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Vacuum dewatered flooring
- 1. VACUUM DEWATERED FLOORING SUBMITTED BY RAMTOSNIWAL UNDER THE GUIDANCE OF Prof. SHASHANK U VANAKUDARI A seminar on, JAIN COLLEGE OF ENGINEERING, BELAGAVI
- 2. CONTENTS • Introduction toVDF • Definition, benefits & History of VDF • Need & Overview of VDF • Process & Equipments • Advantages & Disadvantages of VDF • Steps Involved in VDF & Precaution • Applications • New Techniques for dewatering • Conclusion & References.
- 3. FUNCTIONAL REQUIREMENT OF INDUSTRIALFLOORS • Trouble free movement of Man, Machines & Materials. • Hygienic/anti-bacterial. • Highly cleanable. • Wear (abrasion) resistant. • Chemical Resistant. • Resistance from Impact and Static Loading. • Ease of Maintenance. • Anti-slip/anti-stain properties • Flammability and Fire Safety. • Scratch/scuff resistance
- 4. VDF : Definition AFlooring Technique to achieve •High Strength, •Longer Life, •Better Finish •Faster Work. •High abrasion & heavy traffic movement
- 5. VDF : Benefits •Concrete with better workability than what is normally possible. • Improvement in wear resistance, compressive strength, less shrinkage and minimum water permeability. • Reduction of water content in the concrete by 15-25%. • Tendency of shrinkage and subsequent cracking is greatly reduced. • Concrete of high initial slump can be used while pouring
- 6. HISTORY OF VDF •It was originally invented by Tremix AB, Sweden many years ago. • Scandinavian firms simplified the equipment enough to make it practical for almost any builder. • Vacuum dewatering is used widely throughout Europe today, and in Sweden the method is used for 40 to 50 percent of all concrete floors. • This process was introduced in India by Aquarius Technologies in 1987.
- 7. Need of VDF •The uncontrolled removal of water from the concrete matrix can result in adverse effects such as plastic shrinkage cracking. • Excessive bleeding of concrete can negatively interfere with surface characteristics such as resistance to wear. • It renders an economical, time-efficient compaction technique to concrete that can be placed on a medium to high workability.
- 8. CONDITION OF CONCRETEBEFORE & AFTER VDF
- 9.
- 10. COMPARISION BETWEEN STRENGTHOF VDF & ORDINARY CONCRETE
- 11. EQUIPMENTS •Double beam screedvibrator •Vacuum pump with Hose •Suction mat •Power float •Power trowel
- 12. DOUBLE BEAM SCREEDVIBRATOR • Light weight • Electrically driven. • Overall length – 4200mm • Width – 410mm • Height – 125 mm • Total weight – 128.5 kg
- 13. VACUUM PUMP WITHHOSE • 7.5 H.P electric motor mounted trolley • Capable of 35 sqm in one operation. • Length – 2200 mm • Width - 660mm • Height – 880mm • Weight – 320kg • Pump capacity- 110 m/Hr
- 14. SUCTION MAT • Largesingle PVC sheet • Under surface Nylon cloth to act as very fine filter. • Top mat is provided with junction box and short hose. • The mat size may be 7.5 ×5m or as of the panel size
- 15. POWER FLOAT • Surfacegrinding equipment • It grinds the surface to make it wear resistance • Remove surface modulation prior to final finishing • Overall height – 980mm • Floating speed – 120RPM • Equipment weight – 140kg
- 16. POWER TROWEL • Surfacefinishing equipment, • Polishes the surface after floating operation. • Overall height – 980 mm • Trowelling speed – 120 RPM • Equipment weight – 145 kg
- 17. STEPS INVOLVED INVDF • Prepare sound sub-base • Form work over the base • Concreting & Vibration • Double beam screed vibration • Laying of mat & vacuum suction • Power troweling & finishing
- 18. Filling of Bouldermaterials in the flooring area. Compaction of the boulder materials.
- 19. Filling of Girtin the boulder material. Fixing of Thiyas
- 20. Laying of PCC( 1:3:6) Laying of Bitumen over PCC
- 21. Laying of PVCSheet & Thermocal Sheets for Thermal Insulations. Bar Bending work.
- 22.
- 23. Polishing the surfaceusing power trowel
- 24. Completed Cold Storageproject at KIADB of KAPPEC, Bijapur.
- 25. ADVANTAGES OF VDF •Early setting and high strength. • An ideal water cement ration can be achieved • Increase in compressive strength of concrete by 40-70%. • The surface hardness of the slab increases by 130%. • Water absorption is reduced enormously. • Minimum dusts. • Level floor, high flatness accuracy.
- 26. ADVANTAGES OF VDF •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& Denser concrete. • Elimination of curling • Reduced maintenance cost • Earlier utilization of floors
- 27. DISADVANTAGE OF VDFMETHOD • High initial cost. • Need trained labor. • Need specific equipment. • Need power consumption. • The porosity of the concrete allows water, oil and grease to seep through, consequently weakening the concrete.
- 28. DISADVANTAGE OF VDFMETHOD • Joints are a necessity for concrete floors leading to joint breakage as well as seepage of contaminants. • Concrete floors generate dust due to abrasive movement of vehicles. • Cleanability becomes a problem due to the presence of imperfections, surface roughness and porosity. • The best-laid floor (Tremix) can have undulations of above 5mm
- 29. APPLICATIONS • Industrials floorsheds like cold storages, etc. • Workshops, • Railway goods, platforms, • Godowns, warehouses etc. • Canals • Hydro power plants • Bridges ports and Harbor • Airports runways/ Hangers • Cooling Towers
- 30. NEW TECHNIQUES FORDEWATERING • Permeable and absorbing formworks • Perforated PVC pipes incased in cotton cloth
- 33. CONCLUSION • 200 sqm– 250 sqm of concrete flooring can be done in 8-10 hrs. • Good quality of floors and pavements can be obtained. • The compressive Strength can be increased by 25-45%. • Durability of the floor can be increased. • 15-25% of water can be extracted out.
- 34. References • Construction ofa rigid pavement with vacuum dewatering Indian concrete journal volume 71 – page 13 • Dahl G., (1975), "Vacuum concrete", CBI Reports, 7: 75, Part 1, 10 pp. (Swedish Cement and Concrete Research Inst.,). • Neville A. M., (2011), Properties of Concrete, 5th Edition, Longman Sc and Tech Publishers. • Vacuum dewatering system/tremix method from Aquarius Technologies Private Limited,india www.aquariustech.net • Vacuum dewatering procedures Publication #C750290 Copyright © 1975, The Aberdeen Group • Tanksali Consultants, Bijapur.
- 35.