A

SEMINAR REPORT
ON
“VACUUM DEWATERED FLOORING”
submitted in the partial fulfilment for the award of degree of

Bachelor Of Technology

(Civil Engineering)

BY

AKSHAY MOHAN YADAV (16113271)

UNDER THE GUIDANCE OF

PROF. V.M.BOGAR

ACADEMIC YEAR

2018-2019

DEPARTMENT OF CIVIL ENGINEERING

GOVERNMENT COLLEGE OF ENGINEERING, KARAD

(AN AUTONOMOUS INSTITUTE OF GOVT. OF MAHARASHTRA)

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 Government College Of Engineering , Karad

Vidyanagar, Tal: Karad, Dist.: Satara, Maharashtra, India.

Phone: 02164-271711, 272414

E-mail: principalgcek@gcekarad.ac.in

CERTIFICATE

This is to certify that,

MR. AKSHAY MOHAN YADAV (16113271)

Studying in Final Year Civil Engineering have successfully completed the seminar entitled

“VACUUM DEWATERED FLOORING”

Under the guidance of Prof.V.M.Bogar during the academic year 2018-2019

Prof. V.M.Bogar Prof. B.A.Konnur

( Guide and Professor ) ( Professor and Head )

( Dept.Of Civil Engineering) ( Dept.Of Civil Engineering )

( Govt. College Of Engineering, Karad ) ( Govt. College Of Engineering, Karad )

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 ACKNOWLEDGMENT

I would like to thank my respected Prof. V.M.Bogar, Department of Civil Engineering

for giving me such a wonderful opportunity to expand my knowledge for my own branch and
giving me guidelines to present a seminar report. It helped me a lot to realize of what we
study for. Due to this constant encouragement and inspiration, I am able to present this
seminar.

I express my deep gratitude to Prof. B. A. Konnur, Head of the Department,

Department of Civil Engineering, for his valuable guidance and constant encouragement. I
am thankful to Dr. A. T. Pise, Principal, Government College of Engineering, Karad for
providing all the necessary facilities to carry out seminar work.

Last but not the least, I am thankful to my parents and friends for their moral as well as
financial support.

-AKSHAY YADAV

(16113271)

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 TABLE OF CONTENT

CHAPTER NO TITLE PAGE NO

A A CKNOWLEDGEMENT 3
ABSTRACT 5
LIST OF FIGURES 6
1 INTRODUCTION 7
1.1 Dewatering 7
1.2 Vacuum dewatered
concrete floors 8
1.3 Relevance 9
2 MATERIALS 9
REQUIRED
2.1 Vacuum de-watering 10
pump
2.2 Floater machine 11
2.3 Tremix skin 12
2.4 Double beam screed 13
vibrator
3 CONCEPT 13
3.1 History of vacuum 14
dewatering concrete
flooring
4 WORK 14
METHODOLOGY
5 PROCEDURE 14
5.1 Tremix vacuum system 18
stages
6 NEED OF VACUUM 18
DE-WATERING
CONCRETE FLOORING
7 ADVANTAGES AND 19
DISADVANTAGES
7.1 Advantage of vacuum 19
dewatering concrete
flooring method
7.2 Disadvantage 19
8 TYPICAL 20
APPLICATION AREAS
9 COMPARISON 21
10 CONCLUSION 22
REFERENCE 22

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 ABSTRACT
A flooring work for civil structure that is both time efficient and medium to
high workability process to create a facility that is safe, healthy and comfortable concrete
flooring to be done by used of vacuum dewatering concrete flooring (VDF) technology. This
process is a means to efficiently remove excess water from newly placed, compacted and
levelled concrete surfaces. Vacuum treatment of concrete has been refined to specially
address concreting of large exposed surfaces in hot weather conditions. Vacuum dewatering
greatly improves the abrasion and impact resistance of the concrete surface.
The vacuum dewatering results in coarse aggregate in the fresh mix being
drawn to the top surface a further contributing factor in achieving wear-resistant concrete
surfaces the surface of vacuum treated concrete is free of pitting, an important consideration
for abrasion resistance and the possible exposure to a continuous flow of liquid over the
member. This paper attempts to provide a resumé of current site techniques based on
experience gained during several years as the principal suppliers of de-watering equipment
and advising contractors on its use. Additionally, qualitative aspects of concrete subjected to
vacuum and associated mechanical treatment during the processes of compaction, levelling
and surface finishing are considered.

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LIST OF FIGURES

Fig 1 Schematic showing vacuum dewatering process

Fig 2 Vacuum dewatering of concrete
Fig 3 Vacuum de-watering Pump
Fig 4 Floater machine
Fig 5 Tremix skin(top mat)
Fig 6 Double beam screed vibrator
Fig 7 Filter pads are placing
Fig 8 Top cover is placed
Fig 9 Top cover is connected to vacuum pump
Fig 10 Floating action
Fig 11 Tremix vacuum system stages
Fig 12 Finished industrial floor
Fig 13 Effect of vacuum dewatering of concrete

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 1.INTRODUCTION

 Tremix vacuum flooring method can be defined as Vacuum Dewatered Flooring, it is

a special type of Flooring Technique to achieve High Strength, Longer Life, Better
Finish and Faster Work. Tremix System also known as Dewatering System is used in
making Industrial Floors, Concrete Roads, Runways, Railways Platforms, Warehouse
container Yards, Canal Lining, Pathways, Bridges, RCC Roads, etc .The key is
Dewatering of Concrete by Vacuum Process wherein surplus water from the concrete
is removed immediately after placing and vibration, thereby reducing the water
cement ratio to the optimum level. Tremix Flooring increases the Compressive
Strength, Tensile Strength, and Abrasion Resistance and minimizes the Shrinkage and
Floor Wraps. This type of floor is suitable for high abrasion & heavy traffic
movement areas .Floor in factories and industries have concrete being the most
versatile of flooring material, has been in use for a long time. To overcome the
deficiencies of concrete a system was devised to improve the properties of such
concrete floors.

 Tremix flooring is a special type of flooring mostly being done in the industrial
sector. It is generally used for industrial purposes, where rigid surface necessary for
machine foundation, light load carrier vehicle and light weight cranes. By this method
economic high quality concrete floors can be laid. This method improves the
properties of concrete floors. Tremix flooring is also known as vacuum dewatering
flooring, since in this method vacuum treatment is done to remove the surplus water
from the concrete. With the industrial revolution all over the world, the floor
construction has been on the serious concerns of Architect, Engineers and users. A
high quality concrete floors not only be levelled perfectly but also it should have high
compressive strength with minimum cost. In this flooring the water/cement ratio is
drastically reduced after placing. A lowered water/cement ratio automatically leads to
noticeable improvement of almost all properties of concrete. This technique is
effectively used in industrial floors, parking lots and deck slabs of bridges etc. By the
adoption of Tremix vacuum flooring, more workable concrete floors can be done than
the normal flooring.

1.1 Dewatering

 Through vacuum dewatering, the surplus water is removed from the concrete, which
means that the water/cement ratio automatically leads to a noticeable improvement of
almost each of the concrete properties. These improvements are particularly
noticeable on the top surface i.e. the most vital part of a floor. The 24-hour-strength of
the vacuum dewatered concrete slab is much higher, which reduces the risk of
damage on a newly cast floor. The final strength is about 50 % higher than that of a
conventional concrete floor.

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 Fig:1-Schematic showing vacuum dewatering process

In this fig:1 shows the dewatering by using vacuum pump, excess water is sucked through
the capillaries. Filter mat medium is used at the time of dewatering prevent entry of cement
and other finer particles. Vacuum pump is connected on the top mat then process de
watering is started and water is removed from the concrete floor/slab.

Fig:2-Vacuum dewatering of concrete

1.2 Vacuum de-watered Concrete floor

 Vacuum-de-watered floor, invariable known as VDF or Tremix floor continues to be

the most preferred and cost available floors for various industries for many years. It
can be simplified as consisting of the following steps:
 Concrete of the required grade such as M20, M25 etc (basically means having a
compressive strength of 200Kg/cm2, 250Kg/cm2 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

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  The concrete is then power-trowelled to obtain a smooth and dense concrete
 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.

1.3 Relevance

There are lot of industrial buildings are constructed around which are equipped with modern
industrial machines. These type of high energy operations like hammering, movement of heavy
machinery ,installing , storage of materials, operation of cutting equipments, dragging and pulling
of materials etc also other chemicals which are corrosive may come to contact with the floor .In
all this conditions the floor should be wearing resistant and durable for long time. For achieving
high compressive strength and durability tremix concrete is used.24-hour-strength of the vacuum
dewatered concrete slab is much higher, which reduces the risk of damage on a newly cast
floor.The final strength is about 50 % higher than that of a conventional concrete floor.

2 MATERIALS REQUIRED

All Mason tools and tackles required to available at site & following

2.1.Vacuum de-watering Pump 2.2. Floater machine

2.3. Tremix skin
2.4. Double beam screed vibrator

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 2.1 Vacuum de-watering Pump

Fig:3- Vacuum de-watering Pump

Vacuum Pump is used to reduce water content in the concrete by 15-25%. The dewatered
concrete is compacted and dried. Vacuum Pump is used to suck all the air bubbles that may
have trapped during the laying of the concrete. It allows the cement to come up to upper
layers and hence gives a superior strength to the floor. The three mats: filter mat, suction
mat and top mat, these mats do not allow cement to come up but only sucks the extra
water. Top mat size is 4.5 m x 5.5 m During working, it eludes a vacuum pressure of 450-500
mm/Hg . Maximum pump pressure which can be developed is 650 mm/Hg. It is powered by
7.5 HP motor

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 2.2 Floater machine

Fig:4- Floater machine

Floating & Troweling take place right after dewatering. Floating operation is done with
Floating disc. This makes the cement more compact and enabling to generate a very smooth
finish. Trowelling is done with Trowel blades in order to further improve the wear resistance,
minimize dusting and obtain smoother finish.
Two speed operation for electric version.

Dead man’s grip for operator safety

Adjustable and foldable handle .

Dual function – floating and trowelling

Easy change-over from disc to blades

Blade angle adjustable while machine is in operation

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 All controls on handle, easily accessible.

Also ideally suitable for Epoxy Screed finishing.

Available in two diameters 900 mm and 700 mm

2.3. Tremix skin

Fig:5- Tremix skin(top mat)

Vacuum is immediately created between the filter pads and the top cover. Atmospheric
pressure compresses the concrete and the surplus water is squeezed out. Suction Mat of
special grade multilayered polymer sheets along with reinforced distance cushions on the
Filter Pads ensure sufficient cross-sectional area to squeeze out and remove excess water
from the concrete. This design is a prerequisite for effective dewatering.

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 2.4 Double beam screed vibrator

Fig:6- 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. These
vibrators are self-travelling and only require guiding along the form work, dragged at ends
by two operators without working in the concrete. To get a really levelled & durable
concrete surface , the concrete should be compacted and levelled with Double Beam Screed
Vibrator.


Made from light weight, hollow, Aluminium alloy beams.

Vibrations adjustable from 30% to 100%.

Suitable for concrete depths up to 300 mm in conjunction with poker vibrators.

Tensioning device for level correction.

Specially designed vibrator motor and switches for operator safety.

Sacrificial End Ties for longer beam life.

3. CONCEPT
The key to the use of this method is the dewatering of concrete by vacuum process. Surplus
water from the concrete is removed immediately after placing and vibration, reducing the
water : cement ratio to an optimum level. Therefore, adopting the TREMIX method
facilitates use of concrete with better workability than what is normally possible .A lowered
water cement ratio automatically leads to a noticeable improvement in almost each of the
concrete properties.

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 3.1. History of vacuum dewatering concrete flooring

 The vacuum dewatering process, patented in the United States, nearly half a century
ago, has attracted increased interest in recent years after several 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. Basically, the process 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.
 Tremix or vacuum dewatering flooring is popularly known in India, is actually
Vacuum dewatering process of concrete. It was originally invented by Tremix AB,
Sweden many years ago. This process was introduced in India by Aquarius
Technologies in 1987. In 1991 to start production of Vacuum System in India. It
became so popular in India that almost everybody related to concrete flooring
industry, may be manufacturers / contractors / consultants started calling this
process by the name of its inventor.

4. WORK METHODOLOGY

 Tying Line Threads as per the slope requirements

 Laying Guide Rails to every 4 meters using MS Channels or as required in straight
lines along the Line thread, taking levels as per the slope and fixing them using
concrete also called grouting and left to set for a minimum of 24 hours
 Pouring the concrete in between the channels and spreading using Shovel or Hoe
 Vibrating the concrete with a poker vibrator especially to the sides of the panels
 Surface Vibration the concrete using Double Beam Screed Vibrator running over the
guide rails twice to achieve maximum compaction for RCC with double mats
 Final leveling of the concrete using the Straight Edge. • De-watering by vacuum
pump.
 Application of Power Floater on the surface until the surface is sufficiently
compacted & levelled with no major lines appearing any more
 Final finishing using Power Trowel and trowelling until the required finish is
achieved. Finish could be any of the Smooth Finish, Sand Finish or Line Finish.

5. PROCEDURE

 Generally the mix of concrete used for Tremix is 1:1:5:3 (1 cement: 1.5 sand and: 3
stone aggregates), mostly rich mix of 1:1:2 preferred for better wear and tear.
 In this flooring necessary reinforcement provides depending upon the thickness of the
flooring, whereas the thickness of concrete is decided from 100 to 200 mm over PCC
(1:4:8) and well prepared stone soling base ranging from 230 to 300 mm. In industrial
flooring PCC base should be kept up to 100 mm and same as floor concrete 150 mm,

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 may be satisfactory for heavy duty areas such as warehouses, garage and machine
shops.
 The key of the method is dewatering concrete by the vacuum process. Through
vacuum dewatering ,the surplus water is removed from the concrete, which means
that the water/cement ratio automatically leads to a noticeable improvement of almost
each of the concrete properties.
 Immediately after vacuum dewatering the flatness of the concrete surface is checked
and adjusted with a control tool, and the finishing operation with a power-trowel can
start.
 Vacuum pump is used for the dewatering process, a top cover and filter pads .The top
cover is made of special reinforced, airtight plastic sheet, with a suction channel on
the bottom side.
 It is provided with two lifting tubes which makes it easier to unroll the top cover to
the required length. The filter pad is made of perforated plastic sheet with distance
cushions on the top side. It acts as a filter between the fresh concrete and the top
cover.

Fig:7-The filter pads are placed so that there will be a sealing edge around the entire filter
pad surface

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 Fig:8-The top cover is unrolled over the filter pads

After compaction by surface vibrator, filter pad are placed leaving 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. Vacuum is immediately created between the filter pads and the top
cover.

Fig:9-The top cover is connected to the suction hose of the vacuum pump. Thereafter it is
important to check that the top cover seals against the fresh concrete outside the filter pads.

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Atmospheric pressure compresses the concrete and the surplus water is squeezed out.
Water content in the concrete is reduced by 15-20% during vacuum dewatering process.
Usually it takes about 1.5 – 2 mins for de watering process for one centimetre thickness of
slab.. This is the indication of concrete being properly de watered and ready for finishing.

Fig:10-While vacuum is on , the surface that has already been vacuum dewatered is floated
with a power trowel fitted with a disc.

The finishing operations Floating & Trowelling take place right after de watering. Floating
operation is done with Floating disc. This ensures after mixing of sand & cement particles,
further compaction and closing the pores on the surface. Floating operation generates skid-
free finish. Trowelling is done with Trowelling blades in order to further improve the wear
resistance, minimize dusting and obtain smoother finish.

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 5.1 Tremix vacuum system stages

Fig: 11-Tremix vacuum system stages

By observing this fig:11 we could know easily the procedure of the tremix vacuum system.
Construction is divided in to different stages like clearing, placing of reinforcement, placing
of concrete, levelling and compacting by using double beam screed vibrator, placing of filter
mats, de-watering is done by vacuum de-watering pump and top mat(Tremix skin). Finishing
works are to carried out by using Floater machine(power floater), Trowelling
machine(power trowel).

6. NEED OF VACUUM DEWATERING CONCRETE FLOORING

1) The mixing water added to a concrete mix exceeds the amount of water required to fully
hydrate the cement constituent.
2) The additional water functions as a lubrication medium to allow mixing, placing, leveling
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.
3) 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. Thus the durability and service life of
the flooring element is in question. Concreting in areas exposed to the elements, specifically
in hot and windy conditions poses even higher demands in order to produce quality, durable
concrete.

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7. ADVANTAGES AND DISADVANTAGES

7.1. Advantages of vacuum dewatering concrete flooring method

Reduction in W/C ratio leads to early setting and high strength.

This system removes the excess water after pouring of the concrete & thus 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.

Minimized crack formation, Shrinkage reduced by 50%.

Improved wear resistance.


High and early strength, minimize damage to newly cast floors.

Void-free& Denser concrete.

Elimination or minimization of overtime.

7.2. Disadvantage of vacuum dewatering concrete flooring method

High initial cost.

Need trained labour for the vacuum dewatering process.

Need specific equipment for vacuum dewatering like vacuum pump.

Need power consumption during dewatering process

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 8. TYPICAL APPLICATION AREAS

1. Warehouses
2. Roads, Sports Courts
3. Cellars, Parking Areas
4. Production Areas,
5. Industrial Shop floors
6. Base floor for Resinious floors - Epoxy, PU,Mat, Carpets & Wooden Floors

Fig:13-Finished industrial floor

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 9. COMPARISON

Fig:12-Effect of vacuum dewatering of concrete

• The final strength achieved by ordinary concrete on 28 day will be achieved by tremix
concrete by initial day itself.
• On further curing the vacuum concrete achieves compressive strength far more than
ordinary concrete.
• All layers of the concrete achieve the strength uniformly during curing
• Since the surface is of high strength they are abrasive resistant and non corrosive
• Less cement consumption compared to ordinary concrete

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 10. CONCLUSION

From the literature review it is concluded that, 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 ware house, parking
area, industrial flooring like flooring of large area. And nowadays Vacuum dewatering
process is very easily used in the construction industry using any modern techniques and
machineries. Slab depths up to 12 inches can be effectively dewatered by the vacuum
process. Joint spacing can be increased because vacuum dewatering reduces shrinkage of
floor slab concrete. Better use of construction manpower is possible with tremix technique
because positive control of floors finishing time can be established and overtime for floor
finishes can be reduced or eliminated. For suspended slabs earlier form removal is often
possible because of more rapid early strength development. Tilt-up construction may be
speeded by the improved early strength development achieved with tremix technique .The
lowered water-cement ratio of tremix floor concrete automatically leads to drastic
improvement of almost all of the concrete properties .

REFERENCE

1. Science Direct
2.Vivekkumar patel, Jayeshkumar Pitroda ,J.J.Bhavsar:’Vacuum dewatering: new way for
concrete flooring by tremix method’.

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