Machines are 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 offers significant advantages over conventional concrete removal methods. These include reduced downtime, precision cutting, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the opportunity to cut heavily-reinforced concrete.
There are actually very few organized players inside the core cutting arena. Most of them are extensions of worldwide manufacturers like Hilti, TYROLIT, Husqvarna and Diabu. As in almost every other industry, the current market is flooded with Chinese equipment and fly by night traders who sell inexpensive, inferior machines from China with the goal of making quick money. These machines, however, do not have after sales support nor are the machines suited and built 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 go for low quality Chinese makes but only turn out spending much more about repairs.”
With respect to manufacturing facilities in India, only about 25% are made indigenously, the rest imported and the bulk originating from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is employing it as a its manufacturing facility to further 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. During the last 5 to 10 years, the technologies have 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 over 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the market measurements of controlled concrete dismantling in India is close to INR 120 crores. This includes branded and unbranded market also. TYROLIT has a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can perform drilling around 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is a self-propelled gasoline driven Stack core cutting machine highly suitable for drilling at runways. TYROLIT has 27 Global Production Units and its particular core cutting machines and drills are manufactured in Switzerland, Austria, UsaA. and also other parts around the globe. These machines come with a manufacturing warranty of 12 months. Also these are generally quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides some 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 as well as the Indian operator, Diabu’s floor saws, wall saws and drilling machines are made around the platform of robust, rigid and high productivity. Diabu uses good quality and right configuration steel, long life and maintenance free bearings, dust and water protected motors, bearings and all sliding and rotating parts. Most if not completely fasteners are made from either stainless steel or rust proof and tensile steel. Aside from being user-friendly, maintenance can also be quite simple with very easy to access grease and oil points.
“There is a significant requirement for education about controlled dismantling being a technology in the construction industry. Other challenges connect with acceptability and adaptability in 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 option of the technology.”
Selecting the right blade (to the saw, the fabric and also the job) is the most important consider getting maximum performance. All kinds of other variables also affect blade performance. Changing any variable will have an impact on cutting speed and blade life.
Concrete cutting as an application oriented process, blades are supplied as per end application requirement and job site requirements. The principle concrete cutting tools that are utilized are the wall (or track) saw, the flat (or slab) saw, the core drill, as well as the wire saw. Wall sawing is usually specified to slice precise dimensional door, vent and window openings. Straight along with bevel cuts are possible with all the wall saw. The wall saw is additionally an outstanding selection for creating precise openings in any concrete structure. Flat sawing is generally employed to cut horizontal flat surfaces including floors, bridge decks, and pavement. Flat saws are typically utilized to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and take away concrete sections for demolition purposes. Core drilling techniques are utilized when precise, circular cuts are needed like 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 elimination of thick parts of concrete. It is great for removing large sections of heavily reinforced concrete, including piers, towers and bridge sections, and cutting concrete in places that work area is restricted.
Usually the decision of cutting wet or dry depends on ones preferences and job requirements. While many sawing or drilling is wet, conditions for example water scarcity in sites, requirement to keep the site clean of water/slurry as a result of proximity with existing office/ factory /commercial/residential space, proximity to electrical or another such dangerous areas may warrant dry cutting. However, cautions Mr.Venkatesh of Diabu, “If the cutting is dry it is usually better to use saws that happen to be laser welded or atleast have special reinforced brazing. Using such blades ensure that the very high heat generated during dry cutting is not going to damage the blade which might also cause injury and cause accidents.”
In addition to the form of cutting and dry or wet cutting, forms of concrete also influence your decision in picking a blade. The duration of curing time after concrete is poured greatly affects the way in which a diamond blade will communicate with it during cutting. Curing might be influenced by weather (temperature, moisture and period) as well as the composition (admixtures, aggregate and sand). Cured concrete is normally set a minimum of 48 hrs. The sand is entirely bonded together with the mortar along with the concrete reaches full hardness. Concrete is normally in its green state for 6 to 48 hours after it really is poured. In this early state, the sand is not really completely bonded using the mortar along with 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 considerably more abrasion with a diamond blade. Undercut protection is critical when cutting green concrete to avoid excessive wear around the steel core with the segment weld. Green concrete sawing is common when focusing on new construction projects like; motorways, runways, driveways & industrial flooring.
Both size and kind of aggregate use a great effect on the complete hardness of concrete and also the blade to decide on. The aggregate could make up up to 75% of your total volume. On the whole, larger aggregate will 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 often sand. Sand either can be sharp (abrasive) or round (non-abrasive). To determine the sharpness of sand, you should know where the sand is from. Crushed sand and bank sand tend to be sharp; river sand is often round.
Choice for core drilling operation will likely requires understanding the diameter from the final hole required, surface finish of your drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and simplicity are also necessary 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, 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 fails to 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.
Besides saw speed, the ease of transport and installation is needed in jobsites which have single doors or window openings being reduce or the location where the saw should be constantly moved from a single floor to another. Some machines are employed in a modular system thus attracting certain advantages, since the single component could be easier transported and installed.
When it comes to costs, these machines are not too expensive machines of course, if regularly maintained, the expense of maintenance may be kept as little as any machine a yearly spend of about 6% – 10% of the price of the machine.
The craze is clearly lighter, lesser, faster plus more profitable. But what incorporates this development is really a stronger demand that operators be trained effectively. Also, contractors ought to be made aware or there should be professionals who can suggest the ideal techniques and equipment for the best efficient and price-effective cutting at any stage from the project.
“On the service front, Prime Technologies features a band of service engineers that are 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 an important role inside the everyday operation of our own company. “Akhil Jain, CEO, Prime Technologies.