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. On account of an elevated 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 such sophisticated methods is the constantly rising labour costs. Within the last decade, concrete and construction industry has experienced sharp increases in labor rates and overhead expenses. Considering the high labor and overhead costs linked to most sawing and cut to length machine, the speed which the work is done has become 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 Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator testing only lead to waste of money and time.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, in order to remain competitive, the contractors are under pressure to embrace more sophisticated strategies for concrete sawing & drilling.
“The industry for floor saws, wall saws and high powered drilling machines will be in a nascent stage today but growing at about 40% per annum as the cost of labor rises, the usage of machines to speed up work and increase productivity and excellence of work improves phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines are in operation. Low Powered Handheld Drilling and sawing have been in many thousands and it is hard to give even an approximate number.” – M.Venkatesh, Executive Director, Diabu Diamond Tools
Professional diamond concrete cutting systems can provide significant advantages over conventional concrete removal methods. These include reduced downtime, precision cutting, repair of structural integrity, reduced noise, dust and debris, limited-access cutting, and the capability to cut heavily-reinforced concrete.
There are hardly any organized players within the core cutting arena. Most of them are extensions of worldwide manufacturers for example Hilti, TYROLIT, Husqvarna and Diabu. Like in almost every other industry, the industry is flooded with Chinese equipment and fly by night traders who sell low cost, poor machines from China with the aim of making quick money. These appliances, however, do not have after sales support nor are 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 get inferior Chinese makes but only end up spending much more about repairs.”
With respect to manufacturing facilities in India, approximately 25% are made indigenously, the others imported along with the bulk provided by China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is employing it as being its manufacturing facility to advance develop and expand the development facility for diamond tools and disks as well as strengthen its position from the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. During the last 5-10 years, the technologies have matured to some stage where even on residential sites, coring may be the preferred technology for fast, vibration-free penetrations. Right now we see the market 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 market measurements of controlled concrete dismantling in India is near INR 120 crores. This can include branded and unbranded market too. TYROLIT has an array of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can perform drilling as much as 1000 mm diameters. Its Ultimate Drilling Machine (UDM) is really a self-propelled gasoline driven transformer core cutting machine highly suitable for drilling at runways. TYROLIT has 27 Global Production Units as well as its core cutting machines and drills are produced 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 suprisingly 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 built around the platform of robust, rigid and productivity. Diabu uses excellent and right configuration steel, extended life and maintenance free bearings, dust and water protected motors, bearings and all sorts of sliding and rotating parts. Most if not completely fasteners are made from either stainless-steel or rust proof and high tensile steel. Besides being user-friendly, maintenance is additionally very simple with an easy task to access grease and oil points.
“There is a significant necessity for education about controlled dismantling as being a technology from the construction industry. Other challenges correspond with acceptability and adaptability of your technology in some of the major projects, drilling and sawing vis-à-vis the typical chisel and hammer, economics linked to the technology since this is expensive, application with illiterate labor and localized accessibility to the technology.”
Selecting the most appropriate blade (for your saw, the content along with the job) is the most essential 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 being an application oriented process, blades are supplied depending on end application requirement and job site requirements. The key concrete cutting tools which are utilized include the wall (or track) saw, the flat (or slab) saw, the core drill, along with the wire saw. Wall sawing is typically specified to slice precise dimensional door, vent and window openings. Straight along with bevel cuts are possible with the wall saw. The wall saw is additionally a fantastic selection for creating precise openings in any concrete structure. Flat sawing is generally utilized to cut horizontal flat surfaces for example floors, bridge decks, and pavement. Flat saws are normally utilized 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 being used when precise, circular cuts are needed 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 concrete sample analysis. Wire sawing can be used for 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.
Frequently the decision of cutting wet or dry is dependent upon ones preferences and job requirements. Some sawing or drilling is wet, conditions including water scarcity in sites, requirement to help keep the website 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 is usually advisable 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 is not going to damage the blade which may also cause injury and cause accidents.”
Aside from the form of cutting and dry or wet cutting, types of concrete also influence your decision in picking a blade. The duration of curing time after concrete flows greatly affects just how a diamond blade will connect with it during cutting. Curing could be impacted by weather (temperature, moisture and period) and also the composition (admixtures, aggregate and sand). Cured concrete is generally set at the very least 48 hours. The sand is totally bonded using the mortar and also the concrete reaches full hardness. Concrete is normally within its green state for 6 to two days after it is actually poured. In this early state, the sand is just not completely bonded with all 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 far more abrasion over a diamond blade. Undercut protection is critical when cutting green concrete to prevent excessive wear around the steel core at the segment weld. Green concrete sawing is normal when working on new construction projects like; motorways, runways, driveways & industrial flooring.
Both size and kind of aggregate have a great affect on the overall hardness of concrete along with the blade to select. The aggregate can certainly make up around 75% from the total volume. As a general rule, larger aggregate tends to make 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 generally sand. Sand may either be sharp (abrasive) or round (non-abrasive). To look for the sharpness of sand, you should know the location where the sand is produced by. Crushed sand and bank sand are usually sharp; river sand is normally round.
Choice for core drilling operation will also requires learning the diameter of your final hole required, surface finish from the drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and ease of use will also be important 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, entire core, power and speed of motor, percentage reinforcement, grade of concrete, horizontal or vertical drilling, Transformer core cutting machine, anchor or vacuum fixation aid in deciding which concrete core cutter for the project.”
Conventional concrete cutting and drilling methods generated a lot of dust. While wet cutting or drilling operation does not generate dust as it uses water, the instance of dust is almost 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 comes into play in jobsites who have single doors or window openings to be remove or the location where the saw has to be constantly moved from a floor to the next. Some machines are employed in a modular system thus bringing in certain advantages, because the single component may be easier transported and installed.
With respect to costs, this equipment is not very expensive machines and when regularly maintained, the price of maintenance may be kept as low as any machine an annual spend of about 6% – 10% of the price of the appliance.
The trend is clearly lighter, lesser, faster plus more profitable. But what comes with this development is a stronger demand that operators be trained effectively. Also, contractors should be made aware or there must be professionals who can suggest the very best techniques and equipment for efficient and cost-effective cutting at any stage from the project.
“On the service front, Prime Technologies carries 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 a vital role within the day-to-day operation of the company. “Akhil Jain, CEO, Prime Technologies.