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VDF Flooring:

What is VDF Flooring or Vacuum Dewatered Flooring

VDF Flooring stands for Vacuum Dewatered Flooring. This is a special technique to do the Concrete Flooring to increase the Compressive Strength, Tensile Strength, Abrasion Resistance and to minimize the Shrinkage and Floor Wraps. VDF Flooring results in High Strength, Longer Life, Better Finish and Faster Work. This type of floor is suitable for high abrasion & heavy traffic movement.

The Vacuum Dewatered Flooring or VDF Flooring is a system for laying high quality concrete floors where 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.

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.

Benifits of VDF Flooring – Vacuum Dewatered Flooring
* Increased Compressive strength by more than 50%
* Reduced Cement consumption by more than 30% as no cement is required separately for finishing.
* Increased Abrasion resistance by more than 50%
* Increased wear resistance
* Minimum dusting & crack formation
* Minimum dry and plastic shrinkage and floor wraps
* Uniform homogeneous floor with High flatness accuracy
* Lower water permeability due to increased density.
* High early strength minimizes damage on newly cast floors
* Earlier utilization and Reduced maintenance cost

Typical Application Areas of VDF Flooring
* Warehouses, Godowns
* Roads, Sports Courts
* Cellars, Parking Areas
* Production Areas
* Pharmaceutical Companies
* As the base floor for Epoxy & PU Floorings

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Epoxy Flooring

Epoxy flooring is Smooth, Monolithic Flooring using multiple layers of Epoxy Resins that is applied to the floor to different thicknesses depending upon the requirements. The epoxies are self levelling by nature, thereby spreading across the floor itself, in a manner so as to minimize the undulations and bring about as level a floor as possible.

Concrete surfaces are porous, making them vulnerable to water, abrasion and chemicals. When applied to concrete, Epoxy Flooring creates a protective layer of protection which enhances aesthetics and hardens the surface. Epoxy systems are exceptionally diverse and can be engineered to meet the unique demands of nearly any facility.

Epoxy flooring is tough, smooth, aesthetic and resistance to Moisture, Chemicals and wear & tear which gives abrasion resistance to surfaces, easy to clean and offers a very glossy look to the surface. Due to these properties this kind of flooring is suitable for Industries like Automobile, Pharmaceuticals, Dairy and other Food grades.

Procedure to do Epoxy Flooring
* Cleaning: The substrate should be made structurally sound, dry and free from loose materials. All the surface contamination, laitance, grease and oil must be removed appropriately while deeper penetration should be removed by mechanical means.
* Surface Preparation: Filling cracks & patches if any with epoxy mortar, while bigger pot holes to be treated with non-shrink repair mortars.
* Priming: Application of one coat of solvent free epoxy resin based primer for better adhesion of the subsequent flooring to the substrate.
* Epoxy Topping: - Resin, Hardener, Filler and pigment are mixed together and laid on the floor to required thickness using notched trowel and finished using spike rollers.

Benefits of Epoxy Flooring
* Tough, Smooth, Aesthetic, seamless surface finish
* Low Porosity, Moisture and Water resistant
* Dirt & Dust free and thus easy to clean
* Strong Bond Strength to the substrate
* Provides Safe, Cleaner, Healthier & More Pleasant ambience
* Non Inflammable and Anti-skid thus provides safe surface for Industrial use
* Attractive flooring surface with Glossy or Mat finish as required
* Chemical Resistant and thus protects the substrate from chemical degradation
* High Impact Resistance and thus protects the substrate from wear and tear
* Allow for quick and easy application

Typical Application areas of Epoxy Flooring
* Pharmaceuticals Industries,
* Food Processing Industries,
* Automobile Industries,
* Chemical & Fertilizer Industries,
* Garages & Car Parkings
* Ware Houses

Groove Cutting

Groove Cutting is the technique to provide control joints in Concrete to guide cracks along a predetermined line and to help accommodate the movement of the concrete and avoid Cracking of Concrete and long-term damage.

Concrete expands and contracts constantly with changes in the temperature, the moisture content of the air and due to drying of cement which results in shrinkage. The movements result in stress that can cause cracks in the concrete and destabilization of the base. Uncontrolled cracking can cause an uneven surface, which is subject to increased wear over time and water seepage, which can damage the substrate. Though formation of cracks is almost impossible to prevent, it can be controlled. The purpose of the Groove Cutting is to weaken the slab along the predetermined line so that the slab cracks there instead of somewhere else.

Procedure of Groove Cutting
* Leaving the concrete surface to get cured for a minimum of 72 hours after casting to avoid chipping off of edges
* Locating the joints and marking on the concrete using Line Dori and Paint exactly along the joints making panels of 4Mtrs X 4Mtrs or as specified
* Cutting the concrete using heavy duty Cutting Machine with diamond cutting wheel of 4mm thickness
* The Minimum thickness of the Grooves should be 4mm and Minimum depth of the Groove should be one fourth of the thickness of the concrete.
* Cleaning the Grooves using air blower and filling with appropriate sealant.

Benefits of Groove Cutting
* Prevents cracking of concrete and increases the life of concrete
* Gives Aesthetic Looks

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Laser Screeding

Laser Screeding is the modern way to do the concrete flooring. This technique allows us to lay concrete floors in wider bays of any size. It drastically reduces Time, Labor, number of Construction Joints and eventually improves the flatness of floors. With this technique it is possible to lay concrete floors up to 3,000 Sqm per day. It eliminates the need of fixing guide rails to every 4 meters. Laser screed simultaneously cuts, vibrates and levels the concrete in a single pass. All these operations are controlled by laser transmitter, receivers and computer. So, manual errors are eliminated thereby giving us Zero Level Difference floor (Super Flat).

Benefits of Laser Screeding

* Reduced form work
* Decreased number of cold joints
* Increases Productivity & Efficiency
* Exceeds specified FF and FL's on projects
* Greater accuracy through Laser Technology
* Reduces labour costs due to faster placing times
* Produces floors of unequalled Flatness & Levelness