Vacuum Dewaterd Concrete Floor 4 Dec 2015

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Handbook

Creating Better Communities


Vacuum Dewatered
Concrete Floors
( R1 / 4 Dec. 2015)

Hiranandani Constructions Pvt. Ltd.


This Handbook covers general Specifications, Norms, Guideline, Method study and
requirements of Vacuum dewatered Concrete floor (VDF). Grade of Concrete, Concrete mix
design, thickness, groove cutting pattern etc. may change depending on location, loading and
other site conditions. Hence these details shall be worked out on case to case basis.

Following norms have been finalized for VDF concrete thickness, at various locations, for all
sites:

1- 75 mm thick VDF concrete in car park area at intermediate slab level of basement. ( M12.5
concrete without CAII )

2- 75mm thick VDF concrete in ramp area. (M12.5 concrete without CA II).

3- 100mm thick VDF concrete on stilt/podium suspended slab, open to sky. (M12.5 concrete with
CA II).

4- 100mm thick VDF Concrete using 100mm channel as per current practice, which normally
becomes 125mm thick VDF concrete at ground level due to undulations, over WMM with GSB
or WBM or rubble soling as the case may be. ( M12.5 with CAII as per present practice )

In addition to this, below points shall be considered for VDF

1- Before starting VDF on stilt / podium suspended slabs, all construction joints of slab and any
leaking spots shall be grouted / treated only by waterproofing contractor suitably.

2- Joint of main building and podium slab, to be treated for waterproofing, by Waterproofing
Contractor- wherever specified.

3- Before starting VDF, on suspended slab, it is very important to do the ponding test, to check
leakage in waterproofed slab and rectify the leaking slab- if any.

4- Make sure that locations of groove cutting shall be planned, such that same do not come
exactly above any construction joints of podium slab.

5- No dammar patti (bitumen) filling shall be carried out in groove cutting done in VDF.

6- Above circular shall be followed for all podium suspended slabs (whether having slope or no
slope).

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 2


7- Plan showing groove cutting, locations and direction of channel, slope, etc shall be
approved before starting works.

Also, please note Brick Bat Coba Waterproofing for RCC Ramp Area & Stilt / Podium
suspended slab is replaced by VDF of thickness given.

In addition for garden area Brick Bat Coba or equivalent waterproofing will continue, to be done.

I. List of Equipments required for Vacuum Dewatered Concrete Floors (VDF)

1. Specially Fabricated C Channel 100 x 50mm:

• M.S. “C” Channels are usually used as form-work for casting concrete floors on ground and on
slab.
• In Vacuum Dewatering System, these channels have additional below mentioned functions :
a) Acting as a support on which surface vibrator is pulled.
b) Acting as a stopper, preventing entry of air while vacuum is applied.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 3


NB- For 75mm thickness of VDF, Channel will be straight and no half round pipe will be fixed to
get groove / Key.

2. Rebar Support: It is required for supporting C channel and to firmly hold channel in position
during concreting.

Below picture shows dimension of hook.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 4


Picture showing channel supports held with soil filled gunny bags.

3. 60mm dia Poker vibrator (Needle Vibrator): For Compaction of Concrete.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 5


4. Screed vibrator: For Compaction of Concrete.

5. Double Beam Vibrator : For Surface vibration and Leveling of Concrete

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6. Yellow Color filter pad (1200 mm width): To avoid ingress of cement and sand
particle in suction pad.

7. Blue color suction pad ( approx. 3950 x 5850 mm): For suction of water from concrete.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 7


8. Vacuum pump : For Dewatering of water from the concrete

9. Floater Machine with Disc: For Floating Operation.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 8


10. Floater Machine with Blade: For Trowelling Operation.

11. Groove cutting machine: For Making grooves in VDF Concrete.

Please ensure that all equipments, suction and Filter pads are in good condition. VDF system
should be preferably from Aquarius. In case if agency wish to bring VDF from other
manufacturer, than same to be approved in advance.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 9


II. Preliminary Work before VDF- starting Concreting:

1. Preparation of Plan:

First prepare plan of Vacuum Dewatered concrete keeping ground development plan in
Mind. Plan should include following details and it should be approved by the Project In-charge,
followed by approval of Head of Projects (Director –Engineering, COO, CEO etc)

• Thickness of VDF.
• Grade of Concrete for VDF.
• 4m wide concrete bays and thus construction joints.
• Sequence of alternate concreting.
• Pattern of groove cutting ( direction , spacing etc)
• Depth of groove cutting.
• Direction of slope and half round channel, periphery drain channel in case of suspended slab,
sump etc.

Please refer below mentioned is the example of approved drawing.

2. Level Marking: Mark the Reference level on RCC / masonry surface.

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3. Sub grade preparation: To be carried out having margin of soling / WBM with proper

Slope as per ground development plan & with below mentioned checklist.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 11


HIRANANDANI GROUP OF COMPANIES

FORM/FORMAT Checklist no. 20

Title: Checklist For Sub grade Preparation Rev.1, dated 24-8-09

Building Location
Date

Sr.
No. Activity Acceptance Criteria Observation

1 Soil available , after Excavation or Shall be free from any vegetation,


Filling scrap

2 Compaction of External works sub Rolling shall be done by 10-12 T


grade roller/ 8 T vibratory roller to achieve
95% proctor density.

3 Compaction of Building compound


works Compaction shall be ensured by
Carrying out 30 to 50 passes of
sub grade Roller

4 Level of Sub-Grade Shall be As per Drg. No.:_______,


Rev. No.:________

Shall be As per Drg. No.:_______,


5 Camber/Slope of Sub-Grade Rev. No.:________

Service Chamber/Service Line (if Shall be As per Drg. No.:_______,


any)
Rev. No.:________
6 Location and level.

Note : All dwg numbers , to be referred should be filled in , before the Checklist is
referred to , at location , for Acceptance Criteria , by the Senior Engineer/Sector Engineer
.

Foreman: __________________________ Junior / Site Engineer:


______________________

Senior /Sector Engineer_________________________________________________

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 12


NB: Checklist, to be completed in all respects and signed with date by all concerned, as
designated above.

4. MEP Services work:

• All MEP services like, plumbing, electrical etc. to be carried out as per ground development
plan.
• After completion of all services, carryout balance sub grade preparation.
• Half round channel to be fixed as per ground development plan in required slope and level.

5. Soiling :

• Soling / WBM to be completed in line, level & location as per ground development plan.
• Soling / WBM should be carried out as per checklist.
• No Stone should come out, by applying pressure with hand which indicates proper compaction
is carried out.

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HIRANANDANI GROUP OF COMPANIES

FORM/FORMAT Checklist no. 21

Title: Checklist For Soling Rev.1, dated 24-8-09

Building Location
Date

Sr. No. Activity Acceptance Criteria Observation

Shall be Hard blue/black & free from


1 Quality of rubble cracks.

2 Size of rubble 9" to 1 ft.

Kapachi shall be separately ordered for


3 Filling voids with kapchi filling the voids between soling rubble.

Filling of small size voids No void shall be seen between soling


4 with murrum rubble.

Compaction ( by roller/ No loose kapchi ,should come out , by


5 plate compactor) applying pressure with hand

Shall be as per Drg. No.:_______,

6 Line, level & Slope Rev. No.:________

& with tolerance + 5 mm

Note :All dwg numbers , to be referred should be filled in , before the Checklist is referred to , at
location , for Acceptance Criteria , by the Senior Engineer/Sector Engineer .

Foreman: ______________________________

Junior / Site Engineer: _______________________________

Senior /Sector engineer__________________________________________________________

NB: Checklist, to be completed in all respects and signed with date by all concerned, as
designated above.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 14


HIRANANDANI GROUP OF COMPANIES

FORM/FORMAT Checklist no. 22

Title: Checklist For WBM Rev.1, dated 24-8-09

Building Location
DATE:

Sr.
Activity Acceptance Criteria Observation
No.

Cleaning of excess and loose


1 Soling stone key surface shall be exposed. .
murrum from soling top

Metal shall be Hand broken & Size of the metal


used for WBM shall be cross checked with the help
2 Size of metal
of dumbbell shaped ring Kanda (90 - 60 & 60 - 40)
before spreading the grit powder.

3 Quality of Metal Metal should not get crushed after rolling.


As per slope given in Drg. No.:_______,
4 Level Pads
Rev. No.:________

Water shall be sprayed with sprinkler fixed behind


5 spraying of water
water tanker to ensure uniform spray of water

Shall be removed phase wise, once the compaction


is done. The excess grit powder shall be removed
6 Excess amount of grit before fixing the channels for tremix. The head of
the metal shall be exposed by removing excess grit
& no patches of only grit shall be seen.
Shall be done as per WBM specifications in
Concrete roads manual. No hand broken metal
shall come out with finger pressure. If stone comes
7 Compaction of Metal
out, then rolling shall continue, up to any hand
broken metal, does not come out with finger
pressure.

Note : All dwg numbers , to be referred should be filled in , before the Checklist is referred to , at
location , for Acceptance Criteria , by the Senior Engineer/Sector Engineer .

Foreman: ____________________ Junior / Site Engineer: ______________________


Senior /Sector Engineer____________________________

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 15


NB: Checklist, to be completed in all respects and signed with date by all concerned, as
designated above.
6. Removing Excess Grit / Soil.

• In case of WBM surface, the excess grit powder should be removed before fixing the channels
for VDF.
• In case of soiling surface, at least 2” top of soiling should be exposed after removing of excess
soil from soling surface for better grip to concrete.

7. Setting out channels & Other Activities

a- Now place MS channels having 4m width of bay in position with correct line & level as per
drawing.
b- To achieve a good quality, it is necessary to ensure below points:
 The channels are placed firmly on the ground.
 The bottoms edge of the channels, which usually allows entry of air, to be sealed properly
 The channels must be straight and placed in proper level to ensure flatness of floor.
 If there is any gap below channel, than same to be filled up with concrete just prior to starting of
concrete to avoid any slurry leakage.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 16


• Please refer below sketch showing position of Channel while concreting

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 17


• Below picture shows Key formation after deshuttering of channel for bonding of
concrete with adjacent part / bay.

• Shuttering at half round channel edge at the end of concreting bay should be done using wood
shuttering.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 18


• Fix the services chamber cover as per channel top level.

• Fix 25mm thick Polystyrene around the Column / RCC surface.

• Fix 12 mm thick Polystyrene around the Column / RCC surface in case of 75mm thick VDF to
be carried out on suspended slab.

8. VDF channel / shuttering shall be placed near parapet walls keeping space for any periphery
drain channel as seen in picture given below. Width of drain channel is normally kept 300mm
from parapet walls, or any pedestals. Slope of VDF shall be towards this drain channel.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 19


9. Pest Control Treatment:

Carry out pest control treatment just before the starting of concrete, wherever it is done directly
on Rubble Soling or WBM or WMM.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 20


10. Miscellaneous work :

• Apply shuttering oil to channels & side of shuttering.

• Carry out marking of strip width on the channels and accordingly keep cut pieces of wooden
member as a gauge to maintain half an hour concrete period.

• Place 15 cm cube moulds at appropriate locations in side bay so that dewatering of these cube
also take place along with surrounding concrete.
• Top of cube should be 5mm down from the concrete top so that it does not obstruct movement
of beam vibrator.

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• Cube location should be noted in notebook for easy identification and locating same
after concreting.

III. Vacuum Dewatered Concrete Floor (VDF) Procedure:

Concrete Placing and Compaction:

1. Provide wooden walkway plank above channel in case if wheel barrow carrying concrete is
crossing channel and ensure that channel is not disturbed. Also provide plastic sheet on
Completed VDF if concrete is transported from above same to avoid concrete dropping on
finished surface of VDF as shown in pictures.

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2.
3.
4.
5.
6. Place wooden planks along the sides of the channels to avoid segregation near edges and to
be removed immediately just after placing of concrete.

7. Provide wooden planks for carrying concrete wheel barrow for second layer of concrete as
otherwise it is difficult to move wheel barrow on fresh concrete of first layer.

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8. The above portion to be vibrated by Poker (Needle) vibrator along the channel to ensure no
honeycombing takes place near channel.

9. Poker vibrator to be used only along the channel sides / concrete face and later screed vibrator
for the entire area. Avoid over vibration of concrete.

10. Concrete should be placed and vibrated in two layers for 100 mm thickness and above.

11. Carry out 1st layer of concrete up to the marked portion for maintaining half an hour period and
compact same.

12. Carry out 2nd layer concreting over the 1st layer concreting; again vibrate the concrete using
screed vibrator.

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13. Concrete should have sufficient workability and make sure that no segregation takes place at
the time of placing and vibrating concrete. In case of any local segregation, carry out remixing of
concrete.

14. Surface vibration should always start as soon as there is enough concrete in front of the surface
vibrator.

15. Two passes with the surface vibrator are required. During, the first pass, concrete must be
distributed evenly in front of the surface vibrator.

16. There should always be a roll of concrete of about 10-20 mm in front of the leading beam along
the entire length of the Vibrator. When the concrete has been placed and vibrated to a length of
about 5 meters, the second pass is carried out.

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17. The machine should be pulled at a speed of maximum 1 meter/ min and without interruption to
avoid linings on the surface.

18. Keep the surface of the channels (on which the surface vibrator is supported), clean from
concrete.

19. Carry out beam vibration operation in two passes. See that no excess water is found on the
surface after two passes of beam vibrator.

20. Excess water indicates presence of more water and hence water should be reduced, Excess
water affects proper sealing of suction pad to wet concrete hence affecting Dewatered process.

Vacuum Dewatering Process

21. Place the filter pads as soon as the sufficient concrete surface is vibrated. Please note that the
vacuum dewatering process must start within 30 minutes from the time of starting concrete
pouring. Concrete Supply speed should match with other activities of VDF

22. Lay filter pads (yellow) at least 6" away from channels. (I.e. width of seal should be at least 6"
for effective Dewatering process).

23. Overlap of two filter pads should be around 300mm. But if required overlap can be increased to
adjust with site conditions, since more overlap is better as compared to folding of filter pads.

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24. Lay suction pads (blue) on top of filter pads, covering the entire concrete area, to be Vacuum
dewatered depending on size of concrete bay.

25. Please note that portion near car entry ramp should also be dewatered and accordingly
planning should be done for laying channels, filter and suction pad.

26. Also if required, break corner of the wall to place suction pad properly as shown in photograph.
If there are any areas which cannot be dewatered, should be brought to the notice of Head of
Engineering dept, so that alternatives / solutions can be worked out.

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27. Vacuum Dewatered pump should be started with vacuum breaking valve in open condition.
Achieve the pressure of around 240 mm hg. Start closing the valve gradually. Total closing time
of valve should be 6 to 8 min.

28. The pressure after fully closing of the valve should be in the range of 550 to 600mm hg. Note
down, the drop in the pressure as time passes at every 5 minutes interval. Normally for 1"
concrete Dewatered time is 5 minutes (i.e. for average thickness of 125mm we should continue
Dewatering for at least 25 minutes, without taking the opinion of the Operator i.e. compulsorily
Dewatering process to be done for 25 minutes).

29. Sudden drop in vacuum indicate air leakage taking place in system which will not allow
dewatering of water.

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30. Observe the water coming out. Preferably clear water should come out after 5 min. from the
point of starting of pump.

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31. During Dewatering, suction pad (Blue) top surface should get dried, which is an indication of
proper dewatering process.

32. At the end of Dewatering process, roll the blue suction mat slightly from both ends, so that 6" of
yellow mat is exposed .Keep the blue suction mat in this rolled position, for at least 2 minutes.
Remove pads and check the surface to find out whether there is any moisture present on the
surface by pressing hand on the top surface. Hand should be dry or otherwise dewatering
process is not effective.

33. After first patch in any given panel is dewatered, care should be taken while placing the filters
pads on the concrete surface next to the dewatered concrete. First Filter pads should start from

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 30


the edge of the last filter pad of the previously dewatered concrete. The remaining
filter pads then can be placed as explained above.

34. Remove the cube moulds & refill the concrete & vibrate the same.

Concrete Strength Requirements.

Age of testing Number of cubes Strength requirement

For without Dewatered Concrete Cubes

7 days Min. 3 cubes. 67 % of target strength.

For M12.5 125 x 1.05 x 0.67 = 88 Kg/ Sq.cm.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 31


28 days Min. 3 cubes. 100 % of target strength

For M12.5 125 x 1.05 = 131 Kg / Sq.cm.

For Dewatered Concrete Cubes

7 days Min. 3 cubes. 67 % of target strength.

For M12.5 (125 x 2 x 1.05) x 0.67 = 176 Kg/ Sq.cm.

28 days Min. 3 cubes. 100 % of target strength.

For M12.5 (125 x 2 x 1.05)= 263 Kg Sq.cm.

In case of vacuum dewatered concrete, normally 1.5 times to 2 times of concrete strength is
expected due to reduction in W/B ratio. Thus for e.g. M12.5 grade of concrete shall give M25
strength in 28 days.

In case if VDF is to be carried out on PCC or suspended RCC slab, or ramp etc, than placing of
cube moulds is not possible due to thickness. In this case, concrete cube shall be cast using
concrete being poured on site, i.e concrete which is not dewatered.

35. Floating Operation:

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• The first finishing operation is floating, where floating disc is used.
• Only those areas that cannot be reached by the skim floater are floated by hand.
• Care should be taken while floating near the channels and form edges.
• The Skim floater is run over the channels up to the disc centre in order to avoid unevenness at
the joints.
• All four sides of the dewatered panel must be floated first and the remaining central area is to be
floated later.
• Any corrections, if required, are to be made at this stage with the concrete collected at the time
of raking only. Never use any cement paste, mixture of cement and sand or fresh concrete for
patch work. Such material will peel off or will leave black patches after the concrete floor is
brought to use.
• Normally two passes with the disc with the skim floater operating at higher speed are sufficient
for skid free surface.
• This pass of skim floater should be given perpendicular to the previous pass. Please note that
the floating operation brings up certain amount of water to the surface. This moisture helps in
carrying out finishing operations.

36. Trowelling

• Trowelling is carried out with same machine running on trowelling blades.


• Normally, two passes of Trowelling blades are required for the smooth surface finish.

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• However, the number of passes can be decided depending upon the surface finish
required.
• The first Trowelling operation can start after about 30 minutes after the final floating operation
and surface is sufficiently dry.
• This pass is to be made low speed and minimum blade angle. Please also use the lower speed,
when trowelling near the channels, form edges, obstacles, etc.
• Blade angle and speed can be increased for the subsequent passes to achieve smoother
surface finish.
• Proper finishing near construction joints should be carried out to clean any excess cement slurry
accumulated during diff. operations. New concrete shall be made flush with adjacent concrete
surface.

37. Carry out light scratch (brooming) with wire brush in opposite direction of drive way.

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Any debris particles generated out of this brooming shall be cleared from the surface such that
brooming lines / impressions are not disturbed.

38. After every day work, cleaning of all the equipments as well as suction and filter pads should be
done. Also required cleaning of blades should also be carried out.

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39. Next day, carry out water curing by sprinkling of water followed by making of watta towards
slope. And also write date of concreting nearby.

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40. Now, remove the channel of concreted bay without breaking of edges. Carry out concreting
between two bays without fixing of channel since beam vibrator can be run on adjacent
concrete surface.

41. Concreting sequence to be carried out as per drawing without breaking of wattas & without
disturbing of concrete in curing period.

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42. Below picture shows rain water protection for VDF Concreting which shall be used for
concreting during rain :

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 38


43. Prepare Vacuum Dewatered Concrete Floor (VDF) checklist as per format given
below.

HIRANANDANI GROUP OF COMPANIES

FORM/FORMAT Checklist no. 23

Title: Checklist For Vacuum Dewatered Concrete Floor Rev.1, dated 24-8-09
(VDF).

Building Location

Date

Sr. No. Activity Acceptance Criteria Observation

Shall be removed phase wise, once the


compaction is done. The excess grit powder
Removal of excess grit powder shall be removed before fixing the channels for
1
from WBM Top tremix . The head of the metal shall be
exposed by removing excess grit & no patches
of only grit shall be seen.

Shall be done as per WBM specifications in


Concrete roads manual. No hand broken metal
shall come out with finger pressure. If stone
2 Compaction of WBM
comes out, then rolling shall continue, up to
any hand broken metal, does not come out
with finger pressure.

Shall be as per Drg. No.:_______, Rev.


3 Slope of WBM No.:________

& with tolerance + 5 mm

Shall be as per Drg. No.:_______, Rev.


4 Slope of half round channel No.:________

& with tolerance + 5 mm

Note :All dwg numbers , to be referred should be filled in , before the Checklist is referred to , at
location , for Acceptance Criteria , by the Senior Engineer/Sector Engineer .

Foreman: ____________________ Junior / Site Engineer: ___________________________

Senior /Sector Engineer_____________________________

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 39


NB: Checklist, to be completed in all respects and signed with date by all concerned, as
designated above.

IV. Groove Cutting Procedure ( saw cut) :

1. It is very important to cut groove in VDF as early as possible to avoid cracks. After completion of
curing period, clean the watta & mark the groove cutting line using string as per drawing.

2. Depth and pattern of groove cutting should be done as per approved drawing and it should be
done within 2 to 3 days of concreting.

a- 125mm thick VDF - Normally depth of groove is 20 mm and width of groove is 6mm.
b- 75mm thick VDF - Normally depth of groove is 15 mm and width of groove is 6mm.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 40


c- Below sketch shows any Service chambers coming around the building should be parallel to the
building and not at an angle as shown in sketch, this will help us to have proper groove cutting
in VDF around the chamber.

d- Also groove around chamber to be done as shown in below sketch to take care of crack
formation in VDF, groove cutting should stop at 2” away from chamber cover.

Groove Cutting around Rectangular Chamber

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 41


Groove Cutting around Round Chamber

Groove cutting around column / shear walls shall be in diagonal shape as shown in below
sketch.

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 42


Final picture of Vaccum dewatered concrete floor

Hiranandani Constructions Pvt. Ltd / Handbook on VDF ( R1) Page 43

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