GODREJ PROPERTIES LIMITED SOP No.

: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

TREMIX FLOORING (For Car park and Drive way)

1. Vacuum dewatering flooring for site mix concrete

2. Power trowel tremix flooring without vaccume dewatering for RMC concrete

Common Quality Defects in VDF flooring:

 Cracking of VDF Panels

 Edge damages during deshuttering
 Crazing of concrete surface
 Dusting on floor surface
 Irregular groove cutting
 Water stagnation
 Improper slope towards drain.
 Improper groove/Expansion joint filling

METHOD STATEMENT

PREPARATORY WORKS:

 Ensure availability of latest architectural drawing on site indicating joints, level,

offset, finishing type etc.
 Ensure preceding activities like electrical and plumbing chambers, back filling,
earth trimming, soil compaction etc. completed for the planned bays for
Tremix.
 Ensure availability of required quantity of Materials, PPEs, Tools and
equipment’s are available at site.
 Ensure Level should be marked on adjacent Column/Wall.
 It is advised to take up the Tremix works for alternate bays in a staggered
manner.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

L:B Ratio
Location of the Maximum Length of any Bay
Bay

Internal areas of a building like Thickness of X 35, but not

1.5:1
basements, etc. more than 10m
Thickness of concrete X 25,
External areas like roads, etc. 1:1
but not more than 6m.

 Any Constraints to adopting the above said, then 4m X 4m size panel can be
taken up for VDF works for alternate bays in a staggered manner.
 Alternate bay/ panel can be casted immediate after VDF flooring is completed
and finished as shown in the Image below i.e after 6 hours or the Bay 1
concrete is set without footmark
 Note: After the proper vaccume dewatering, the sides can be deshuttered

with extra care without breaking edges as the surface will be able to deliver
the foot mark free surface(Refer VDF detail in below)
 Ensure Anti-termite treatment done for the earth surface to protect it from the
attack by sub terrane termites before VDF.
 Ensure 1000 gauge LDPE sheet to be laid over compacted earth or
GSB/WMM surface prior to begin with VDF.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

 Ensure the compacted earth surface to be tested and certified to precede the
VDF works so that the compacted surface will sustain the loads that come
over it.
 Ensure GSB/WMM surface to be compacted and tested for road works if any.
And lay the LDPE sheet prior to Reinforcement work, RF work to be done as
per approved drawings or as per Site requirements with consultant advise
 Ensure existing concrete surface prior to VDF, is rough with wire mesh,
cleaned and moisten to SSD condition.
 If any leakage observed due to plastic shrinkage cracks should have been
treated as per GPL concrete repair SOP. (SOP No.: GPL-RCC-CONCRETEREPAIR-029)
 Ensure the slope to be maintained 1:150 for areas like basement, car parking
and roadwork in the compacted earth level itself. This will ensure GSB/WMM
and concrete quantities in control.
 Ensure drainage angles with weep holes and proper alignment being marked
as per drainage layout approved in GFC/shop drawing.
 If the expansion joint of the building in place kindly take necessary
precautionary approval taken and action for basic expansion treatment
methodology adopted for the location.

During Concreting:
 The casting of concrete flooring shall be carried in panels to avoid shrinkage
cracks and work as a control joint. The size of panel for concreting should be
followed as per details mentioned in preparatory works.
 Ensure the provision of expansion joint, 25mm thick HDF board to be placed
all around the columns, in between wall and floor junction and once in every
3rd panel or each 10mm gap.
 VDF to be done as per slope ratio defined in approved shop drawing or 1:150
towards drain as per layout shown in the MEP drawing and recommend to
keep minimum 50mm thickness at the lowest location for the effective VDF.
 The VDF concreting works should be produced only based on approved mix
design with M20 grade.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

 The mix design may be carried out by the contractor or the RMC vendor or a
concrete consultant and the same should be approved by the EIC.
 For concrete works, concrete mix design, batching, transport, placing (Tower
crane / pump),Sampling of cubes, curing to be adhered as per concrete
SOP(GPL-RCC-CONCRETING-043)
 Before placing the concrete, spread the cement slurry of consistency 2.0
kg/sqm.
 Before placing the concrete, Slump of concrete to be checked. The slump of
the concrete used for Flooring being should be 100 +/- 10 mm.
 Then concrete poured on the surface levelled up to the button mark level.
 Button marks to be placed at each 1.2m interval and the panel size to be
supported in straight line.

Compaction:
 Compaction of concrete is the process of expelling entrapped air from the
concrete.
 It has been found from the experimental studies that 1% air in the concrete
approximately reduces the strength by 6%.
 Voids increase permeability of concrete and in turn reduce its durability.
 Fully compacted concrete will be dense, strong, durable, and impermeable.
 Concrete is vibrated using Needle vibrator on both sides of the panel.
 Then concrete is compacted using double beam screed vibrator.
 Trowel the concrete when required for it end-use. Smooth the surface with a
steel trowel after it is partially hardened.
 Hold the trowel almost flat and swing it in large overlapping arcs while
applying pressure.
VACUUM DEWATERING FLOORING FOR SITE MIX CONCRETE
 Recommend NO dewatering of RMCs. RMCs have water cement ratio
already maintained to its minimum possible level by addition of admixtures.
Further dewatering decreases the water cement ratio below the required level
 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

thereby causing undulations in the surface, loss in strength and formation of

cracks.
 Hence the below proposal is only for Site Mix concrete, in which the excess
water added for Slump requirements to be removed using vaccume
dewatering
 For RMC concrete, follow the Power trowel tremix floor finish listed below. If
Project team or site management feel to go with VDF with RMC is as per site
discretion basis mock-up approval
 Vacuum dewatering process removes the surplus water presence in the
concrete
 This is done using Vaccume equipment comprising of Suction Mat Top cover,
Filter pads and vaccume Pump
 This process to be started immediately after concrete compaction is done
 Filter pads are placed on the Fresh concrete leaving about 4 inches of fresh
concrete exposed on all sides
 The Top cover is 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
 Vaccume 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 concrete by 15-25%
 Care should be taken to stop vacuum de-watering at the correct time so that
excess water is not removed. The rate of de-watering is as 1 min dewatering
for every 1cm thickness of the laid concrete
 For E.g.: If the thickness of the concrete that has been laid is 15 cms, then de-
watering should be done to a period of 15 minutes.
 The dewatered concrete is compacted and dried to such an extent that is
possible to walk on it without leaving nay foot prints
 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

 This is the indication of concrete being properly dewatered and ready for
finishing
 However, the concrete surface should not be loaded or stepped upon for 2 to
3 hrs.
 During this process ensure constant pressure of suction should be
maintained during vacuum de-watering (11.6 PSI or as per approved capacity
pump)
 The excess water that is being removed is the water which has been added to
concrete to increase its workability.
 Then the top surface of the concrete is finished using a power trowel
immediately after de-watering.
 Sprinkling of surface hardener (approved brand) of coverage 5kg/m2
(Considering medium duty) to be done at the concrete surface after finishing
of green concrete.
 The power trowel is floated on the concrete surface to give it a firm and
smooth finish.
 Cement or cement mortar should not be laid while power floating to achieve a
smooth finish.
 The power trowel is then fitted with the blade rotor tool and floated on the
concrete to get a shiny finish.
 Delay in starting this activity could lead to the extraction of the coarse
aggregates from the concrete.
 Date of casting should be written in the adjacent column or on the floor to
monitor the curing.
POWER TROWEL TREMIX FLOORING WITH OUT VACCUME DEWATERING
 If Vacuum dewatering is not required for the RMC supplied concrete locations
use the below method after concrete is compacted using Double beam
vibrator and uniform Trowel levelling as explained in Compaction work
 The concrete is left to stiffen. When the base concrete has stiffened to the
point when foot traffic leaves an imprint of about 3-6 mm and any bleed water
should now have evaporated, but the concrete should have a wet sheen
 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

 Floor Hardener is applied at an even application rate (approved brand) of

coverage 5kg/m2 (Considering medium duty) to be done at the concrete
surface after finishing of green concrete.
 Application of Power Floater on the surface until the surface is sufficiently
compacted & levelled with no major lines appearing any more. Ensure power
trowel speed is min 120RPM.
 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 as per Architect approval in Mock-up
CURING:
 Curing is the process in which the concrete is protected from loss of moisture
and kept within a reasonable temperature range. It is necessary for
uninterrupted hydration.
 Concrete curing should be commenced immediate after initial setting/non foot
mark stage. Start sprinkle curing to avoid hydration and commence the curing
with gunny bag or ponding after 10 hrs.
 Concrete shall be cured for a minimum of 10days.
 Curing is also a key player in mitigating cracks in the concrete, which severely
impacts durability.
 Curing has a strong influence on the properties of hardened concrete such as
durability, strength, water tightness, abrasion resistance, volume stability and
resistance to freezing and thawing.
 Heavy vibrations should be avoided in the vicinity of the VDF area for the first
24 hrs.

GROOVE CUTTING AND FILLING:

 Recommend groove cutting to be done when the adjacent panel casted and
concrete is set and green (i.e. after 10 hrs), however at any case the groove
cut should be completed within 48 hrs after casting the adjacent panel.
 The groove should be 2-3 mm in width and to a depth of min 35mm from the
Flooring top for effective control joint.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

 The grooves to be filled with bitumen (grade 60/70) or approved PU sealant

within 7 days after cleaning the grooves, removing the dust and cleaning with
air blower machine and water.
 All top surface expansion joint to be cleaned and filled with PU sealant or
bitumen (grade 60/70).

CHECKS AFTER COMPLETION OF VDF FLOORING

 Check the level of the flooring, ensure the slope provided as per proper
direction.
 Ensure there is no water stagnation on finished floor.
 The finishing should be uniform and as per mock up approved.
 Check the groove cuts are in straight line as per panel size approved.
 Grooves are cleaned and filled to the full depth and width by bitumen 60/70 or
PU sealant
 Ensure expansion joints are in straight line, cleaned well and filled with PU
sealant or bitumen 60/70.

MATERIAL STORAGE GUIDELINES

 Cement bags, Surface Hardener, Expansion boards, PU sealant shall be

stacked above the floor and away from the wall in the closed room to keep
away from moisture and sunlight.
 For all materials FIFO to be adhered.

Material Testing Guidelines:

 Concrete for RMC mix, cubes to be taken as per cube sampling procedure stipulated
in IS 456 or minimum of 3 cubes per day tested for 28days compressive strength.
 Site mix for VDF if done as per EIC approval do the cube sampling and testing. All
the ingredients to be checked with MTC /site test as per ITP for concrete
 Hardener MTC to be reviewed for each batch of material received at site as per
approved TDS.
 Mesh to be checked on arrival using MIR as per approved TDS.
 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

 Bitumen (60/70) and Sealant MTC to be reviewed for each batch of material.
 Expansion joint board to be checked as per approved TDS using MIR.

 Note: ITP to be overlooked with the listed Testing Guidelines, if ITP is missing for any
material the Test Guidelines will be adhered, If not listed as per MAS SOP No.: GPL-
PROCESS-MATERIALAPPROVAL-056 and MIR

A typical cycle:
 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

TOOLS & TACKLES:

 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

Tools criteria for use:

 7.5 H.P. Motor

 Vacuum pressure to achieve while suction -11.6 PSI to achieve

 Flow Rate: 110 Mtr_Cube per hour

 Power trowelling equipment speed – Min 120 RPM

FIXING OF EXPANSION JOINT BOARDS:

GRAPHICAL REPRESENTATION OF ALTERNATE BAYS:

 GODREJ PROPERTIES LIMITED SOP No.: GPL-RCC-TREMIX Flooring-047A
STANDARD OPERATING PROCEDURE Rev No.: 00
ACTIVITY : VACCUM DEWATERING FLOORING
Date: 27-03-2020
FOR PARKING AND DRIVE WAY LOCATIONS

VACCUM DEWATTERING FLOORING:

GROOVE CUTTING: