A PRESENTATION ON

SHOTCRETE
CONCRETE TECHNOLOGY



UNDER THE GUIDANCE OF
ASST PROF. R.L.SIRALE


Submitted by
SINGH NITESH J.
ROLL NO. 49


INTRODUCTION
Shortcreting has proved to be the best method for construction
of curved surfaces.
Domes are now much easier to construct with the advent of
shotcrete technology. Tunnel linings are also becoming easy with
this technology.
Not only are these but there a wide range of applications where
this technology has been a leading one.
This technical paper includes the concept of shotcrete and how it
differs from conventional concrete.
It also enumerates the different types of process involved in
shotcreting
DEFINITION OF SHOTCRETE
Shotcrete is a mortar or high performance concrete conveyed
through a hose and pneumatically projected at high velocity onto
a backing surface.
It is the force of this spraying action that leads to compaction of
the concrete or mortar which then forms layers of concrete to the
required thickness.
Shotcreting has been an acceptable way of placing cementitious
material in a variety of applications.

Usually patented polypropylene fibers are included in the
shotcrete which increases the cohesive nature of the shotcrete
through mechanically binding the cementitious materials
together.
This mechanism reduces the rebound waste that occurs through
the shotcreting process and these fibers also resist plastic
shrinkage and cracking through their ability to enhance the early
stage tensile strength of concrete.
SHOTCRETE VERSUS
CONVENTIONAL CONCRETE
Unlike conventional concrete, which is first placed and then
compacted in the second operation, shotcrete undergoes
placement and compaction at the same time due to the force
with which it is projected from the nozzle.
Shotcrete is more dense, homogeneous, strong, and waterproof
than is possible to obtain by any other process.
Shotcrete is not placed or contained by forms. It can be impacted
onto any type or shape of surface, including vertical or overhead
areas.
It forms an excellent bond with the substrate and can be given a
variety of surface finishes.

DRY PROCESSES














Simplified sketch of a typical dry mix shotcrete system
DRY PROCESS - AN OVERVIEW
Working of dry process proceeds as per the following steps:

Step1: Pre blended, dry or semi-dampened materials are placed
into shotcrete equipment and metered into a hose.
Step2: Compressed air conveys materials at high velocity to the
nozzle where the water is added.
Step3: Then the material is consolidated on receiving surface by
high impact velocity.
The dry process can be used for any shotcreting applications
from the smallest patching and sealing works to largest projects.
The maximum production achievable with dry process
equipment ranges from 10-12 yards per hour of dry mix
depending on the conditions.
To achieve ultimate capacity it is necessary to use 2-2.5 hose
and larger compressors.
Most applications have production rates of 2-6 cubic yards per
hour of mix.


WET PROCESSES















One typical type of wet-mix shotcrete system

WET PROCESS - AN OVERVIEW
Working of wet process proceeds as per the following steps:

Step1: All ingredients, including water, are thoroughly mixed and
introduced into the shotcrete equipment.
Step 2: Wet material is pumped to the nozzle where compressed
air is introduced to provide high velocity for placement and
consolidation of the material onto the receiving surface.
Step 3: Mostly wet-process shotcreting is done with premixed
mortar or small aggregate concrete.
The mix design and consistency of supply are very important in
order to provide a mix with the workability or plasticity to be
pumped through a small-diameter hose.
Sand gradation is the same as for the dry process and for coarse
aggregate mixes; 20-30 percent of 20mm aggregate is added.
Cement content will vary according to the aggregate gradation
and surface area.
However, most mixes contain approximately 700 pounds or more
of cement.
NOVEL SHOTCRETE MATERIALS

POLYMER MODIFICATION
POZZOLANIC ADMIXTURES
FIBER REINFORCEMENT
LOW VELOCITY SHOTCRETE
STEEL FIBRE REINFORCED MICRO SILICA
SHOTCRETE

EQUIPMENTS USED IN SHOTCRETE
Batching and mixing equipment
Admixture dispensers
Air compressor
Nozzles

APPLICATION OF SHOTCRETE
Support of underground openings in tunnel, mines,
drainage adits and exploratory audits.
Rock slope stabilization and support for excavated
foundations, often in conjuction with rock and soil anchor
systems.
Channel linings, protection of bridge abutments and
stabilization of debris-flow prone creeks.
Rehabilitation of reinforced concrete structures such as
bridges ,chemical processing and handling plants.
Rehabilitation of deteriorated marine structures such as
bulkheads, piers, sea wall and dry docks.

Shotcrete finds a major application in tunneling. Tunnel lining is
made much easy by this process









Rehabilitation of subway tunnels

Shotcrete technology proved to be more efficient and easy for the
construction of domed roofs









Domes

ADVANTAGES
Little or no framework is required.
Cost effective method for placing concrete.
Ideal for irregular surfaces application.
Allows for easier material handling in areas with difficult
access.
Easy start up, shutdown and clean up.
An increase in load bearing capacity due to redistribution
of stresses.
Excellent corrosion resistance.


DISADVANTAGES
Rain may wash out the cement leaving a sandy surface, or it may
saturate the shotcrete and cause sloughing or sagging
Strong wind will separate the material between the nozzle and
the point of deposit, reducing the strength
It requires skilled and experienced labours.
A greater degree of geotechnical knowledge is required
Improperly applied shotcrete may create conditions much worse
than the untreated condition


CONCLUSION
The use of Shotcrete to build new concrete structures as well as
to restore and repair existing structures is well known and
documented and it is perhaps the most diverse method available
for concrete construction.
The use of this innovative technology is increasing day by day
and procedures for its proper performance are well developed
and high quality work is regularly obtained.
Shotcrete is a viable option for doing superstructure repair
(unformed) and substructure repair (unformed) if done strictly
according to specifications and best practices.
It is a good substitute for the manual lay-up method for vertical
and overhead applications using rapid set mortar.


REFRENCES
Shotcrete in concrete restoration by Ivan Razal (Ph.D., P.Eng,
Technical Director Gemite Products Inc.)
Bieniawski Z.T. 1989. Engineering Rock Mass Classifications.
New York:Wiley. 251pages.
Mahar, J.W., Parker, H.W. and Wuellner, W.W. 1975. Shotcrete
practice in under ground construction. US Dept. Transportation
Report FRA-OR&D 75-90.Springfield, VA: Nat. Tech. Info.
Service.
Morgan, D.R. 1993. Advances in shotcrete technology for support
of underground openings in Canada. In Shotcrete for
underground support V, proc. engineering foundation conf.,
Uppsala, (eds J.C. Sharp and T. Franzen), 35
Standard practice for shotcrete concrete (U.S.ARMY MANUAL)