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Vacuum Dewatered Flooring
Mr. Kandavel Raja P
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Vacuum Dewatered Flooring
Its a special type of concreting in which water is expelledfrom concrete which reduces the capillary pores and
increases the early strength of the concrete. This process
of expulsion of water from concrete increases its density,water impermeability & resistance to abrasion. This process
of concreting used in industrial flooring, parking areas etc..
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Vacuum Dewatered Flooring
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TOOLS AND EQUIPMENTS
Trowels Leveling Trowels
Straight Edge Sprit Level
Dumpy Level Measuring Tape
Gum Boot Hammer
Wheel Barrow Guide channel
Vacuum Dewatering machine
Suction mat & Filter pad
Power Trowel
Floor Vibrator / Vibrator
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SAFETYTOOLS
Hand Gloves Concrete Boots
Industrial Pins
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VDF Concrete Preparatory works
All the latest GFC drawings should be available.
Different Levels for Soil, Soling & PCC has to be worked out
based on the slope if any and marked in all the columns for
reference.
Incase of Backfilled soil, the surface should be compacted
layer by layer so that it can take further load without failure
Ensure the proper consolidation of the sub grade.
Electrical / Plumbing Lines to be laid & Checked.
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VDF Concrete Preparatory Works
Soling has to be laid as required and filled with Quarry Dust
A layer of LDPE Sheets is to be provided over the sub grade
and then PCC of thickness as per drawing is laid and cured for
min 3 Days
This PCC Creates a leveled sub strata which will facilitate easy
and proper laying of reinforcement works.
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VDF Concrete Preparatory Works
Expansion Joints to be provided at the junction of existing
structure like columns, Retaining walls etc..
It has been to provided to allow the VDF concrete to work
Structural Expansion joint is also to be provided
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VDF Concrete Preparatory works
In case of any openings / Drains, Angles or Krebs
withA
ngles has to be placed.Execution plan has to be made considering of vehicle
movement, avoid more preparatory works.
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VDF Concrete Execution
PCC Area should be cleaned & free from soil particles
It has been suggested a LDPE Sheets to be provided over the
PCC surface based on site condition.
Reinforcement has to be placed with Cover blocks as per
drawings.
Button Marks / Bull fixing has to be done at required intervals.
Guard rails / Channels has to be placed rigid at the sides of the
bays keeping the top at required Finish level.
Shuttering has to be done to avoid slurry leakages.
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VDF Concrete Execution
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VDF Concrete Execution
Specified grade of concrete has to be poured with the slump of
100mm 10mm.
Cube Samples to be taken as per BIS Norms
Concrete has to be leveled & Compacted by using Pocker / Needle
Vibrators. Compaction is very essential especially at the edges of the
bays
Essential to combine this vibration with surface/ screed vibration.
The Dewatering Process Starts immediately after surface
vibration.
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VDF Concrete Execution
Vacuum equipment comprising of 3 equipment, Suction mat
top cover, Filter Pad & Dewatering Pump.
Filter Pads are placed on the Fresh Concrete leaving about 4
inches of concrete exposed on all the sides.
The Top cover is then placed on the Filter pads and rolled out
till it cover the strip of exposed concrete on all sides.
The Top cover is then connected to the Dewatering Pump
through a suction hose and the pump is started.
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VDF Concrete Execution
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VDF Concrete Execution
The dewatering operation takes approx. 1 min per centimeter
thickness of the Floor.
The Dewatered concrete is compacted and dried to such an extent
that it is possible to walk on concrete without leaving any footprints.
Finishing Operation will be done by using Floating Disc. This ensures
after mixing the sand & Cement particles, further compaction & closing
the pores on the surface.
Trowelling is done with trowelling blades in order to further improve
the wear resistance, minimize dusting & obtain Smoother Finish.
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VDF Concrete Execution
Finishing Operation will be done by using Power Floating
It comprises two steps
Power Float Disc. This ensures proper leveling, further compaction &
closing the pores on the surface.
Power Troweling is done with troweling blades in order to further
improve the wear resistance, minimize dusting & obtain Smoother/
Mirror Finish.
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VDF Concrete Execution
Loading or Stepping on
concrete should be avoided,
before initial set of finished
concreteTouch up with mortar should
be avoided which will be peal off
as and when it is loaded
Heavy Vibrations should beavoided in the vicinity of the
VDF Area
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VDF Concrete Grooves on the Floors
A Groove of 3mm thick &
60mm deep has to be made on
the Floor
It should be made after 10 hrsor before 48 hrs of finishing.
The grooves at internal can be
left open & External has to be fill
by bitumen.It Acts as an Expansion Joint /
Control Joint
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VDF Concrete - Benefits
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VDF Concrete - Benefits
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VDF Concrete - Benefits
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VDF Concrete Benefits
Through the vacuum treatment, it is possible to reduce the water
content in the concrete by 15 25% which greatly increases the
compressive strength.
Thus, by lowering the water/ cement ratio, the tendency of
shrinkage and subsequent cracking is greatly reduced.
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VDF Concrete Benefits
Thus by removing excess water from concrete, the concrete attains
its high density which results greater durability compared to the
ordinary concrete.
The operational convenience offers, can be very simply put as
pouring concrete having higher water/ cement ratio giving excellent
workability and removing the excess water immediately after surface
vibration, resulting in a zero slump concrete.
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VDF Concrete Benefits
Saving in cement since the compressive strength of the pavement is
increased giving flexibility to adopt either leaner mix or design a slab
of lesser thickness giving the required strength.
Very high output exceeding 100 200 sq. meters. in a day (depending
upon the configuration of Vacuum De watering System and other site
conditions like concrete mixing and pouring speed).
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VDF Concrete Benefits
Single panel without joints up to 100 sq. meters. (depending on
design specifications)
Very high splitting strength.
Monolithic, Shrinkage free pavements.
Controlled and uniform surface finish.
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Finished surface of VDF
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EQUIPMENTS
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Check List for on - site Inspection
Sl
NO
ITEM YES NO Remarks
1.
2.
3.
4.
5.
.
Name, date and number of the
drawing
PRE - VDF CHECKS
Has the surface been cleaned,
rammed and well compacted?
Have the guiding channels been
placed according to the vibrator plate
length?
Are the guiding channels rigid?
Has the slope been maintained as per
the requirements?
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6.
7.
8.
9.
10.
11.
12.
13.
Are the required tools available?
CHECKS DURING VDF
Is the concrete as per design mix?
If the area is too large ,has it been dividedaccordingly, to do concreting alternatively?
Has the concreting been done evenly and
leveled with vibrating machine?
Has the sucking mat been spread evenly to
facilitate maximum withdrawal of water?Is the pump pressure maintained constant
throughout?
Has the sucking mat been spread evenly to
cover any undulations?
Has the floating started immediately afterspreading of mortar?
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14.
15.
16.
17.
18.
Has the floating been done evenly?
Has the drying process been done along with
Floating to get a mirror finish?
POST-VDF CHECKS
Has curing been done ,either with a curing
compound or7 days of curing?
Have the guiding channels been removed
carefully without damaging edges of concrete
after24 hours?Is the finished floor, level?
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MESH FIXING
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Have you ever noticed a crack in between the door
Frames & the Masonry / concrete walls?
WHY?
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DEFINITION & PURPOSE
Due to different coefficients of thermal expansion of
concrete and block masonry, cracks may develop at their
junction, after plastering is completed. This can beprevented by fixing GI expanded metal rolls (rhombus
shaped mesh) of desired width over these junctions.
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S/N NAME USE
1. Hammer To drive the nails into the walls
2. Masons trowel To apply mortar on the expanded
mesh.3. Safety goggles To protect the eyes from flying
debris
4. Safety gloves To protect the hands during nail
fixing5. Measuring tape To measure any distance
6. Hammer drilling machine
To drill holes in concrete elements
Expanded Metal Fixing - Tools
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1. Hammer 2. Mason Trowel
Expanded Metal Fixing - Tools
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3. Safety goggles 4. Safety Gloves
Expanded Metal Fixing - Tools
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5. Measuring Tape 6. Hammer Drilling
Machine
Expanded Metal Fixing - Tools
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PROCESS
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1.Nail rhombus mesh rolls over the blockwork and
concrete junctions with steel nails/ wooden plug and
nails.
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2. This strip has to be plastered and cured for minimum of 3
days before the entire wall is plastered.
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3. fixed over the junction with 1 lay wise nails & GI washer
of20
mm round of1mm thick.
The nails shall be driven into the RCC beams/columns after
drilling a hole and over brick/block masonry directly. The nails
shall be staggered and folded to secure the mesh reinforcement.
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4. Cement mortar 1:3 proportion shall be laid over the mesh to a
thickness to curb the mesh and not exceeding plastered wall
thickness and imprint shall be made over it to create bond withthe plastering to be done. This will be cured for three days prior
to commencing plastering.
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INSPECTION METHODOLOGY
Ensure metal meshes are properly stretched and nailed
with GI square washer, with sufficient overlap.
Plastering on these surfaces to be done precisely with
no protruding surface/edgesEnsure right width of plastering mesh has been used
depending On the height of adjustor course.
Establish if proper curing has been done.
Inspection to be done at the joints to ensure no cracksat joints/plaster..
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INSPECTION METHODOLOGY
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INSPECTION METHODOLOGY
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Check List for on - site Inspection
Sl NO ITEM YES NO Remarks
1.
2.
3.
4.
Name, date and number of the
drawing
PRE - EXECUTION CHECKS
Has the area been prepared forexecuting the work?
Has the packing between beam
/column and top most level of
blockwork complete?
Has hacking been done on the beam?
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5.
6.
7.
8.
9.
10.
Is the mesh of the required size and
thickness?
Are the required tools and safety equipments
(scaffolding) available?CHECKS DURING EXECUTION
Is the mesh evenly distributed between the
beams and blockwork?
Is the mesh provided throughout the length of
the wall?If Overlapping has to be done, has an overlap
of 10cms been provided?
POST-EXECUTION CHECKS
Is the mesh rigid?
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CORNER BEAD FIXING
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Corner beads are fixed at all exposed edges of walls where
plastering is to be done. It helps to protect the corner from
breaking or chipping off due to minor impacts.A
lso, itgives a good finished surface after plastering and painting.
CORNER BEAD FIXING
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TOOLS AND EQUIPMENTS
S.N NAME USE
1. Masons Trowel To apply the mortar for the corner beads
2. Spirit level To check the verticality of the corner bead after they arefixed.
3. Measuring Tape For distance measuring purpose
4. Plum bobs To check the verticality of the corner bead after they arefixed.
5. Aluminium straightedge
To check the straightness of the corner bead.
6. Measurement box To measure the quantities of aggregates on volumetricbasis
7. Spade For mortar mixing
8. M S Sheet For mortar mixing
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CORNER BEAD
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PROCESS
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Metal corner beads to befixed before internal
plastering to maintain
vertical levels.
CORNER BEAD
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Corner beads shall be initially
fixed over plaster dabs in
neat cement plaster paste
on both sides of the
corner bead. Place the
straight edge against both
sides of the bead to checkthe straightness .Also
Plumb bob shall be used
to ensure vertical plumb.
CORNER BEAD
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The curved edge of the bead should project the finished surface ofplaster slightly to form a smooth external curve . After completingthe alignment after 48 hours of curing the bead shall be filled with 1:2cement sand mortar ,and cured for 3 days
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INSPECTION METHODOLOGY
Ensure the corner bead is inplumb, use spirit levels andplumb bob along with bull
marking.
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Ensure the corner bead is
well packed with absolutely
no gaps.
Ensure the Cement Mortar is
cured for min 3 days
Ensure the Corner bead is
flawless with no cracks or
dents around the installed
bead.
INSPECTION METHODOLOGY
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CheckList for on - site Inspection
SlNO
ITEM YES NO
Remarks
1.
2.
3.
4.
Name, date and number of thedrawing
PRE - EXECUTION
CHECKS
Has the area been prepared forexecuting the work?
Has the bull marking been done?
No damages on the cornerbeads?
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5.
6.
7.
8.
9.
10.
11.
Is the block work at right angles?
Are the required tools and safety equipments
(scaffolding) available?CHECKS DURING EXECUTION
Is the corner bead plumb?
Is the packing between corner beads and
blockwork done with rich cement mortar 1:2?
POST-EXECUTION CHECKSIs the button mark and corner beads in line
and at right angles?
Has curing been done for 3 days?
Are the corner beads rigid?
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