VACUUM DEWATERED FLOORING

SEMINAR REPORT

Submitted by
ATHUL.C
(19011696)

To
the Board of Technical Education, Kerala
in partial fulfillment of the requirements for the award
of Diploma in Civil Engineering.

DEPARTMENT OF CIVIL ENGINEERING

MALABAR POLYTECHNIC CAMPUS
CHERPULASSERY
2021-22
 DEPARTMENT OF CIVIL ENGINEERING
MALABAR POLYTECHNIC CAMPUS, CHERPULASSERY

CERTIFICATE

Certified that this report entitled ‘VACUUM DEWATERED FLOORING’ is the report
of seminar presented by ATHUL.C, (19011696) during year 2021-22 in partial
fulfillment of the requirements for the award of the Diploma in Civil Engineering of the
Board of Technical Education, Kerala.

LECTURE Head of the Department

Dept. of Civil Engineering Dept. of Civil Engineering

.
Internal Examiner External Examiner
Seminar Report 2021-22 Vacuum Dewatered Flooring

AKNOWLEDGE
MENT

First and foremost, I wish to thank the omnipotent God for his blessings.

I would like to express my deep sense of gratitude to our honorable Principle

Mr. Muhammed Sirajudheen A, Malabar Polytechnic Campus, Cherpulassery

for his motivation and for creating an inspiring atmosphere in the college by
providing state of art facilities for seminar presentation.

Our sincere thanks to Mrs. Sunaina K, Head of section, Department of Civil

Engineering, for her whole hearted support in completion of the seminar
presentation.

I am highly indebted to my guide. Mr. Anoop K, Lecture, Department of

Civil Engineering, for his valuable support and guidance throughout the seminar
presentation.

I also take the opportunity to thank my Parent, Friends and loved one who
has contributed well through the proper guidance and encouragement towards the
completion of the seminar presentation.

Last but not least, I would like to thanks The Teaching & Non-Teaching
Staffs of Civil Engineering Department, and to thank one and all who have helped us
during the seminar.

ATHUL.C

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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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CONTENT
TITL PAGE NO
ACKNOWLEDGMENT i

ABSTRACT ii

CONTENT iii

LIST OF FIGURES iv

LIST OF TABLES V

1.INTRODUCTION 1

2. LITERATURE REVIEW 2

3. VACUUM DEWATERED CONCRETE FLOOR 6

3.1.DEWATERING

3.2.RELEVANCE

4. MATERIALS REQUIRED 7

4.1.VACUUM DE-WATERING PUMP

4.2. FLOATER MACHINE

4.3.TREMIX SKIN

4.4.DOUBLE BEAM SCREED VIBRATOR

5. CONCEPT 8
5.1. HISTORY OF VACUUM DEWATERING CONCRETE
….FLOORING

6. WORK METHODOLOGY 10

7. PROCEDURE 11

7.1. TREMIX VACUUM SYSTEM STAGES

8. NEED OF VACUUM DEWATERING CONCRETE FLOORING 15

9. ADVANTAGES AND DISADVANTAGES 16

9.1. ADVANTAGES OF VACUUM DEWATERING CONCRETE
…. FLOORING METHOD

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9.2. DISADVANTAGE OF VACUUM DEWATERING .

….CONCRETE FLOORING METHOD

10. TYPICAL APPLICATION AREAS 21

11. COMPARISON 24

12. CONCLUSION

REFERENCES 25

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LIST OF FIGURES

TITLE PAGE NO
FIG.3.1: SCHEMATIC SHOWING VACUUM DEWATERING PROCESS 1

FIG.3.2: VACUUM DEWATERING OF CONCRETE 8

FIG.4.1: VACUUM DE-WATERING PUMP 8

FIG.4.2: FLOATER MACHINE 9

FIG.4.3: TREMIX SKIN 9

FIG.4.4: DOUBLE BEAM SCREED VIBRATOR 10

FIG.7.1: THE FILTER PADS ARE PLACED SO THAT THERE WILL BE A

SEALING EDGE AROUND THE ENTIRE FILTER PAD SURFACE 11
FIG.7.2: THE TOP COVER IS UNROLLED OVER THE FILTER PADS 12

FIG.7.3: THE TOP COVER IS CONNECTED TO THE SUCTION HOSE OF THE

VACUUM PUMP. 13

FIG.7.4: WHILE VACUUM IS ON , THE SURFACE THAT HAS ALREADY BEEN

VACUUM DEWATERED IS FLOATEDWITH A POWER TROWEL FITTED
WITH A DISC. 14

FIG.7.5: TREMIX VACUUM SYSTEM STAGES 14

FIG.10.1: FINISHED INDUSTRIAL FLOOR 18

FIG.11.1: EFFECT OF VACUUM DEWATERING OF CONCRETE 19

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CHAPTER 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.

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CHAPTER 2
LITERATURE REVIEW

D. Subhash, "Estimating the compressive strength of concrete, using vacuum

dewatering Technique",(2019) Investigate the potential of vacuum dewatering process
of on three different grades of concrete namely M20, M30 and M40 to evaluate its
compressive strength.The application of vacuum dewatering technique gives a freedom
to use as much of water cement ratio as required for desired workability without
inducing any adverse effect on the performance of hardened concrete.
 The effect of the technique on early compressive strength of the concrete was
found very significant. The
early increase in strength was of the order of about 60%, 57% and 54% for M20,
M30 and M40 grades of concrete mixes respectively. So, formwork and
shuttering may be removed earlier and working time is also reduced. It all results
in cost optimization of concrete construction.
 The increase in 28 days compressive strength was observed about 40%, 36%
and 32% for M20, M30 and
M40 grades of concrete mixes respectively. Being this an appreciable increment
of compressive strength if taken in account in the design, the thickness/size of
the element will be reduced, the application technique was found very useful.

Vivekkumar Patel, "Vacuum dewatering: new way for concrete flooring by tremix
method" (2015)
 This paper provides a review on a new way of concrete flooring by the used of
vacuum dewatering concrete technique/remix method in the area of concrete
flooring in civil structure with its advantages & disadvantages of VDF system.
 Vacuum treatment of concrete based on Portland cement results in a marked
increase in compressive strength. In general, compressive strength of vacuum
dewatering processed concrete is 25-45% higher at 28 days after casting.
Increased flexural strength as well as a higher dynamic modulus of elasticity is
measured.
 Vacuum treatment of concrete based on Portland cement results in a marked

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increase in compressive strength. In general, compressive strength of vacuum

dewatering processed concrete is 25-45% higher at 28 days after casting.
Increased flexural strength as well as a higher dynamic modulus of elasticity is
measured.
 Durability considerations include the improved impermeability, higher density,
lower Member absorptiveness and reduced shrinkage

Haitham H. Saeed "Study a new technique for producing Vacuum-dewatered

concrete", (2014)
 In this work, investigate a new technique for producing vacuum-dewatered
concrete. Perforated PVC pipes incased in cotton cloth are used in this technique
to dewater concrete from inside of concrete volume,rather than from the surface,
as is the case in the conventional vacuum dewatering method.
 These pipes are laid In position inside concrete forms, and a vacuum pump is
connected to the dewatering pipes,which is operated After casting of fresh
concrete to remove the excessive water.
 In this method vacuum dewatering is processed from inside of the freshly placed
concrete rather than the surface, through perforated PVC pipes encased in
moslin (cotton cloth) to prevent the removal of cement and other fine particles
with water.
 These pipes are embedded and fastened in place in forms via reinforcement bars
or any other means, a steel bar or wire can be inserted in the PVC pipes to give
the required stiffness, keep alignment, facilitate bending and prevent pipes from
clogging due to external pressure during vacuum process.

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CHAPTER 3
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
andreinforcement bars as per design.
 Vacuum de-watering (VDF) is a process by which excess water is removed in
acontrolled fashion by applying vacuum
 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
compressivestrength 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 anon-VDF concrete floor.

3.1.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.3.1: Schematic showing vacuum dewatering process

In this Fig.3.1 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.3.2: Vacuum dewatering of concrete

3.2.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

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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.

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CHAPTER 4
MATERIALS REQUIRED

All Mason tools and tackles required to available at site & following
4.1.Vacuum de-watering Pump
4.2. Floater machine
4.3.Tremix skin
4.4.Double beam screed vibrator

4.1.VACUUM DE-WATERING PUMP

Fig.4.1: 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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4.2. FLOATER MACHINE

Fig.4.2: 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

 All controls on handle, easily accessible.

 Also ideally suitable for Epoxy Screed finishing.

 Available in two diameters 900 mm and 700 mm

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4.3.TREMIX SKIN

Fig.4.3: Tremix skin

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.

4.4.DOUBLE BEAM SCREED VIBRATOR

Fig.4.4: Double beam screed vibrator

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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.

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CHAPTER 5
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.

5.1. 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.

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CHAPTER 6
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.

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CHAPTER 7
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
 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.

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Fig.7.1. The filter pads are placed so that there will be a sealing edge around the
entire filter pad surface

Fig.7.2. 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.

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Fig.7.3. 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.

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.7.4. While vacuum is on , the surface that has already been vacuum
dewatered is floatedwith a power trowel fitted with a disc.

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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.

7.1 TREMIX VACUUM SYSTEM STAGES

Fig.7.5. 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).

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CHAPTER 8
NEED OF VACUUM DEWATERING CONCRETE FLOORING

1)The mixing water added to a concrete mix exceeds the amount of water required to
fullyhydrate 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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CHAPTER 9
ADVANTAGES AND DISADVANTAGES

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.

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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CHAPTER 10
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.10.1. Finished industrial floor

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CHAPTER 11
COMPARISON

Fig.11.1. 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 thanordinary 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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CHAPTER 12
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 .

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REFERENCES

1. D. Subhash, "Estimating the compressive strength of concrete, using vacuum

dewatering Technique", (2019)

2. Vivekkumar patel, Jayeshkumar Pitroda J.J.Bhavsar, (April 2015). "Vacuum

dewatering: new way for concrete flooring by tremix method".

3. Haitham H. Saeed,Anas A. Ezzulddin. (October 2014), "Study a new technique for

producing Vacuum dewatered concrete", Vol. 3 Issue 10.

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