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Vacuum Dewaterd Concrete Floor 4 Dec 2015
Vacuum Dewaterd Concrete Floor 4 Dec 2015
Vacuum Dewaterd Concrete Floor 4 Dec 2015
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 )
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).
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.
• 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.
2. Rebar Support: It is required for supporting C channel and to firmly hold channel in position
during concreting.
7. Blue color suction pad ( approx. 3950 x 5850 mm): For suction of water from 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.
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.
Slope as per ground development plan & with below mentioned checklist.
Building Location
Date
Sr.
No. Activity Acceptance Criteria Observation
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
.
• 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.
Building Location
Date
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: ______________________________
NB: Checklist, to be completed in all respects and signed with date by all concerned, as
designated above.
Building Location
DATE:
Sr.
Activity Acceptance Criteria Observation
No.
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 .
• 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.
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.
• Shuttering at half round channel edge at the end of concreting bay should be done using wood
shuttering.
• 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.
Carry out pest control treatment just before the starting of concrete, wherever it is done directly
on Rubble Soling or WBM or WMM.
• 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.
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.
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.
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.
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.
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.
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.
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.
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.
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
34. Remove the cube moulds & refill the concrete & vibrate the same.
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.
36. Trowelling
37. Carry out light scratch (brooming) with wire brush in opposite direction of drive way.
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.
41. Concreting sequence to be carried out as per drawing without breaking of wattas & without
disturbing of concrete in curing period.
Title: Checklist For Vacuum Dewatered Concrete Floor Rev.1, dated 24-8-09
(VDF).
Building Location
Date
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 .
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.
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 column / shear walls shall be in diagonal shape as shown in below
sketch.