Professional types 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. Due to an increased 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 the 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. Given the high labor and expenses involved with most sawing and Core cutting machine, the pace with which the task is done has grown to be vital. Using outdated cutting &drilling techniques and drilling equipment that heavily relies upon guessing and operator trial and error only cause waste of money and time. Today, as a way to remain competitive, the contractors are under pressure to embrace modern-day types of concrete sawing & drilling.
“The market for floor saws, wall saws and high powered drilling machines happen to be in a nascent stage today but growing at about 40% each year as the expense of labor rises, the use of machines to speed up work and increase productivity and excellence of work will increase phenomenally. Presently about 600 machines Floor Saws, Wall Saws and High Powered Drilling Machines have been in operation. Low Powered Handheld Drilling and sawing happen to be in many thousands which 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. Included in this are reduced downtime, precision cutting, maintenance of structural integrity, reduced noise, dust and debris, limited-access cutting, and the ability to cut heavily-reinforced concrete.
There are only a few organized players inside the core cutting arena. Many of them are extensions of worldwide manufacturers such as Hilti, TYROLIT, Husqvarna and Diabu. As in every other industry, the current market is flooded with Chinese equipment and fly by night traders who sell low cost, low quality machines from China with the goal of making quick money. These machines, however, have no post sales support nor are the machines suited and built 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 low quality Chinese makes only find yourself spending more on repairs.”
With regards to manufacturing facilities in India, only about 25% are manufactured indigenously, others imported along with the bulk coming from China. Hilti which acquired Bhukhanvala Diamond Systems in 2010 is using it as being its manufacturing facility to further develop and expand the development facility for diamond tools and disks and to strengthen its position within the Indian diamond consumables market.
“HILTI was the pioneer in introducing diamond coring technology in India. Over the past 5 to 10 years, the technologies have matured to some 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 greater than 50 crores.” Shyam Raghunandan, Head Marketing, Hilti India
Manval Goel, Business Head – Construction at TYROLIT India Superabrasives Tools believes the market scale 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 a wide range of core cutting electric, hydraulic and petrol driven machines. TYROLIT’s machines can do drilling approximately 1000 mm diameters. Its Ultimate Drilling Machine (UDM) can be a self-propelled gasoline driven EI core cutting machine highly ideal for drilling at runways. TYROLIT has 27 Global Production Units and its core cutting machines and drills are created in Switzerland, Austria, United statesA. and also other parts around the world. These appliances come with a manufacturing warranty of 1 year. Also they are quite sturdy machines and require very low mainte-nance. TYROLIT’s Unique Service Concept provides a few of the service requirement at site to deal with emergency Breakdowns.
Diabu Machines has entered the Indian market. Designed keeping in mind the Indian working conditions and also the Indian operator, Diabu’s floor saws, wall saws and drilling machines are designed around the platform of robust, rigid and high productivity. Diabu uses excellent and right configuration steel, long 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 steel or rust proof and tensile steel. In addition to being user friendly, maintenance can also be very easy with very easy to access grease and oil points.
“There is actually a significant necessity for education about controlled dismantling as a technology inside the construction industry. Other challenges relate with acceptability and adaptability of the technology in a number of the major projects, drilling and sawing vis-à-vis the conventional 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 as well as the job) is a vital consider getting maximum performance. Various other variables also affect blade performance. Changing any variable may have an effect on cutting speed and blade life.
Concrete cutting becoming an application oriented process, blades are supplied as per end application requirement and job site requirements. The main concrete cutting tools that 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 cut precise dimensional door, vent and window openings. Straight as well as bevel cuts are possible together with the wall saw. The wall saw is likewise an outstanding option for creating precise openings in any concrete structure. Flat sawing is typically employed to cut horizontal flat surfaces such as floors, bridge decks, and pavement. Flat saws are normally employed 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 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 perhaps for concrete sample analysis. Wire sawing can be used removing of thick parts of concrete. It is great for removing large sections of heavily reinforced concrete, for example piers, towers and bridge sections, and cutting concrete in areas where work area is fixed.
Often the decision of cutting wet or dry is determined by ones preferences and job requirements. Some sawing or drilling is wet, conditions such as water scarcity in sites, requirement to keep the internet site clean of water/slurry on account 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 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 fails to damage the blade which can also cause injury and cause accidents.”
Besides the type of cutting and dry or wet cutting, forms of concrete also influence the choice in choosing a blade. The duration of curing time after concrete is poured greatly affects the way a diamond blade will interact with it during cutting. Curing may be afflicted with weather (temperature, moisture and period) along with the composition (admixtures, aggregate and sand). Cured concrete is typically set no less than 48 hrs. The sand is completely bonded with all the mortar and the concrete reaches full hardness. Concrete is typically in their green state for 6 to 48 hours after it is poured. In this early state, the sand is not really completely bonded with the mortar and 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 with a diamond blade. Undercut protection is critical when cutting green concrete to prevent excessive wear on the steel core with the segment weld. Green concrete sawing is typical when working on new construction projects like; motorways, runways, driveways & industrial flooring.
The size and type of aggregate use a great effect on the complete hardness of concrete as well as the blade to choose. The aggregate can make up as much as 75% of your total volume. As a general rule, larger aggregate will make the concrete act harder, slowing drilling process. Smaller aggregates tend to make a blade cut faster. Sand is area 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 discover the sharpness of sand, you have to know where sand originates from. Crushed sand and bank sand are generally sharp; river sand is often round.
Choice for core drilling operation will even requires knowing the diameter in the final hole required, surface finish in the drilled hole, surface and accessibility from the drilling area.
“Tool horsepower, tool reliability and simplicity are also essential for selecting the right tool”, adds Mr. Shyam Raghunandan of Hilti, India.
Manav Goel, of TYROLIT summarizes, “Overall, factors such as diameter from the core, entire 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 large amounts of dust. While wet cutting or drilling operation does not generate dust because 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.
Besides saw speed, the ease of transport and installation is necessary in jobsites which may have single doors or window openings being remove or the location where the saw needs to be constantly moved from a single floor to the next. Some machines work in a modular system thus bringing in certain advantages, since the single component could be easier transported and installed.
Regarding costs, these machines are not too expensive machines and when regularly maintained, the price of maintenance may be kept as little as any machine a yearly spend of about 6% – 10% of the cost of the appliance.
The craze is clearly lighter, lesser, faster and a lot more profitable. But what incorporates this development can be a stronger demand that operators be trained effectively. Also, contractors needs to be made aware or there should be experts who can recommend the very best techniques and equipment for the most efficient and expense-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. Also, they are involved in training the dealers and customers’ maintenance personnel. They perform a crucial role in the everyday operation of the company. “Akhil Jain, CEO, Prime Technologies.