Concrete vacuuming technology

Concrete vacuuming technology is a cutting-edge technique that improves concrete structures’ performance and quality considerably. With this creative method, extra water and air are taken out of freshly poured concrete, making the material denser and more resilient. Understanding and applying cutting-edge technologies, such as concrete vacuuming, can result in stronger, more durable buildings and infrastructure as building requirements change.

Concrete vacuuming essentially uses specialized equipment to produce a vacuum effect on the concrete’s surface. This procedure aids in the removal of trapped water and air, which, if ignored, could deteriorate the concrete. These components are eliminated from the concrete, improving compaction and reducing voids for a stronger finished product.

The increase in the concrete’s compressive strength is one of the main advantages of concrete vacuuming. Vacuumed concrete constructions are more resilient to large loads and environmental stresses, which makes them perfect for high-traffic locations and important infrastructure projects. Furthermore, by lowering the possibility of cracks and surface flaws, this technique guarantees a smoother, more visually pleasant finish.

Additionally, vacuuming concrete can shorten construction schedules. Concrete can set and cure more quickly by removing excess water sooner, which frees up time for other construction tasks to get done. This effectiveness improves overall project management, saves money on labor, and saves time.

It’s important to comprehend the particular tools and methods needed to apply concrete vacuuming technology. For construction professionals to fully benefit from this technology, they must be trained in the proper use of vacuum pumps, mats, and other tools. Concrete vacuuming, when done correctly, can revolutionize construction by providing longer-lasting, more robust structures.

Concrete vacuuming technology is improving the quality and longevity of concrete surfaces, thereby revolutionizing the construction industry. By eliminating extra water and air from freshly poured concrete, this ground-breaking method increases strength, speeds up the curing process, and produces a smoother surface. Concrete vacuuming ensures longer-lasting structures and lowers maintenance costs by lessening the chance of cracks and imperfections. This article examines the advantages, methods, and uses of concrete vacuuming, demonstrating how this cutting-edge method is raising the bar for construction quality and efficiency.

When is vacuuming required?

Standards state that the concrete mix should contain no more than 20% liquid. When water content is excessive, it will begin to evaporate and create mass cracks. This will result in a reduction in the key properties of concrete, such as density, water resistance, and thermal insulation. This is a major infraction that shortens the building’s or concrete structure’s useful life considerably.

While it makes sense to reduce the amount of water added right away, doing so will cause the solution’s workability parameter to significantly worsen. For this reason, it should be between 35 and 55 percent moisture when pouring. Here, there is no danger of delamination because the mixture will not set right away. For this reason, more "watery" concrete is poured first, and then the excess moisture is drained out of it by compacting it.

Vibration is one method that can be used for this. However, in this instance, just a portion of the surplus moisture will be drawn to the surface. Excess water is removed more effectively and in the necessary volume when vacuuming. With the use of technology, the moisture content can be raised to 10–25%. This allows for the use of a mixture with a maximum mobility of 10 cm.

Nonetheless, it’s not always necessary to use this compaction technique. Compacting is typically done when:

  • laying roads;
  • pouring a concrete floor or sub-layer;
  • forming open-type concrete platforms;
  • installing power lines;
  • erecting bridge supports;
  • manufacturing floor slabs;
  • construction of foundations, side walls, vaults.

Vacuuming expedites formwork removal, saves cement, and expedites construction work overall. Concrete has better qualities, such as resistance to frost, and is more durable. Either upper or lateral vacuuming can be produced, depending on the type of construction.

Carrying out vacuuming from above

Rigid shields or specialized vacuum mats are used for this kind of concreting. They are placed with a tiny gap on the prepared surface, creating a space for the air to be pumped out. Following that, vacuuming is done. The concrete solution’s porosity is eliminated at the end.

In order for the process to be executed accurately, the solution must satisfy GOST 7473-94 as well as additional standards:

  • Portland cement must be grade M400. To obtain concrete B15, the cement consumption, according to GOST 10178-85, must be 300 kg / m 3 .
  • No more than 7% of dust particles (size up to 0.14 mm) and no more than 20% of small particles (size 0.31 mm) are allowed in sand. Detailed information is contained in GOST 8736-93.
  • When using gravel, sand in the composition should be 32-45% of the total mass. If crushed stone is filled up, it is necessary to increase the fraction of sand to 40-60%.
  • Concrete should contain 150-200 kg more sand if subsequent vacuuming is envisaged.

The following is the work algorithm:

  1. The surface is prepared for concreting. It is necessary to clean it and install guides.
  2. After the concrete is poured evenly, a filter material is placed on it. It is necessary to prevent the cement and sand from being washed out along with the water.
  3. A flexible mesh is placed on top. It will form the necessary gap.
  4. Vacuum shields with a sealing lock are laid on the mesh. They resemble boxes measuring 100×125 cm. Each shield consists of two parts: an external one (made of steel, fiberglass or waterproof plywood) and an internal one, which is in contact with the mesh laid on the concrete. Inside each shield there is a nozzle through which air and moisture are extracted. It is connected to the vacuum unit using a three-way valve.
  5. The vacuum installation is turned on (consists of a hose, manifold, suction hoses, water separators, vacuum chamber and pumps). Since vacuuming is usually performed as the composition is poured, it is important to ensure access to the equipment. Concrete placement and removal of excess moisture should be performed simultaneously, at the same speed. Therefore, it is better to lay the hoses in advance, check that they are not tangled, and that their length is sufficient.

Practical! Vacuum units can be stationary (found in factories) or mobile (found in monolithic or reinforced concrete structures), which is useful for producing larger structures.

This technique works best when building ceilings. Lateral vacuuming takes precedence when discussing the building of tall structures.

Feature Description
Definition Concrete vacuuming is a process that removes air bubbles and excess water from freshly poured concrete using a vacuum pump.
Purpose The goal is to increase the density and strength of the concrete, leading to a more durable and stable structure.
Process A vacuum mat is placed on the concrete surface, connected to a vacuum pump, which then extracts the air and water.
Benefits This method reduces shrinkage, enhances compressive strength, and improves the surface finish of the concrete.
Applications Commonly used in large-scale construction projects such as bridges, dams, and industrial floors.

Concrete vacuuming technology improves the quality and longevity of concrete structures and provides the construction industry with significant benefits. This technique contributes to the creation of a stronger and more durable final product by eliminating extra water from the concrete mixture. Vacuum-processed concrete will not crack as easily and will be more resilient to wear and tear, which makes it perfect for a range of uses, from industrial floors to roads.

The decrease in concrete porosity is one of the main advantages of concrete vacuuming. This increases the material’s resistance to environmental elements like chemical exposure and freeze-thaw cycles in addition to improving its overall strength. Because of this, buildings made of vacuum-treated concrete typically last longer and require less upkeep over time.

Additionally, vacuuming concrete is a fairly simple process that can be easily incorporated into regular construction methods with little to no disruption. Both new construction and repair projects can use this technique, and the necessary equipment is easily accessible. Because of its flexibility, it’s a desirable choice for contractors who want to raise the caliber of their work.

Concrete vacuuming technology is one useful and efficient way to build more sustainable and long-lasting structures as the construction industry looks for new and creative ways to do so. Contractors who invest in this technology are able to meet the increasing demands of modern construction for longevity and dependability, resulting in higher-quality projects.

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Dmitry Sokolov

Chief engineer in a large construction company. I have extensive experience in managing construction projects and implementing modern technologies.

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