The Science of Shotcrete

CIB Meeting June 5th 2012

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A mixture of cement and sand and water that is sprayed on a surface under pneumatic pressure

*Websters Dictionary

What is Shotcrete? Mix Design

o Key Factors

Water to cement ratio Sand and Stone Gradation Cement and Pozzolans HRWR Hydration Stabilizers

Other Materials
o Accelerators o Fibers

Steel Macro

Keys to Application

Sprayed Concrete was invented in 1907, and is today widely used for rock support world wide, both in mining and tunnelling. For a long time dry mix application was the only way of applying Sprayed Concrete, but in the seventies the wet mix method was having its breakthrough in underground works The development in Sprayed Concrete has gone a long way since 1907, both in terms of equipment and concrete technology. Especially since the wet mix method started to get implemented, large technology steps has taken place

How Sprayed Concrete Works

Thin layers (315 cm): Bridging effect
Shear strength of shotcrete recess Adhesion Shear strength along shotcrete-rock interface

Weight
Te ns ion
Co m pr es sio

mp Co

n sio s e r

on si n Te

Tangential stresses Fines in cracks, fissures in shotcrete Tension rock and joints Stiffen and strengthen the Shear resistance to blocks rock mass Rock must cut through to fall Transfer the rock load to Sprayed concrete layer acts as a adjacent stable rock (shear shell taking bending forces and and adhesion) tension when bond is low Prevent relative movements 5 No loosening over the time

In the dry mix method, a premix of sand and cement is fed into the hopper of a machine that with the help of compressed air convey the mix through the hose to the nozzle where water is added.
Dry cement, sand and accelerator mix Screen

Agitator Compartment Air line Wear pad

Water line

Water control valve

Wear plate Rotating barrel Compressed air Water ring Nozzle tip

For the wet mix method, sand, aggregate, cement, water and admixture are premixed in a concrete plant Application of wet mix Sprayed Concrete is mainly performed by the use of piston pumps, that convey the concrete through the hosing system, and at the nozzle a set accelerator and air is added. The main benefit with the wet mix method vs. the dry is; improved quality, less dust/improved working environment, less rebound, higher capacity and improved safety

Dense stream system

Sand/aggregate grading Cement type and amount

Temperature
Accelerator dosage Pulsation Nozzle systems /set up Nozzle distance Nozzle angel

W/C ratio
Type of Plastiscizer/Superplasticizer Workability

Accelerator type

Hydration Control

High w/c ratio gives slow setting and influences end quality Watch the moisture content in the sand/aggregate

Moisture will vary depending on where the measurement are taken

Keep control

W/c ratio is critical to o Early setting and strength development o Long term strengths o Long term durability resistance to chemical attack W/c ratio should be less than 0.45, and preferably closer to a 0.4
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 Sand/aggregate grading curve influences: Water demand Workability Reactivity with Accelerator Rebound Shrinkage Durability

Mixing of different fractions in the right proportions is the key

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Combined gradation of aggregates should fall within these limits Usually a 2:1 sand to stone ratio

#8 stone or gravel is primarily used

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Type I, Type II or Type I/II Cement

o

Cementitious content ~ 800lbs

Fly Ash; Class F or C Slag Silica Fume

Proportion similar to how pozzolans are proportioned in concrete

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Superplasticisers for very low w/c ratios and high workability

Hydration control admixtures for maintaining workability from 3 to 72 hours

Alkali-free accelerators for safety and durability Micro Silica

And Slump Retainers

Additions of steel and high performance polymer fibers, micro silica slurries
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Low water - cement ratios 0.32 to 0.45 Allows for higher slumps High early and long term sprayed concrete strengths Pumpable shotcrete mixes Durability enhancement

Low dosage - cost effective

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Hydration stabilizers
Needed in almost every mix design Control the hydration of cement

Maintain open time and pumpability for up to 72 hrs

Adjust dosage according to the needs The addition of shotcrete accelerators re-starts the hydration process and causes immediate setting
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Traditional Sprayed Concrete

New Flexibility with Hydration Stabilizer

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Alkali-free offers setting performance of traditional accelerators All alkali-free accelerators promote strength and durability of sprayed concrete

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Setting time (mins)

15 10 5 0
Initial set

766 140 145 160 161 170

Blisadonna Railway Tunnel, Austria

Final set

S 71 S 51 TCC SA

SA

SA SA SA

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pH Scale 0 pH Scale 0

10

10

14

14

Safe to human body ACIDIC

Alkali-free accelerators

NEUTRAL

BASIC
Conventional accelerators

Improved working safety Modified sodium Less strength difference to base mix silicate accelerators Less dust and rebound Lowered risk of ASR Improved sulphate resistance when using standard OPC Reduced environmental impact in hardened concrete
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Slump below 4in can prove difficult

o o o

Poor mixing efficiency of accelerator into stiff material Overdosing of accelerator due to poor pump piston filling efficiency High pulsation - layering effect

AFA has a lower viscosity, and more efficiently mixed with the shotcrete at a temperature around 70 F than at lower temperatures

Correct set-up with air and accelerator lines and correct nozzle type is key
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3D, Discrete Reinforcement

2D, Wire Mesh Reinforcement

Multi-dimensionally throughout entire concrete thickness

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On a single horizontal plane only

 For reinforcement, direct

cost of fiber is 50 60 % of wire mesh Shotcrete can be sprayed in one layer Reduces shotcrete volume due to following of irregular substrate Better Logistics

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Steel fibres

Typically 1.25 in length 0.02 inches in diameter Type I high tensile strength (ASTM 820) Provides uniform reinforcement Prevents brittle failure of sprayed concrete linings Promotes durability Faster reinforcement method than mesh 50 to 60 % cost saving over mesh

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Macro Synthetic Fibres

o o o o o o

High performance replacement for mesh and/or steel fibers Typical dose of ~ 10lbs per yard Flexural toughness equal to steel As cost effective or better than steel Increased fire resistance Reduced wear on concrete pumping equipment

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Flexural performance
(ASTM C 1609)

Flexural toughness
(ASTM C 1550)

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This test is used to determine flexural performance characteristics of fiber-reinforced concrete; e.g., first-peak strength, residual loads and strengths, toughness (energy absorbed), and Re,x. 25
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Load, kN

15

10

0 0.0 0.5 1.0 1.5 2.0 2.5

Deflection, mm

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 This test is used to determine the flexural toughness of fiber-reinforced concrete (i.e., energy absorbed); this test is specified mostly for underground (UGC) applications.
35 600

Applied Load
30 25 400 20 300 15 200 10 5 0 0 5 10 15 20 25 30 35 40 45 100

Energy Absorbed

500

Deflection, mm

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Energy, J

Load, kN

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Pulsation

Type of equipment may influence pulsation Low workability is low filling ratio, high pulsation, reduced quality and higher cost

Integration with accelerator pump

A good concrete pump is not necessary a good pump for application of sprayed concrete

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Layering or Lensing

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Nozzle system and set up Air and accelerator introduction Air volume Air pressure

Air and accelerator hose Air hose

Wrong

Concrete hose Air and accelerator hose

Accelerator hose
Wrong
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Application Technique Nozzle Angle

Nozzle should always point 90to the receiving surface

90

For spraying onto steel arches/lattice girders exceptions are required

90

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Application Technique Nozzle Distance

For applications the distance should be between 1 2 m

90

Influence of nozzle distance Incorrect nozzle angle and distance have a significantly negative influence on concrete quality, such as poor compaction, strength, etc., and will dramatically increase rebound

90 1-2 m

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Same concrete mix from one truck, sprayed 10 minutes apart! 37 Sprayed by two different nozzlemen during training

Questions?
For More Info: Wes Morrison wesley.morrison@basf.com 571.344.3286 www.meyco.basf.com
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