Nowadays biggest issue in Industrial Concrete Flooring is Floor Dusting, Floor cracks, Floor strength & Level variations. These all problems can be solved while we do VDF Flooring. So now we will see about VDF Flooring.
VDF FLOORING
Vacuum Dewatered Flooring (VDF) is a special type of Flooring in Industrial Flooring sector, to achieve High Strength, Longer Life, Better Finish and Faster Work. This type of Industrial flooring is suitable for high abrasion & heavy traffic movement. DUST FREE INDUSTRIAL FLOORING can be achieved with this method.
BENEFITS OF VACUUM DEWATERED FLOORING
1.Concrete with better workability than what is normally possible.
2.Improvement in wear resistance, compressive strength, less shrinkage and minimum water permeability.
3.Reduction of water content in the concrete by 15-25%.
4.Tendency of shrinkage and subsequent cracking is greatly reduced.
5.Concrete of high initial slump can be used while pouring.
6.When we use power trowel we will get levelled even Concrete Flooring
- If we broadcast floor hardner ,improved strength concrete flooring and Dust free Industrial flooring can be achieved.
- Concrete Flooring water column level Variation will be very less.
- Floor cracks can be avoided by taking groove cut after water curing
PROCEDURE OF VDF FLOORING
- Tying Line Dori (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 Dori, 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 (Kudal/Parah)
- 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/Bull Float/Aluminium Bottom (Fanti/Baddha)
- A system of lower mats & top mat is laid on the green concrete & this is attached to a vacuum pump. This draws out surplus water if any. (We strongly oppose 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 thereby causing undulations in the surface, loss in strength and formation of cracks.)
- 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, Floor Hardener is applied at an even application rate of 3-7 Kg/Sqm or as per the requirement of the floor.
- 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.
- Floor Hardner also can be broadcasted while doing power trowelling. It will give us dust free industrial flooring and High abrasion resistance concrete flooring.
TYPICAL APPLICATION AREAS OF VDF FLOORING
- Warehouse Flooring Godown Flooring
- Roads, Sports Court Base Floor
- Cellars, Parking Area Base floor
- Production Areas
- Pharmaceutical Companies
- As the base floor for Epoxy Flooring& PU Floorings
ADVANTAGES OF VDF FLOORING
- Low cost compare to other floor
- First construction process
- Smooth and heavy pavement
DISADVANTAGES OF VDF FLOORING
- Crack will form, if groove cutting is not done properly, water curing is not done properly.
- Dust Free Industrial Flooring can not be achieved, if we use low quality RMC
VDF FLOORING SPECIFICATION
- (VDF Flooring Specifications or Concrete Flooring Methodology or VDF Flooring Procedure or Vacuum Dewatered Flooring Procedure)
- Tying Line Dori (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 Dori, 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 (Kudal/Parah)
- 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/Bull Float/Aluminium Bottom (Fanti/Baddha)
- A system of lower mats & top mat is laid on the green concrete & this is attached to a vacuum pump. This draws out surplus water if any.
- Application of Power Floater on the surface until the surface is sufficiently compacted & leveled 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.
VDF FLOORING PROCESS
1.The first step in laying down the Concrete flooring is to clean the whole area. After that, a base of plain cement concrete is laid down.
2.Then reinforcement steel bars are fixed with the provision of dowel bars. These short steel bars provide a mechanical connection between the slabs.
3.After the reinforcement placement, the channels are fixed at about 3 – 4 meter space, depending on the required thickness of the flooring.
4.Generally,M20 to M30 grade of concrete is used, this concrete is poured on the base and compacted thoroughly using the needle vibrators.
5.After that, a double beam screed vibrator is used for levelling and compaction of the concrete, it helps in the proper levelling of concrete.
6.Next is the dewatering process, for which a bottom mat, filter mat, and top mat are placed on the concrete surface, and connected to a vacuum pump.
7.This vacuum pump creates a vacuum between the top mat and filter mat, and the water is sucked from the surface of the concrete.
8.The dewatering process reduces the water content in concrete by almost 20%, which means that the slab gets compressed by about 2%.
9.This dewatering process is carried on for about 20 to 30 minutes depending upon the thickness of the slab.
10.After that dewatered concrete is compacted and dried with the help of a rotating disc or the troweling blades.
11.The grooves can be made on the newly created floor to avoid cracks from expansions and contractions.
12.The final step in the VDF flooring is the curing of the newly created VDF floor for atleast 15 to 20 days.
CONCRETE FLOORING GRADE:
Concrete grade plays important role in Industrial Flooring & Warehouse flooring. Concrete grade determines quality and Life of Epoxy flooring, PU Flooring & Concrete Polishing. Minimum Concrete grade requirement is M25 and above for Industrial flooring & Warehouse flooring
If Base Concrete grade is M25 it will be strong enough to increase the life of Epoxy Flooring & PU Flooring. Then only we can achieve the Glossy Finish in Concrete Polishing.
Dust free Industrial Flooring & ware house flooring can be achieved only through the better abrasion resistance. Epoxy Flooring, PU flooring & Concrete polishing will help to improve the abrasion resistance drastically.
We at Texel Agency will help you to achieve best in class Industrial Flooring & warehouse flooring. We do help you to lay VDF Flooring and all Epoxy flooring, PU flooring & concrete polishing
Texel agency is one of the best VDF flooring contractors in Coimbatore. Our VDF Flooring price is very optimum with best quality.
Texel Agency is also one of the best epoxy flooring applicators in Coimbatore. Our Epoxy flooring service is being extended to all over south india.
Our Epoxy Flooring service is being given in important cities like Coimbatore,Chennai,Bangalore, Hosur, Madurai, Thiruvananthapuram,Kochi & Calicut. Our Epoxy flooring service is being given at very optimum price.
Please call us for the best Industrial flooring solutions,
