Vacuum dewatered flooring, also known as vacuum-assisted flooring or tremix concrete flooring or VDF flooring, is a construction technique in which a vacuum is used to remove excess water and air from the concrete mixture before it is placed and finished. This process can create a stronger, more durable, and more consistent concrete floor with a smoother surface finish.
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See also: SPC flooring: Advantages, disadvantages, cost in India, and how to install
What is VDF flooring?
Vacuum dewatered flooring or VDF flooring is a construction technique that uses a vacuum to remove excess water and air from concrete while it is being poured and cured. It helps create a strong, durable, and stable floor resistant to cracking and other types of damage.
The process typically involves pouring a layer of concrete onto a prepared base before using a vacuum pump to remove excess water and air from the mix. It can be done manually using a portable vacuum pump or automatically using a machine specifically designed for this purpose. The resulting floor is typically smooth, level, and ready for use once fully cured.
VDF flooring: Process
Vacuum dewatered flooring, also known as “dry shake” floor hardener, is a process used to improve the surface density and wear resistance of concrete floors. It involves applying a dry, powdered hardener to the surface of freshly placed and finished concrete before using a vacuum to remove excess material and water from the surface.
Here is a step-by-step procedure for applying vacuum-dewatered flooring:
- Prepare the concrete surface: Make sure the concrete is placed correctly and finished with a smooth, level surface. Remove any excess water from the surface using a squeegee or broom.
- Mix the floor hardener: Follow the manufacturer’s instructions for mixing the floor hardener. It typically involves adding water to the dry powder and stirring to create a slurry.
- Apply the floor hardener: Spread the floor hardener evenly over the surface of the concrete using a shovel or spreader.
- Vibrate the surface: Use a vibrating screed or hand-held vibrator to compact the floor hardener and ensure good coverage and penetration into the concrete.
- Vacuum the surface: Use a wet/dry vacuum to remove excess water and hardener from the surface of the concrete. It helps to prevent ponding and ensures that the hardener is evenly spread.
- Cure the surface: Allow the concrete to cure according to the manufacturer’s recommendations before walking on it or using it for any purpose. It typically involves keeping the surface moist and covered for some time.
- Finish the surface: After the concrete has cured, you can proceed with any desired surface finishing techniques, such as grinding, polishing, or applying a sealer.
This is just a general outline, and the specific steps and equipment used may vary depending on the project and the vacuum dewatering machine used. Following the manufacturer’s instructions and safety guidelines when using this equipment is essential.
VDF flooring: Advantages
There are several advantages to using VDF flooring method:
- Faster construction: VDF allows for a faster construction process because it removes excess water from the surface of the concrete more quickly than traditional methods. It means that the concrete can be finished and ready for use sooner.
- Better surface finish: Because the vacuum system removes excess water from the surface of the concrete, the resulting slab has a smoother, more uniform finish. It can be crucial for flooring applications where a smooth surface is desired.
- Less cement required: One of the benefits of VDF flooring is the reduced cement consumption by over 30% as additional cement is not required for finishing purposes.
- Reduced cracking: VDF flooring can reduce the risk of cracks forming in the concrete slab. It is because the vacuum system removes excess water from the slab’s surface, which can help prevent shrinkage cracks from forming.
- Increased durability: VDF can result in a more durable concrete slab because the vacuum system removes excess water from the slab’s surface, which can help reduce the risk of freeze-thaw damage.
- Increased strength: Removing excess water from the concrete allows the concrete to reach its maximum strength more quickly.
- Abrasion resistant: VDF flooring has increased abrasion resistance by over 50% compared to other flooring types.
- Energy efficiency: VDF flooring can be more energy efficient than traditional methods because it uses a vacuum system to remove excess water from the slab’s surface, which can be more energy efficient than other methods, such as using heat or drying fans.
VDF flooring: Disadvantages
There are a few potential disadvantages to using vacuum-dewatered flooring:
- Cost: The equipment and materials needed for vacuum dewatered flooring can be expensive, which may make this type of flooring more costly to install than other options.
- Limited thickness: The flooring produced by the vacuum dewatering process tends to be relatively thin, typically just three to four inches thick. More than this may be required for certain applications, such as in areas where heavy loads will be placed on the floor.
- Complexity: The process of installing vacuum-dewatered flooring can be complex and may require specialised equipment and trained professionals. It can make it difficult for homeowners to install this flooring independently.
- Limited design options: There may be fewer design options available for vacuum-dewatered flooring compared to other types of flooring, such as tile or hardwood.
- Risk of damage: The vacuum dewatering process can be sensitive to temperature changes and variations in humidity, which can affect the quality of the finished floor. If the process is not carefully controlled, it can damage the flooring.
- Maintenance: Vacuum-dewatered flooring may require more maintenance than other types of flooring, such as regular sealing and waxing, to protect the surface and maintain its appearance.
VDF flooring: Applications
There are several applications for vacuum dewatered flooring (VDF flooring), including:
- Industrial floors: Vacuum dewatered flooring is often used in warehouses, manufacturing facilities, warehouses, godowns and other industrial settings where a strong and durable floor is required.
- Parking garages: This technique can create smooth and level floors in parking garages, which can help reduce the risk of accidents and damage to vehicles.
- Retail spaces: Vacuum dewatered flooring can be used in retail spaces, such as stores and malls, to create a durable and attractive floor that can withstand heavy foot traffic.
- Residential spaces: This technique can also be used in residential settings, such as homes and apartments, to create durable and low-maintenance floors.
- Public spaces: Vacuum-dewatered flooring is often used in public spaces, such as schools, hospitals, sports courts, roads and government buildings, to create a durable and safe floor surface.
Why is VDF flooring needed?
VDF flooring serves as a crucial solution to overcome the challenges posed by traditional concrete flooring, especially in high traffic zones and expansive areas exposed to hot weather conditions. The application of conventional concrete flooring in such contexts can lead to various issues, including dry shrinkage, inadequate finishing, warping and excessive load on concrete. These concerns can significantly compromise the durability and lifespan of the flooring. VDF flooring offers a strategic remedy by optimising the water-cement ratio, effectively addressing the limitations associated with conventional concrete flooring. Here are the issues that CDF flooring can help address:
- VDF flooring minimises the occurrence of plastic shrinkage cracks caused by excess water content in the concrete mix.
- The controlled water-cement ratio in VDF flooring mitigates excessive bleeding of concrete, which can otherwise compromise the durability of the flooring.
- VDF flooring prevents the untimely evaporation of water within the concrete mixture. This preservation of water content facilitates better mixing, placing, and consolidation of the flooring material.
- Particularly in hot and windy climates, VDF flooring excels by providing a smoother finish compared to conventional concrete flooring. This advantageous finish is maintained even in challenging weather conditions.
What is a VDF flooring machine?
A VDF flooring machine is a device for flooring construction that utilises vacuum pads to remove excess water and compaction from fresh concrete panels. It comprises of a vacuum dewatering pump that sucks air bubbles trapped during the concrete laying process. It lets the cement rise to the upper layers, giving strength to the floor.
VDF flooring vs IPS flooring
IPS, which refers to Indian Patient Stone, is a flooring material widely used in industrial spaces, residential complexes, etc. IPS comprises a mixture of cement, marble powder and colour pigments.
VDF flooring and IPS flooring are both regarded as a durable flooring option. However, VDF flooring is more durable compared to IPS flooring. Moreover, IPS flooring is cost-effective compared to VDF flooring.
VDF flooring cost
The price of VDF flooring in India ranges from Rs 80 to 90 per square foot (sqft), including labour and installation charges. On the other hand, the price of IPS flooring can range from Rs 60 to 80 per sqft, including installation costs.
FAQs
What is vacuum dewatered flooring?
Vacuum dewatered flooring (VDF) is a type of concrete floor construction that uses a vacuum pump to remove excess water from the concrete mix before it is placed and finished. This results in a hard, dense floor with a smooth surface finish.
How is vacuum-dewatered flooring different from other types of concrete flooring?
One of the main differences between vacuum-dewatered flooring and other types of concrete flooring is the use of a vacuum to remove excess water and air from the mix. It can result in a stronger and more durable floor than other types of concrete flooring. Vacuum-dewatered flooring is often more dimensionally stable, making it less likely to crack or shrink over time.
Is vacuum-dewatered flooring more expensive than other types of concrete flooring?
The cost of vacuum-dewatered flooring will depend on several factors, including the project's size, the design's complexity, and the local cost of materials and labour. In general, vacuum-dewatered flooring may be more expensive to install than other types of concrete flooring. Still, it can provide long-term cost savings by requiring less maintenance and having a longer lifespan.
What are some applications for vacuum dewatered flooring?
Vacuum-dewatered flooring is commonly used in a variety of applications, including:
Industrial and manufacturing facilities
Warehouses and distribution centres
Retail spaces
Office buildings
Parking garages
How do I maintain VDF?
Regular sweeping and mopping with a pH-neutral cleaner is typically sufficient to keep the floor looking clean and in good condition. Avoid using abrasive cleaners or high-pressure water jets, as these can damage the floor's surface.
Is VDF suitable for all types of projects?
VDF may not be suitable for all types of projects. It is typically used in industrial and commercial settings, such as warehouses, factories, and retail stores. There may be better choices for residential or outdoor projects, as they require specialised equipment and trained personnel to install. Additionally, the vacuum pump may not be able to access certain areas or remove all of the excess water from the concrete mix in certain situations.
