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. On account of an increased shelling out for 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 the sophisticated methods may be the constantly rising labour costs. In 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 pace that the position is done is now vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator testing only bring about waste of money and time. Today, to be able to remain competitive, the contractors are under pressure to embrace more sophisticated methods of concrete sawing & drilling.
“The marketplace for floor saws, wall saws and high powered drilling machines are in a nascent stage today but growing at about 40% yearly as the fee for labor rises, the application of machines to quicken work and increase productivity superiority work boosts 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 are in many thousands which is hard to give even an approximate number.” – M.Venkatesh, Executive Director, Diabu Diamond Tools
Professional diamond concrete cutting systems can offer significant advantages over conventional concrete removal methods. Such as reduced downtime, precision cutting, upkeep of structural integrity, reduced noise, dust and debris, limited-access cutting, and the opportunity to cut heavily-reinforced concrete.
You can find hardly any organized players within the core cutting arena. The majority of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. Like in any other industry, the industry is flooded with Chinese equipment and fly by night traders who sell low priced, inferior machines from China with the objective of making quick money. These machines, however, have zero after sales support nor would be the machines suited and created to operate 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 but only end up spending much more on repairs.”
With respect to manufacturing facilities in India, approximately 25% are created indigenously, the remainder imported and also the bulk coming from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is using it as a its manufacturing facility to increase develop and expand the production facility for diamond tools and disks as well as to strengthen its position within the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the last maybe five or ten years, the technologies have matured into a stage where even on residential sites, coring will be the preferred technology for fast, vibration-free penetrations. We currently 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 industry dimensions of controlled concrete dismantling in India is close to INR 120 crores. This can include 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 do drilling up to 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is actually 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 made in Switzerland, Austria, United statesA. along with other parts around the globe. These appliances feature a manufacturing warranty of one year. Also they are quite sturdy machines and require suprisingly low mainte-nance. TYROLIT’s Unique Service Concept provides several of the service requirement at site to take care of emergency Breakdowns.
Diabu Machines has recently entered the Indian market. Designed remembering the Indian working conditions and the Indian operator, Diabu’s floor saws, wall saws and drilling machines are constructed about the platform of robust, rigid and productivity. Diabu uses good quality and right configuration steel, longevity and easy to maintain bearings, dust and water protected motors, bearings and sliding and rotating parts. Most if not completely fasteners are manufactured from either stainless or rust proof and tensile steel. Aside from being user-friendly, maintenance is additionally really easy with simple to access grease and oil points.
“There can be a significant necessity for education about controlled dismantling like a technology within the construction industry. Other challenges relate to acceptability and adaptability from the technology in a few of the major projects, drilling and sawing vis-à-vis the standard chisel and hammer, economics related to the technology as this is expensive, application with illiterate labor and localized accessibility of the technology.”
Selecting the most appropriate blade (for the saw, the content along with the job) is a vital element in getting maximum performance. Various 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 principle concrete cutting tools that are utilized are the wall (or track) saw, the flat (or slab) saw, the core drill, and also the wire saw. Wall sawing is usually specified to slice precise dimensional door, vent and window openings. Straight in addition to bevel cuts are possible using the wall saw. The wall saw is also an excellent selection for creating precise openings in virtually any concrete structure. Flat sawing is normally used to cut horizontal flat surfaces like floors, bridge decks, and pavement. Flat saws are normally accustomed to provide expansion joints, remove damaged pavement sections, neat and repair random cracks dexqpky76 repair, and take off 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 even for concrete sample analysis. Wire sawing can be used removal of thick sections of concrete. It is perfect for removing large parts of heavily reinforced concrete, such as piers, towers and bridge sections, and cutting concrete in locations where work area is fixed.
Most of the decision of cutting wet or dry is determined by ones preferences and job requirements. While many sawing or drilling is wet, conditions such as water scarcity in sites, requirement to hold the web page clean of water/slurry on account 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 which are laser welded or atleast have special reinforced brazing. Using such blades ensure that the extremely high heat generated during dry cutting does not damage the blade which may also cause injury and cause accidents.”
Apart from the type of cutting and dry or wet cutting, kinds of concrete also influence your choice in choosing a blade. The length of curing time after concrete flows greatly affects the way in which a diamond blade will communicate with it during cutting. Curing can be affected by weather (temperature, moisture and time of the year) along with the composition (admixtures, aggregate and sand). Cured concrete is generally set a minimum of 2 days. The sand is utterly bonded together with the mortar and also the concrete reaches full hardness. Concrete is normally in the green state for 6 to 48 hours after it is actually poured. In this early state, the sand will not be completely bonded using the mortar and also 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 over a diamond blade. Undercut protection is essential when cutting green concrete to stop excessive wear about the steel core at the segment weld. Green concrete sawing is typical when working on new construction projects like; motorways, runways, driveways & industrial flooring.
Both the size and type of aggregate have got a great effect on the entire hardness of concrete as well as the blade to select. The aggregate could make up around 75% of your total volume. As a general rule, larger aggregate is likely to have 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 can either be sharp (abrasive) or round (non-abrasive). To determine the sharpness of sand, you need to know where sand originates from. Crushed sand and bank sand are often sharp; river sand is usually round.
Selection for core drilling operation may also requires understanding the diameter of the final hole required, surface finish from the drilled hole, surface and accessibility of the drilling area.
“Tool horsepower, tool reliability and simplicity of use may also be required for choosing the right 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, Silicon steel core cutting machine, anchor or vacuum fixation help in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated huge amounts of dust. While wet cutting or drilling operation is not going to generate dust mainly because it uses water, the instance of dust is nearly 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 necessary in jobsites which have single doors or window openings to become eliminate or in which the saw has to be constantly moved from one floor to another. Some machines work in a modular system thus attracting certain advantages, as the single component may be easier transported and installed.
When it comes to costs, this equipment is not expensive machines and if regularly maintained, the price of maintenance can be kept as little as any machine an annual spend around 6% – 10% of the buying price of the machine.
The popularity is clearly lighter, lesser, faster plus more profitable. But what comes with this development is actually a stronger demand that operators be trained effectively. Also, contractors ought to be made aware or there must be professionals who can recommend the most effective techniques and equipment for the best efficient and expense-effective cutting at any stage of 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 associated with training the dealers and customers’ maintenance personnel. They perform a huge role from the everyday operation in our company. “Akhil Jain, CEO, Prime Technologies.