SEMINAR REPORT ON Micro Electro Mechanical Systems

SUBMITTED TOMr. Brijesh Kumar

SUBMITTED BYMohit Singh Rawat

SEC-C ROLL NO. 08 VIII SEM (ECE)

I. CERTIFICATE

This is to certify that Mr.NeerajTewari, B.Tech VIII sem, Civil Engineering has successfully completed his term work in seminar report presentation for the session 2012-2013. The report submitted by him is in accordance with the technical requirements and fulfills all the necessary criteria.

Seminar coordinator(Head of Department)

II. ACKNOWLEDGEMENT

The following project report SHORTCRETE TECHNOLOGY is a detailed estimate of various quantities of work which are to be performed during construction of any building. The following report would not have been possible without the guidance of our honorable President sir Mr. Kamal Ghanshala , our respectful Head of Department Mr. KK Gupta ,my seminar coordinator Mr. Sushil Kumar, all the faculty members of Civil department and my friends who have helped me out during the preparation of this report. I hope that this report of mine would help in understanding the basic concepts of estimation and various kinds of construction activities.

III. ABSTRACT

The report consists of a detail of Shortcrete technology. It includes all the necessary items which are to be carried out during use of this technique.

TABLE OF CONTENTS TOPICS PAGE NO.

I. CERTIFICATE.2 II. ACKNOWLEDGEMENT...3 III.ABSTRACT4

1. INTRODUCTION....6 2. TYPES OF SHOTCONCRETE TECHNOLOGY...........8 3. HISTORY..............................................................9 4. DRY MIX AND WET MIX...............................10 5. APPLICATION...................................................12 6. PREPARATION AND OPERATION..............15 7. EQUIPMENTS USED....18 8. CONCLUSION................21 9. REFERENCES....22

Shotcrete orGunite :
Shotcrete is a mixture of portland cement, aggregate, and water conveyed by compressed air to a spray gun. For structural uses, shotcrete is usually sprayed over a framework of reinforcing bars and steel mesh. Because it can take any shape, is easily coloured, and can be sculpted after application, it is used for a variety of specialized structures, including artificial rock walls, zoo enclosures, canopies, shell structures, pools, and dams. It is sometimes used to bind the walls of tunnels. Concrete applied by spraying. Concrete or mortar which is pumped through a hose and projected at high velocity onto a surface. Shotcrete as a building process was discovered in 1911 and ever since have been used extensively for various residential and nonresidential construction projects with success. The system allows quick installation because the wall forms are lightweight and are easy to handle. Builders can complete the project easily with the help of manual labor and less number of equipment. Shotcrete in Canada is also used for the construction of bridges, tunnels, dams, tanks, swimming pools and earth retention systems. After placement shotcrete can be done in a variety of finishes, including broom finish, natural finish, smooth steel trowel finish and rough trowel finish. Multicrete Systems is the only authorized distributor for ALIVA shotcrete and shotcrete equipment in Western Canada. Founded in 1989, the company is a leading supplier of shotcrete, concrete, grout, ready mix concrete and dry mix shotcrete in Western Canada. Shotcrete is concrete (or sometimes mortar) conveyed through a hose and pneumatically projected at high velocity onto a surface, as a construction technique. Shotcrete is usually an all-inclusive term that can be used for both wet-mix and drymix versions. In the pool construction trade however, the term "shotcrete" refers to wet-mix and "gunite" refers to dry-mix. Shotcrete undergoes placement and compaction at the same time due to the force with which it is projected from the nozzle. It can be impacted onto any type or shape of surface, including vertical or overhead areas.

Shotcrete

nozzle

with

75 mm

concretehose from line pump and 20 mm compressed air line.

Shotcrete swimming pool under construction in Northern Australia.

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Introduction :
The shotcrete process has grown into an importantand widely used construction technique. In 1910, a double chambered cement gun wasintroduced to the construction industry. The sand-cement product of this device was given theproprietary name Gunite. In the ensuing years, trade marks such as Guncrete,pneucrete, Blastcrete, Blocrete, Jetcrete, and the termspneumatically applied mortar and concrete, wereintroduced to describe similar processes. The early 1930s saw the generic term Shotcreteintroduced by the American Railway Engineering Association to describe the Gunite process. In 1951, the American Concrete Institute (ACI) adopted the term shotcrete to describe the dry-mixprocess. Shotcrete is now applied to the wet-mix process.

Classification of Shotcrete : There are two classification of shotcrete namely :1. Dry process. 2. Wet process.

Dry process : Working of dry process proceeds as per the following steps :
1. Pre blended, dry or semi-damped materials are placed into shotcrete equipment and metered into a hose. 2. Compressed air conveys materials at high velocity to the nozzle where the water is added. 3. Then the material is consolidated on receiving surface by high impact velocity. The dry process can be used for any shotcreting application from the smaller patching and sealing works to largest projects like tunnel linings, pools, canal linings or reservoirs. 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.

Advantages of dry process : 1. Easy start up, shutdown and clean up.
2. Control of materials is on site. 3. Nozzle man can be yp to 1000ft horizontally or 500ft vertically from the gun.

History :
Shotcrete, then known as gunite, was invented in the early 1900s by American taxidermistCarl Akeley, used to fill plaster models of animals. He used the method of blowing dry material out of a hose with compressed air, injecting water at the nozzle as it was released. This was later used to patch weak parts in old buildings. In 1911, he was granted a patent for his inventions, the "cement gun", the equipment used, and "gunite", the material that was produced. Until the 1950s when the wet-mix process was devised, only the dry-mix process was used. In the 1960s, the alternative method for gunning by the dry method was devised with the development of the rotary gun, with an open hopper that could be fed continuously. Shotcrete is also a viable means and method for placing structural concrete. The nozzleman is the person controlling the nozzle that delivers the concrete to the surface. The nozzle is controlled by hand on small jobs, for example the construction of small swimming pools. On larger work the nozzle can sometimes be held by mechanical arms where the nozzleman controls the operation by a hand-held remote control.

Dry mix vs. wet mix :

The dry mix method involves placing the dry ingredients into a hopper and then conveying them pneumatically through a hose to the nozzle. The nozzleman controls the addition of water at the nozzle. The water and the dry mixture is not completely mixed, but is completed as the mixture hits the receiving surface. This requires a skilled nozzleman, especially in the case of thick or heavily reinforced sections. Advantages of the dry mix process are that the water content can be adjusted instantaneously by the nozzleman, allowing more effective placement in overhead and vertical applications without using accelerators. The dry mix process is useful in repair applications when it is necessary to stop frequently, as the dry material is easily discharged from the hose. Wet-mix shotcrete involves pumping of a previously prepared concrete, typically ready-mixed concrete, to the nozzle. Compressed air is introduced at the nozzle to impel the mixture onto the receiving surface. The wet-gun procedure generally produces less rebound, waste (when material falls to the floor), and dust compared to the dry-mix procedure. The greatest advantage of the wet-mix process is that larger volumes can be placed in less time. Shotcrete vs. Gunite : Shotcrete is today an all-inclusive term that describes spraying concrete or mortar with either a dry or wet mix process. However, shotcrete may also sometimes be used (incorrectly) to distinguish wet-mix from the dry-mix method. The term shotcrete was first defined by the American Railway Engineers Association (AREA) in the early 1930s. By 1951, shotcrete had become the official generic name of the sprayed concrete process - whether it utilizes the wet or dry process. Gunite is a trademarked name that is incorrectly used to describe the dry-mix shotcrete process, in which the dry cementitious mixture is blown through a hose to the nozzle, the water being injected at the nozzle immediately before it exits the nozzle. Gunite was the
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original term coined by Akeley, trademarked in 1909 and patented in North Carolina. The concrete is blasted by pneumatic pressure from a gun, hence "gun"-ite. The term "Gunite" became the registered trademark of Allentown Equipment, the oldest manufacturer of gunite equipment. Other manufacturers were thus compelled to use other terminology to describe the process such as shotcrete, pneumatic concrete, guncrete, etc. Shotcrete emerged as the only acceptable industry term to correctly describe "pneumatically applied concrete" - either the wet or dry process. Because the term "Gunite" is a noun (product name) and not a verb (action), it is impossible to "gunite" anything. As Per the American Shotcrete Association (ASA) the correct terminology is "shotcrete - wet mix" or "shotcrete - dry mix."

Shotcrete vs. 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. For most bridges original concrete will require additional repair long before shotcrete needs repair and it suffers little detoriations. 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.

Reinforcement :
Sprayed concrete is reinforced by conventional steel rods, steel mesh, and or fibers. Fiber reinforcement (steel or synthetic) is also used for stabilization in applications such as slopes or tunneling.

A 76 mm borehole in fibre reinforced shotcrete on a tunnel wall.

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Example of shotcrete :
The Flintstone House is a free-form, single-family residence in Hillsborough, California overlooking, and best seen from the Eugene A. Doran Memorial Bridge on Interstate 280.It was designed by architect William Nicholson and built in 1976 as an experiment in new building materials, in the form of a series of domes. It was constructed by spraying shotcrete onto steel rebar and wire mesh frames over inflated balloons. Originally off-white in color, it was repainted a deep orange in the mid-2000s. The house contains three bedrooms and two bathrooms. Known popularly as "The Flintstone House", it derives its name from The Flintstones, a Hanna-Barbera Productions animated cartoon series of the early 1960s about a Stone Age family.

Disrepair and restoration :

By the mid-1980s the house fell into disrepair, as water runoff from higher on the mountainside damaged the foundation, causing the walls to crack. After several unsuccessful attempts, an extensive restoration commenced around 1987. San Francisco Bay Area architect Eugene Tsui undertook to remodel the house during the first decade of the 2000s. The results of Tsui's remodel appear as the "Edises Kitchen" project, pictured on Tsui's Web site. Tsui's original concept for the remodel, including a thenproposed, complementary second residence on the property, is detailed in depth on his earlier site.

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Component Materials :
Aggregate
Fine = 60 - 70% of combined weight of aggregates. Coarse = 30-40% of combined weight of aggregates.

Portland Cement
Types I, II = 6.5 - 9.0 sack (611 - 846 lb/yd3) Water (potable) Target W/C = 0.33 - 0.45

WRA
Objective = workability with reduction of W/C ratio.

Microsilica
Typical range = 5% - 15% by weight of cement.

Latex Modifier
More commonly used in thin layer repair work than in ground support.

Accelerator
Silicates Aluminates Dosage = 2 - 5% by weight of cementitious material.

Strength Development :

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Applications of Shotcrete :
Sealing of Ground Mass Interface. Prevent erosion and/or air slaking (crumbling). Deter exfiltration/infiltration. Component of Excavation Support System. Sole Support. Rockbolt / shotcrete system. Rockbolt / shotcrete / lattice girder system. Final Lining. Practical, functional or esthetic considerations do notrequire formed concrete. Repair Work.

What is Shotcrete Good For?

Very wet conditions. Frozen ground conditions. Ground conditions whereinbond is unreliable. Intermittent application small. Quantities - remote areas.

Dry process :
Dry materials arecombined in a "pot", transportedpneumatically to a nozzle wherewater, any liquid admixtures andaccelerator are introduced intothe streamfeed and thenimmediately sprayed onto thetarget surface with a velocity developed by compressed airunder a pressure of 90 - 100 psi.

Wet process :
All materialswith exception of acceleratorare combined within abatch/mix plant, transported viapositive displacement pump toa nozzle where accelerator isintroduced into the streamfeedand then immediately sprayed onto the target surface with avelocity developed bycompressed air under apressure of 90 - 100 psi.

Comparison of Dry-Mix and Wet-MixProcesses :

Dry-mix process :
1. Instantaneous control over mixingwater and consistency of mix at thenozzel to meet variable fieldconditions. 2. Better suited for placing mixescontaining lightweight aggregates, refractory materials and shotcreterequiring early strength properties. 3. Capable of being transported longerDistances. 4. Start and stop placementcharacteristics are better withminimal waste and greaterplacement flexibility.

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Wet-mix process : 1. Mixing water is controlled at thedelivery equipment and can beaccurately measured. 2. Better assurance that the mixingwater is thoroughly mixed withother ingredients. 3. Less dusting and cement lossaccompanies the gunningoperation. 4. Normally has less reboundresulting in less material waste.

Equipments :

Batch/Mix Equipment
Weigh batcher. Drum (turbine-screw) mixer. Admixture feeder(s) - furnished bysupplier. Fiber feeder - furnished by supplier. ASTM Spec ref = C94-90 Standard Specification for Ready-MixedConcrete.

Volumetric batcher
Screw (drum, turbine) mixer Admixture feeder(s) - furnished by suppliers Fiber feeder - furnished by suppliers ASTM Specification reference =C685-90 Standard Specification for Concrete Made By VolumetricBatching and Continuous Mixing.

Placement Equipment Selection :

Wet Process Equipment
Compressed Air Water (construction water for cleanup) Positive displacement pump (or shotcrete pot) Accelerator dosing pump Robotized placer

Dry Process Equipment

Compressed Air Water (potable) Shotcrete Pot Accelerator dosing device Robotized placer

Preparation :
Procure materials (compatibility testing). Develop trial mixes (compatibilitytesting!!!). Mobilize equipment and labor force. Shoot test panels.
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Operation :
Surface preparation is essential - will probably requirepressure washing. Make up a cement /water mix about the consistency ofmayonnaise (a volume of 1 ft3). Pour this lubricating mix into pump hose before starting topump the production mixture. When the pumped production mixture reaches the nozzle,turn on compressed air, accelerator and robotic placermotions. Using good nozzle technique, apply shotcrete evenly to targetsurfaces. Clean pump lines by blowing a rabbit and finishing with athorough water flush of the entire system. Cure of in place material = important consideration(+85% humidity = best solution).

Some other Applications :

Shotcrete is concrete conveyed through a hose and pneumatically projected at high velocity onto a surface. Shotcrete undergoes placement and compaction at the same time due to the force with which it is projected from the nozzle. It can be impacted onto any type or shape of surface including vertical or overhead areas. Conventional steel rods, steel mesh, and/or fibers reinforce sprayed concrete. Steel or synthetic fiber reinforcement is used for stabilization in applications such as slopes and tunnelling.

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Shotcrete applications are frequently used due to the quality, speed and convenience of applications. Shotcrete can be done in places where other methods of delivery are difficult or impossible such as elevated, tight or confined places. Shotcrete can be used in a wide variety of applications including building new structures and reinforcing existing ones. PCiRoads uses shotcrete applications for tunnel reinforcements, slope stabilizations, concrete repairs and many other purposes across all markets and industries.

SHOTCRETE FINISH WALL :

Buesing Corp. is now self performing shotcrete work. We have years of experience working with shotcrete subcontractors on multiple projects. In 2009 we began self performing shotcrete & finish wall related work to strengthen our ability to better serve our customers with a complete shoring/shotcrete package. There are a variety of applications for shotcrete in which we can serve your project; Including:

FACING FOR SHORING. SLOPE STABILIZATION. STRUCTURAL FINISH WALLS (wall line basements). CHANNEL LINING. GROUTED RIPRAP.

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Dry-Mix Gunite Equipment :

Gunite Supply & Equipment manufactures gunite machine, shotcrete pumps, rotary guns, rotary gunite machines, bowl-type guns, bowl guns, gunite mixers, gunite batch plants, shotcrete mixers, shotcrete batch plants, predampeners, pre dampener and other guniteequip.and shotcrete equipent for spraying concrete.

C-10 Gunite machine :

The C-10 gunite machine is designed and manufactured to fulfill the need for powerful material placement using a compact, mobile machine. The C-10 delivers a smooth, steady flow of pre-mixed material into various hose sizes and allows even hydration at the nozzle. MADE IN USA. More info about this dry-mix gunite machine.

Cyclone Rotary Gunite Machine:

The Cyclone's tried-and-true design is performance that you can count on. The Cyclone performs in open spaces as well as confined work areas providing the mobility and power to meet the demands of many applications. The assembly is rugged and reliable to withstand even the harshest working conditions so that you get the job done!MADE IN USA.More info about this dry-mix gunite machine.

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Mix-Elvator 634 Gunite Batch Plant :

The C-10 gunite machine is designed and manufactured to fulfill the need for powerful material placement using a compact, mobile machine. The C-10 delivers a smooth, steady flow of pre-mixed material into various hose sizes and allows even hydration at the nozzle. MADE IN USA. More info about this dry-mix gunite machine.

Cyclone Rotary Gunite Machine :

The Cyclone's tried-and-true design is performance that you can count on. The Cyclone performs in open spaces as well as confined work areas providing the mobility and power to meet the demands of many applications. The assembly is rugged and reliable to withstand even the harshest working conditions so that you get the job done!MADE IN USA.More info about this dry-mix gunite machine.

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Mix-Elvator 634 Gunite Batch Plant :

The Mix-Elvator 634 is a medium to high production batch plant, aka "Micon Rig" used for continuous, automatic proportioning, mixing and conveying of dry gunite/concrete/refractory materials. It features a 30 hp diesel engine, low-maintenance hydraulic drive train and the Airplaco Hydraulic-Ratio control system. The Mix-Elvator offers ease of control to allow even a minimum crew to get the job done efficiently. MADE IN USA. More info about this self-containedgunite rig.

914 MB Gunite Batch Plant :

The AIRPLACO 914MB is a truck-mounted gunite batch plant that puts you in control of your material production. The Airplaco 914MB Mobile Batch Plant is a self-contained gunite rig for larger operations. The 914MB increases efficiency by allowing you to mix the desired material consistency and volume at the jobsite, eliminating the need for ready-mix truck deliveries. MADE IN USA. More information about this self-contained gunite batch truck.

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914 MBT Gunite Batch Plant :

The AIRPLACO 914MBT is a trailer-mounted gunite batch plant for proportioning of dry-mix gunite / refractory materials. The Airplaco 914MBT Mobile Batch Plant trailer gives you complete control of your material production and delivery.

Conclusion of Shotcrete technology :

1. Shotcrete is a method of applying concrete or mortar through pressure hoses pneumatically projected at high velocity onto a surface. 2. It saves a lot of time and money and offers ease of use and flexibility. 3. Material used are similar to conventional concrete, namely, cement, water, light weight aggregate and admixtures. 4. One of the biggest advantage of utilizing the process is fast erection, especially on complex shapes, designs, arches and curved walls. 5. The use of shotcrete offers compressive strength similar to normal or high strength concrete but in a shorter time. This process is now being used in various construction projects in Winnipeg.

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REFERENCES
FaaDoOEngineers.com Seminarproject.com Wikipedia.com Google.com

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