Vacuum dewatering

The vacuum dewatering process basically improves strength, durability, and other properties of concrete by reducing the water-cement ratio immediately after the mix is placed, usually in floors and other flatwork. A Bridgeport, Connecticut vacuum dewatering demonstration, although it involved no new ...

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1. Vacuum Dewatering Concrete Flooring 1 Vaccum Dewatering Concrete Flooring PRESENTED BY AGLAIA

2. What Is Vacuum Dewatered Floors..??? Concrete is being the most versatile of flooring material has been in use for a long time To overcome the deficiencies of concrete flooring, a system was devised to improve the properties of such concrete floors. This system was “VACUUM DEWATERED FLOORS” It permits to add much water for workable and easily pourable. 2 Vaccum Dewatering Concrete Flooring

3. The addition of water reduces the strength of the concrete. This system removes the excess water and maintain an ideal water/cement ratio. This system will maintain all the properties of the concrete. 3 Vaccum Dewatering Concrete Flooring

4. Vacuum de-watered Concrete floor Concrete of the required grade such as M20, M25 etc are poured over the PCC and reinforcement bars as per design. Vacuum de-watering (VDF) is a process by which excess water is removed in a controlled fashion by applying vacuum The concrete is then power-trowelled to obtain a smooth and dense concrete 4 Vaccum Dewatering Concrete Flooring

5. VDF floors are known to provide a good concrete floor and is known to achieve strength earlier than a control concrete However, contrary to the popular belief, for a specified design mix, the compressive strength cannot be more than the targeted strength. Due to controlled water-removal as well as power-trowelling, the surface is quite dense and levelled and hence is expected to provide a better abrasion resistance than a non-VDF concrete floor. 5 Vaccum Dewatering Concrete Flooring

6. FUNDAMENTALS FOR DEVELOPMENT OF V D F Value for money Level floor, high flatness accuracy Improve wear resistance 6 Vaccum Dewatering Concrete Flooring

7. NEED OF V D F The mixing water added to a concrete mix exceeds the amount of water required to fully hydrate the cement constituent. The additional water functions as a lubrication medium to allow mixing, placing and consolidation. In conventional concreting practice, an important challenge is the prevention or limiting of evaporation of mixing water out of the freshly placed concrete. 7 Vaccum Dewatering Concrete Flooring

8. The uncontrolled removal of water from the concrete matrix can result in adverse effects such as plastic shrinkage cracking. Excessive bleeding of concrete can caused for wear resistance. Thus the durability and service life of the flooring element is in question. In hot and windy conditions it produce quality, durable concrete. 8 Vaccum Dewatering Concrete Flooring

9. INSTRUMENTS USED IN V D F Vacuum de-watering Pump Vacuum Pump is used to reduce water content in the concrete by 15-25%. It is used to suck all the air bubbles that may have trapped during the laying of the concrete. 9 Vaccum Dewatering Concrete Flooring Fig. 1 Vacuum de-watering Pump (Source: www.skylarkrebar.in)

10. Floater machine Floating & Troweling take place right after dewatering This makes the cement more compact and enabling to generate a very smooth finish. 10 Vaccum Dewatering Concrete Flooring Fig. 2 Floater Machine Source: Google images

11. Tremix skin Suction Mat of special grade multilayered polymer sheets ensure sufficient cross-sectional area to squeeze out and remove excess water from the concrete. 11 Vaccum Dewatering Concrete Flooring Fig.3 Tremix Skin Source:constructor.org

12. Double beam screed vibrator Double beam screed vibrator consists of a Beam unit and a vibrator unit Double beam screed vibrator is used to vibrate the concrete to give a compact and levelled surface 12 Vaccum Dewatering Concrete Flooring Fig. 4 Vacuum de-watering Pump (Source: www.skylarkrebar.in)

13. VACUUM DEWATERING PROCESS Preparation of sub base. Divide floor area into panels. Preparation of framework using steel channels. Laying down of steel bars of specified size. Mix design of concrete. Placing of concrete and compacting. The vacuum dewatering process removes surplus water present in the concrete. 13 Vaccum Dewatering Concrete Flooring

14. This is done using the Vacuum Equipment comprising of Suction Mat Top Cover, Filter pads and Vacuum Pump. This process starts immediately after surface vibration. Filter pads are placed on the fresh concrete leaving about 4 inches of fresh concrete exposed on all sides. The top cover is then placed on the filter pads and rolled out till it covers the strips of exposed concrete on all sides. The top cover is then connected to the vacuum pump through a suction hose and the pump is started. 14 Vaccum Dewatering Concrete Flooring

15. Vacuum is immediately created between the filter pads and the top cover. Atmospheric pressure compresses the concrete and the surplus water is squeezed out. This process lowers the water content in the concrete by 15 – 25%. The dewatering operation takes approximately 1.5 – 2 minutes per centimetre thickness of the floor. The dewatered concrete is compacted and dried to such an extent that is possible to walk on it without leaving any foot prints. This is the indication of concrete being properly dewatered and ready for finishing. 15 Vaccum Dewatering Concrete Flooring

16. The filter pads are placed so that there will be a sealing edge around the entire filter pad surface 16 Vaccum Dewatering Concrete Flooring Fig.5 Filler Pads (Source: www.skylarkrebar.in)

17. Fig.6 The top cover is unrolled over the filter pads . (Source: www.skylarkrebar.in) 17 Vaccum Dewatering Concrete Flooring

18. Fig. 7 The top cover of filter pads is connected to the suction hose of the vacuum pump. (Source: www.skylarkrebar.in) 18 Vaccum Dewatering Concrete Flooring

19. While vacuum is on , the surface that has already been vacuum dewatered is floated with a power trowel fitted with a disc. 19 Vaccum Dewatering Concrete Flooring

20. Tremix vacuum system stages 20 Vaccum Dewatering Concrete Flooring Fig. 8 Stage of tremic vaccum system (Source: www.skylarkrebar.in)

21. ADVANTAGES OF V D F Reduction in W/C ratio leads to early setting and high strength. It removes the excess water of the concrete & an ideal W/C ratio can be achieved. Increase in compressive strength of concrete by 40 – 70%. The surface hardness of the slab increase by 130%. Water absorption is reduced enormously. 21 Vaccum Dewatering Concrete Flooring

22. Minimum dusts. Level floor, high flatness accuracy. Minimized crack formation, shrinkage reduced by 50%. Improved wear resistance. Elimination or minimization of overtime. High and early strength, minimize damage to newly cast floors. Void – free and Denser concrete. 23 22 Vaccum Dewatering Concrete Flooring

23. APPLICATIONS OF V D F Warehouses Roads , Sports Courts Cellars , Parking Areas Production Areas, Industrial Shop floors Base floor for Resinious floors - Epoxy, PU,Mat, Carpets & Wooden Floors 24 23 Vaccum Dewatering Concrete Flooring

24. CONCLUSION Vacuum Dewatering process is very important modern construction work in the context of economy, facility, modern technology and comfort. It is very useful for special purpose projects like for the use of wear house, parking area, industrial flooring like flooring of large area. 25 24 Vaccum Dewatering Concrete Flooring

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