Industrial flooring by tremix vacuum system

JYOTHI ENGINEERING COLLEGE

INDUSTRIAL FLOORING BY TREMIX VACUUM SYSTEM

A Seminar Report

Submitted by

HEBIN J CHIRIYANKANDATH (JYANECE021)

In partial fulfillment of the academic requirements for the award of the Degree

of

BACHELOR OF TECHNOLOGY

in

CIVIL ENGINEERING

under

UNIVERSITY OF CALICUT

MARCH 2017

Department of Civil Engineering


CHERUTHURUTHY, THRISSUR 679531

DEPARTMENT OF CIVIL ENGINEERING


CHERUTHURUTHY, THRISSUR 679531

CERTIFICATE

This is to certify that the Seminar Report entitled INDUSTRIAL FLOORING

BY TREMIX VACUUM SYSTEM was presented by HEBIN J

CHIRIYANKANDATH (JYANECE021) in partial fulfillment of the academic

requirements for the award of the degree of Bachelor of Technology in Civil

Engineering under the University of Calicut

Asst. Prof. NEERAJA.P.G Prof. S RATHISH

SEMINAR GUIDE HEAD OF DEPARTMENT

Place: Cheruthuruthy

Date: 20.02.2017

ACKNOWLEDGEMENT

I am deeply indebted to my seminar guide Neeraja.P.G, Assistant Professor, Department

of Civil Engineering, Jyothi Engineering College, for her valuable guidance, persistent

encouragement and suggestions. I extend my hearty thanks to the Seminar Coordinators, Ms.

Sinu.C.G. and Ms. Lakshmi Divakaran.P, Assistant Professors of Department of Civil

Engineering, Jyothi Engineering College, for their enterprising attitude,timely suggestions

and support that made the seminar fruitful.

I am also grateful to Prof. S. Rathish, Head of the Department of Civil Engineering, Jyothi

Engineering College, for giving me the support and timely decisions. I express my sincere

gratitude to Dr.K.K.Babu, Principal, Jyothi Engineering College, for giving me the

opportunity to prepare this seminar and the facilities offered throughout this endeavour. I

express my thanks to all other faculty members of Civil Engineering Department.

I thank all my friends and classmates for the co-operation that they extended to me in

conducting this seminar. And last but not the least God almighty.

HEBIN J CHIRIYANKANDATH

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TABLE OF CONTENT

CHAPTER NO TITLE PAGE NO

ACKNOWLEDGEMENT iii

ABSTRACT v

LIST OF FIGURES vi

1 INTRODUCTION 1

1.1 Dewatering 1

1.2 Vacuum dewatering concrete flooring 3

1.3 Relevance 3

2 MATERIALS REQUIRED 4

2.1 Vacuum de-watering pump 4

2.2 Floater machine 5

2.3 Tremix skin 6

2.4 Double beam screed vibrator 6

3 CONCEPT 7

3.1 History of vacuum dewatering concrete

flooring

7

4 WORK METHODOLOGY 8

5 PROCEDURE 8

5.1 Tremix vacuum system stages 11

6 NEED OF VACUUM DE-WATERING

CONCRETE FLOORING

12

7 ADVANTAGES AND

DISADVANTAGES

12

7.1 Advantage of vacuum dewatering

concrete flooring method

12

7.2 Disadvantage 13

8 TYPICAL APPLICATION AREAS 13

9 COMPARISON 14

10 CONCLUSION 15

REFERENCE 16

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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Industrial flooring by tremix vacuum system Seminar Report 2017

1

Dept. of Civil Engineering Jyothi Engineering College, Cheruthuruthy

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


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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.

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


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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

- 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.


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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

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

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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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.

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


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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.

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


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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 levelling 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, 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


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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.

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.


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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.

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).


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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.

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.

Elimination or minimization of overtime.


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

Void-free& Denser concrete.

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

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 .


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REFERENCE

1. Anas A. Ezzulddin Haitham H. Saeed: ‘Study a new technique for producing Vacuum-

dewatered concrete’.

2. Dahl G: ‘Construction of a rigid pavement with vacuum dewatering’ ,Indian concrete journal

volume, 71 – page 13.

3. Tophan T. E., (2013): ‘Vacuum dewatered flooring in durable construction’, International

Journal of Civil Engineering Research Vol. 4, No 1.

4.Vivekkumar patel, Jayeshkumar Pitroda ,J.J.Bhavsar:’Vacuum dewatering: new way for

concrete flooring by tremix method’.

Industrial flooring by tremix vacuum system

Engineering

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