Beruflich Dokumente
Kultur Dokumente
Abstract--This ITA Report is a compilation of guidelines from 15 Rdsumk---Ce rapport de I'AITES est un recueil de directives de 15
countries on materials and mix design, production and performance pays sur le sujet du dimensionnement des matdriaux et du mortier,
of shotcrete, as well as national guidelines concerning quality la production et la qualitd du bdton profitd, ainsi que les directives
control and test methods. The report also deals with the extent and concernant des mdthodes d'essais et de contr6le de la qualitd. Le
requirements of both preconstruction tests and routine tests, and apport traite aussi des besoins, d la fois en tests de prdconstruction
applicable test methods. It should be observed that although the et de routine et en mdthodes de test d'application. Il sera intdressant
report itself does not put forth recommendations, it presents a de noter que bien que le rapport en lui-m$me n'avance aucune
summary of what is generally official recommended or suggested recommandation, il prdsente un consensus pratiques aetuelles
practice in different countries today. officiellement recommanddes ou suggdrdes dans divers pays.
Tunnelling and Undergrou~wlSpace Technology, Vol. 8, No. 4, pp. 441~170, 1993. 0886-7798/93 $6.00 + .00
Printed in Great Britain. 0~) 1993 Pergamon Press Ltd 441
some others are officiallyestablished vide an overview of the work o n Italy: Societ~ Italiana Gallerie (SIG)
national regulations. shotcrete that is now underway or that has established a working group o n
This compilation is intended to serve has been recently carried out, as well shotcrete. The group has been divided
as a reference for those who are in- as existing guideline s for different coun- into five subgroups, dealing with the
volved in making specifications for tries. This overview is mainly based on following topics:
shotcrete support, as well as to inspire information provided in the Working 1. Characteristics of shotcrete for
and inform national committees who Group's status report to the Interna- structural use;
are preparing or updating any recom- tional Tunnelling Association in 1991
mendations of their own. Further- 2. Mix design (criteria): aggregate,
(ITA 1991).
cement, tests, and research on
more, today's ongoing European inte- Australia. The Australian Under-
gration includes normative work, e.g., the behaviour of green concrete;
ground Construction and Tunneling 3. Additives, admixtures and fibres;
in the construction sector, also involv- Association (AUCTA) has a subcom-
ing concrete technology. Thus far, no 4. Equipment and safety in works;
mittee on shotcrete.
technical committee on shotcrete has 5. Items for contract and tender
been established within the CEN Austria. The Austrian Concrete specifications.
[Commitd Europden de Normalisation] Society has established a working com-
mittee which has published the Aus- Japan: The J a p a n Tunnelling As-
organization. Therefore, it is vitally sociation h a s a working group o n
important that the tunnelling commu- trian Guideline on Shotcrete, Part 1,
=Application". Part 2, =Testing of shotcrete. Existing standards and
nity be aware of and participate in any guidelines are:
planned work in this respect. Shotcrete', is in preparation.
It is the hope of the ITA Working Canada. N o formal shotcrete * "Tunnelling Standard Specifica-
Group on Shotcrete Use t h a t this re- organisation exists. For general tion ", published by the Society of
port will serve as a basis for further shotcrete applications, reference is Civil Engineers (JSCE) in 1986
enhancement of shotcrete technology, m a d e to documents presented by (in Japanese);
and the exchange of information in this ASTM, ACI and CSA (Canadian Stan- * =Standard Specifications for the
field within the international tunnel- dards Association). Design and Construction of Con-
ling community. Finland. Finland has nopermanent crete Structures", published by
working group on shotcrete. Working the JSCE in 1986 (in English);
--Tomas Franz~n, Animateur, ITA * "Recommendations for the De-
Working Group on Shotcrete Use groups are established for special pur-
poses when the need arises. Finland's sign and Construction of Steel-
"Guidelines for Shotcreting" (1991) are Fibre-Reinforced Concrete", pub-
intended for shotcreting in rock engi- lished by the JSCE in 1983 (in
1.0 Introduction neering applications. The Guidelines Japanese);
This report is a compilation of exist- represent the measures by which a good ~NATM Guideline for Design and
ing guidelines and recommendations technical and economical result can be Construction", published by the
concerning shotcrete and, particularly, obtained; and also deal with aspects of J a p a n Railway Construction
fibre-reinforced shotcrete, for rock sup- working safety. The Guidelines can be Public Corporation in 1983 (in
port. The work has been performed at included in contract documents, but do Japanese);
the request of the ITA Working Group not replace specifications for an actual Construction Manual for Civil
on Shotcrete Use. job. They consist of recommendations, Engineering Work, published by
The aim of the work is to present a which are not official standards. the J a p a n Highway Public Cor-
summary of what is generally consid- France: Working Group No. 6 poration (JHPC) in 1989 (in
ered officially recommended practice ( " S h o t c r e t e " ) of t h e A s s o c i a t i o n Japanese);
in different countries today. Fran~alse des Travaux en Souterrain =Guideline for Construction",
This compilation is mainly based on (AFTES), drafted the AFTES =Recom- published by the J H P C in 1987
documents received from different m e n d a t i o n s on T e c h n o l o g y a n d (in Japanese);
members of the Working Group at the Application of Shotcrete" in 1974. In =Guidelines for Steel-Fibre-Re-
request of BeFo in 1991, and on comple- 1989, the Working Group was asked to inforced Concrete", published by
mentary documents received at and update existing texts and to draft a the J a p a n Tunnelling Associa-
after the ITA conference in Acapulco in recommendation on the use of fibre- tion (JTA) in 1980 (in Japanese).
May 1992. reinforced shotcrete. The group's Norway: A working group on
The author has primarily compiled recommendations were published by shotcrete was establishedin 1990, sup-
and put in order different quantified AFTES in 1992. ported by the Norwegian Rock Blast-
and, preferably, measurable recom- Germany: Existing working groups ing Association. The working group
mendations or standards for a variety are: has presented a draft on the use of wet-
of properties of shotcrete, without at- The Working Group Shotcrete- mix shotcrete for rock support; it is
tempting any deeper analysis concern- DIN 18551, of the German Com- expected to be adopted as an official
ing the reasons for the reported values. mittee on Concrete (DAfStb); recommendation in 1993.
The list of references is as extensive
Committee for National Railway South Africa. The South African
as possible, so that readers may find
Standards-DS 853 Shotcrete, of N a t i o n a l Council on T u n n e l l i n g
f u r t h e r i n f o r m a t i o n in c u r r e n t
the Central Department of the (SANCOT) has established a Working
publications.
It is hoped that this compilation will National Railway (BZA); Group on Shotcrete, representing tun-
serve as a basis for further discussions Working Group "Steel-Fibre- nel owners, the mining industry, con-
concerning reasonable recommenda- Reinforced Shotcrete" of the sulting engineers, contractors, and
tions and standards on shotcrete. German Concrete Institute material suppliers.
(DBV). National standards exist concern-
The most recently presented Ger- ing both safety and general specifica-
2.0 National Work in Progress tions. The former include particular
on Shotcrete m a n g u i d e l i n e is t h e h a n d b o o k
=Stahlfaserbeton ~, which was published specifications concerning protection of
Before examining the various rec- in 1991. This reference was not avail- workers from rebound material, insuf-
ommendations, itm a y be useful to pro- able for use in this compilation. ficient lighting, and dust levels. The
Table 1. Austrian Concrete Society and Japan Tunnelling Society guidelines on cement specifications for shotcrete.
Sieve (mm) 16 16 8 16
32 100 (2) 100 (31 100 (3) 100 (5) 100 (5)
100 (4) 100 {8) 100 (~)
No single fraction > 30% of total aggregate Norwegian Concrete Association 1992
Surface area:
> 1800 m 2 /kg (densified) SANCOT 1991
_>1200 m 2 /kg (BET) EFNARC 1992
Recommended amount:
Powdery type: 6-8% Austrian Concrete Society 1990
average 6% EFNARC 1992
Liquid type: 4-6% Austrian Concrete Society 1990
6-8% EFNARC 1992
Water glass 10-15% Austrian Concrete Society 1990
Not specified: 2-5% Morgan 1991
Dry mix: 4-7% Japan Tunnelling Association 1991
Wet mix: 5-10% Japan Tunnelling Association 1991
Allowable amount:
Powdery type: _<10% Austrian Concrete Society 1990
Liquid type: _<8% Austrian Concrete Society 1990
Not specified < 3% (documented experience _>5 SANCOT 1991
years)
Allowable decrease of strength: < 45%, powdery accelerators Austrian Concrete Society 1990
_<30%, liquid accelerators
Approval test:
Proctor test 10 min.: _>130N EFNARC 1992
Water-soluble aluminate: _<0.6% if shotcrete exposed to water Austrian Concrete Society 1990
with SO 2- content > 600 mg/I
4
the pumpability of the shotcrete (Nor- nants or surface coating (JCI 1991). the hardened properties is negligible.
wegian Concrete Association 1992). 2. Fibres should be high strength, The normal dosage is 1-2 kg/m s.
When several admixtures are con- deformed, drawn or slit sheet steel
templated, a compatibility study should fibres (Morgan 1991). 4.0 Mix Design and
be carried out before the suitability 3. A particular product should be Performance
trial (AFTES 1992). specified(e.g.,Fibrex H C 25 or Dramix 4.1 Composition
ZC 30/.50).
3.5 Fibres The contractor should be free to
R e b o u n d reduces the effective design the mix to achieve the specified
The use of steel fibres as reinforce- amount of fibres in dry-mix shotcrete characteristic strength (Sprayed Con-
ment in shotcrete (SFRS)is well estab- to about 50-70% of the amount in the crete Association 1990).
lished in m a n y countries, including the mix. For wet-mix shotcrete, the amount According to the Austrian guide-
U.S.A., Canada, South Africa, Ger- of fiber rebound is approximately 5 - lines(Austrian Concrete Society 1990),
many, Sweden, and Norway. 10% (EFNARC draft 1992). shotcretewithout specialrequirements,
Other countries regard the fibre- Galvanized fibers, which are some- up to certain strength levels (SC 16),
reinforcement technique as a special times usedin aggressive environments, can be produced without any trialmix
method (Austria) or as a technique to give very good bond to the concrete; tests, using mix proportions for dry or
be used only after sufficient structural however, there is a risk of gas genera- wet mix.
tests have been performed (Finland). tion in reaction with de-chromatized The composition of the shotcrete
Regarding different kinds of fibre cement. The use of de-chromatized mix normally is determined by long
reinforcement, ASTM 820 classifies fi- cement is prescribed in some coun- experience or by trial mix tests. One
bre reinforcement in three categories: tries, e.g., Sweden and Norway (Nor- example ofrecommended trialmix pro-
* Type I: Steel-fibre-reinforced wegian Concrete Association 1992). portions is presented in Table 9.
concrete or shotcrete. Other types of fibres, such as glass, Recommendations concerning com-
* Type II: Glass-fibre-reinforced polymer and carbon fibres, may be used position normally refer to "designated ~
concrete or shotcrete. if the requirements are fulfilled ac- composition. It should be noted that
cording to applied guidelines (Austrian the in-situ composition, i.e.,in the lin-
* Type III: Concrete or shotcrete Concrete Society 1990).
reinforced with syn- ing, deviates from the original compo-
Synthetic fibres contribute to the sta- sition, due to rebound. This is espe-
thetic fibres. bility of shotcrete material (AFTES ciallyimportant for dry-mix shotcrete
Recommendations for Type I fibre 1992). Their excessively low mechani- (DIN 18551, 1992).
are given in Table 8. cal properties can modify the rheologi- According to A F T E S (1992), the re-
Other, not quantified, recommen- cal behaviour of the fresh concrete and sult is an average increase ofthe order
dations are as follows: of the concrete during hardening (e.g., of 10 to 20% in cement proportioning
1. Fibres must be dry, free from improved cohesion and shearing resis- for spraying of an area approximately
corrosion, oil, grease, or other contami- tance). Their contribution to improving 70 m m thick, and a transfer towards
Fiber length: < 30 mm for dry mix Austrian Concrete Society 1990
< 20 mm for wet mix Austrian Concrete Society 1990
< 0.7 x internal dia. of pipes and EFNARC 1992
hoses used
Table 9. Trial mix batch proportions for 1 m 3 dry mix shotcrete, k g / m s. regulates the maximum mass ratio
and the minimum cement content as
shown in Table 11.
Shotcrete Class A B
The mass ratio is as follows:
V
Description Plain Steel Fibre m=
c+Kxp
where:
Normal Portland Cement 380 380
v = water content.
Silica Fume 50 50
c = cement content.
Coarse Aggregate (SSD) 500 500
p = silica fume content
10 X 2.5 mm
K= coefficient of efficiency
Concrete Sand (SSD) 1230 1230
= 2.0 for silica fume content < 8%
Steel Fibre N/A 65 of Portland clinker content
Water (estimate) 140 140 = 1.0 for silica fume content 8-
15% of Portland clinker content.
A similar classification is proposed
by the EFNARC draft (1992). As
fine aggregates of 10 to 20% (relative Rebound may be reduced for dry- shown in Table 12, requirements for
value of the undersize) on the grading mix shotcrete by: air content also are considered, in or-
curve of the concrete in place. The * Increasing fines. der to guarantee freeze-thaw durabil-
thinner the applied layer, the greater . Process-controlled pre-dampening. ity on shotcrete that is used primarily
this increase in proportioning will be, for repair work.
for ceiling applications. * Reducing air pressure.
When calculating water content for
Japanese guidelines (Japan Tun- The cement content should be higher wet-mix s h o t c r e t e , c o n s i d e r a t i o n
nelling Association 1991) state that than for normal concrete in order to should be given to the water content in
the rebound, when tested, should be improve pumpability and shotcrete admixtures and additives (Norwegian
less than 25%. production (Norwegian Concrete Asso- Concrete Association 1992). If no spe-
According to Vandewalle (1991), ciation 1992). cial agreement exists between the con-
rebound may be reduced for wet mix The ready-mix concrete supplier tractor and the concrete supplier, it
shotcrete by" must not reduce the cement content should be assumed that 25-30 1/m3 of
* Increasing the cement content. due to high-strength margins without accelerator will be used. This means
the consent of the shotcrete contractor. that the concrete recipe must have a
Adding fines. Other quantified recommendations margin for addition of 25 litres of water
Decreasing the maximum size of regarding shotcrete composition are at the site.
aggregate. given in Table 10.
Attaining the proper moisture According to the Norwegian draft
content for the aggregate. document (Norwegian Concrete Asso- 4.2 Performance--Fresh
Achieving finer gradation. ciation 1992), the shotcrete should be Shotcrete
Including fly ash or silica in the classified according to the aggressive- P r o p e r t i e s of fresh concrete to be
mix. ness of the current environment, which considered are:
Cement content: 3
Vandewalle 1991
Fine shotcrete, 0-4 mm: 450-600 kg/rr~
Shotcrete, 0-8 mm: 350-450 kg/rn3
Coarse shotcrete, 0-15 mm: 330-350 kg/m
Water/cement ratio:
For dry mix shotcrete: 0.3-0.4 Morgan 1991
0.45-0.55 Japan Tunnelling Assoc. 1991
< 0.5* DIN 18551, 1992
* Not measurable. If there are demands on maximum w/c, it may be assumed that w/c < 0.5.
Consistency or workability. Table 11. Environmental classes and corresponding specifications of concrete
Air pore volume. composition according to Norwegian dra~ guidelines for shotcrete (Norwegian
* Setting time or workability time. Concrete Association 1992).
R e c o m m e n d a t i o n s for each of
these aspects are given be]ow. Envlron- Max. Mass MIn. Binder
Consistency (wet mix): ment Class Envlronment Ratio Content (kg)
Class KP-KF for dense-flow con-
veying according to DIN 18551 NA Somewhat aggressive 0.60 360
(1992),. NMA More aggressive 0.50 420
Class KS-KP for thin-flow con- MA Very aggressive 0.45 470
veying (DIN 18551, 1992).
MMA Extremely aggressive 0.40 530
* Slump:
60-100 mm (Japan Tunnelling
Assoc. 1986; Morgan 1991).
100-150 mm (AFTES 1992).
Table 12. Environmental classes, according to the EFNARC dra ~ (1992).
Air pore volume. The use of air-
entraining agents for shotcrete is not Mln. Fresh Air
very common. Thus, there are only a
few recommendations concerning air
Max. Cement Content
pore volume, and they are concentrated
Class Environment W/(C+) (kglm) (%)
on wet-mix shotcrete where freeze/thaw
durability is important. 2a Humid, no frost 0.60 360
The following two recommendations
regarding air pore volumes are cited in 3 Humid, frost, de-icing salt 0.50 380
DIN 18551 (1992):
10-12% air pore volume at the 5c Highly aggressive chemicals 0.45 400
discharge pump.
3
4-6% air pore volume as shot. EA Extremely aggressive:
Setting time. The setting time often No frost 0.40 350
refers to tests according toASTM C403. Frost 0.40 450
Recommended time ranges for plain or
steel-fibre-reinforced shotcrete with an
accelerator are:
Initial set" 3-10 min. (SANCOT 4.3 Performance--Young Requirements for young concrete
1991; Vandewalle 1991; Morgan Shotcrete are prescribed when there is a need to
1991). The term "young concrete" refers to protect against:
Final set: 9 - 3 0 min. (Wood the state of hardening of concrete to a The influence of blasting near
1992). strength level ofapproximately 10 MPa. the shotcreting site; and/or
4.4.3 T o u g h n e s s
The use of toughness values to char-
Table 18. Strength classes for sprayed concrete tested on sawed or drilled samples from sprayed panels.
Characteristic
strength/MPa
Cylinder 20 25 30 35 40 45 50
Cube 25 30 37 45 50 55 60
Table 19. Minimum strength of concrete cores in different concrete strength classes, according to the Norwegian draft
document (Norwegian Concrete Association 1992).
Minimum strength cores, h/d = 2.0 (MPa) 19.2 22.4 25.6 28.8 32.0 35.2
Strength Class, Sprayed Concrete 030 035 040 C45 C50 C55
Minimum strength class before spraying C38 C43 C48 C54 C60 C65
Table 2I. Examples of requirements for first crack strength and~or ultimate
7exural strength.
7
28
Table 22. Minimum flexural strength in different compressive strength classes, according to Norwegian draft document
(Norwegian Concrete Association 1992) and the EFNARC draft (1992).
Strength
Class C25 C30 035 C40 C45 C50 C55
1 5
7 3.5 SANCOT 1991 ; Specs. for Lesotho Highlands Project 1991; Wood 1992
-
3.5 Morgan 1991
28 5.0 JC11991
1 7 5.0 SANCOT 1991 ; Specs. for Lesotho Highlands Project 1991 ; Wood 1992
10
5.0 Morgan 1991
7.0 (for C25) EFNARC 1992
28 7.0 Swedish National Rescue Services Board
28 8.0 JC11991
~e
1 2O 10.0 (for C25, EFNARC 1992
35, 45)
1
3O
.
14.0 Morgan 1991
28 19.0 JC11991
28 21.0 Swedish Natlional Resque Service Board
Rs io 4.0 MPa** Swedish Railroad Department 1991b
Rio30 'it
--'-- xf s 2.5MPa** Swedish Railroad Department 1991b
100
* Not specified.
** Requirements for routine tests. Corresponding requirements for preconstruction tests: 5MPa and 3 MPa.
Table 24. Requirements, flexural strength and toughness in bending according 5.1.7 Water pressure
to the EFNARC draft (1992). In order to achieve complete wet-
ring of the moist mix at the nozzle,
Concrete Grade C25 C35 C45 the water pressure must be suffi-
ciently high. A pressure greater
Average flexural strength MPa 35 42 46 than 1 kp/cm 2 higher than the
working pressure in the convey-
ing line is recommended, i.e., a
Average toughness indices: desired pressure of > 6 kp/cm 2
Io 6 6 6 (SANCOT 1991).
1 12 12 12
20
Table 25. Toughness values for various performance levels, according to A S T M Cl16 (1989).
Performance Level Specified Value Test Result Specified Value Test Result
Table 26. Suggested descriptions for steel-fibre-reinforced shotcrete, according to Vandewalle (1991).
Toughness Class 1 mm 3 mm
20 15
35 30
Volume of permeable voids (ASTM C642), 7 days: SANCOT 1991, ASTM C1116.89
Without accelerator: 17%
With acceleator: 19%
Watertightness:
Fulfilled according to Swedish standard Swedish Railroad Dept. 1991a and
1991b, Stockholm City Street and
Traffic Admin. 1990
Fulfilled for strength class > SC 22.5, according to C)NORM Austrian Concrete Society 1990
_<50 mm and mean average < 20 mm, according to ISO 7031 EFNARC 1992
Permeability < 10 "1=m/s, according to CEN EFNARC 1992
Other properties:
Splitting tensile strength: AFTES 1992
7days: 2MPa
28 days: 2.7 MPa
Should not be used in design nor as reference parameter, due to sensitivity
to specimen size and durability.
The best wetting is achieved (Specification for Lesotho High- The Norwegian draft document
when the water ring is placed 1- lands Project 1991). (Norwegian Concrete Association 1992)
3 m from the nozzle (semi-wet The temperature before placing prescribes that wet-mix shotcrete shall
process). should not exceed +30C (EF- be manufactured by a ready-mix con-
N A R C draft 1992). crete supplier approved in high class
5.1.8 Pot life In case of intermediate storage (class A). For strength class > 40 M P a
or long transport, the effect of and for shotcrete in very aggressive
Mixed shotcrete (cement + moist environments, the ready-mix concrete
aggregate) should be applied partial hydration should be con-
sidered ( E F N A R C draft 1992). supplier shall be approved in an even
within 45-90 rain. at 20C. At higher class (class A1).
+10C, this time maybe prolonged The use of automatic mixers is al-
to 2-3 hours (P611a1991;JC11991; 5.2 Wet-mix Shotcrete lowed only for lower-quality concretes.
Specific. for Lesotho Highlands Requirements for wet-mix shotcrete
Proj. 1991; E F N A R C dmlt 1992). normally refer to different national 5.2.1 Addition of cement and
Dry-bagged shotcrete without standards and recommendations for aggregate
accelerator should be applied normal ready-mix concrete, e.g.,
within 30 rain. of the addition of O N O R M B 4200 (Austria) and A S T M Ifsite-batched concrete isto be used,
mixing waterin the predampener C94. then the required proportions of ce-
ment to aggregate should be deter-
mined by weight-batching. For small-
scale projects, volume-batching may
Table 29. Requirements for uniaxial tensile strength, according to the EFNARC be permitted (Sprayed Concrete Asso-
draft (1992). ciation 1990).
Shotcrete/rock: >_0.5 MPa Swedish Railroad Dept. 1991a and 1991 b, Stockholm City
Streets and Traffic Administration 1990
> 0.5 MP (structural) EFNARC 1992
> 0.1 MPa (non structural)
effect of the admixtures. In addition, In very bad formations (e.g., charac- rear face. In constricted areas, it may
the mix capacity is reduced because of terized by lack of cohesion or intense be preferable to spray the rear layer of
the longer total mixing time. fracturing), it may be necessary to con- reinforcement to ensure good encapsu-
2. The fibres can be added to the sider a special mix design for the lation of the steel prior to fixing the
ready-mix concrete mass. It is impor- shotcrete to be used in the primary front layer (Sprayed Concrete Associa-
tant to consider that the fibres must be layer, called the "safety layer". tion 1990).
spread carefully into the mix. The It is desirable that reinforcement
consistency must be modified after the 6.3 Spraying over a Layer of panels be fixed rapidly on a first layer
fibres are added. Young Shotcrete of shotcrete at least 20 mm thick
(AFTES 1992).
According to AFTES (1992), if spray- Several attachment points should
5.2.3 Transport
ing takes place before the preceding be provided per square meter on the
Long-term mixing under transport layer of shotcrete has hardened, no working face or on a sublayer of the
at a low w/c-ratio increases the water surface preparation is necessary, pro- shotcrete (AFTES 1992). The distance
evaporation, which will decrease the vided that the latter has not been soiled. between a reinforcement layer and the
slump. In addition, the friction in the
wall on which the shotcrete is applied
concrete mass increases the heat evalu- 6.4 Spraying over an Existing should be as small as possible; the
ation which, in turn, will influence the optimum is 20 mm. After spraying,
slump reduction (Norwegian Concrete Structure
On a concrete substrate where it is any movement or shifting of the rein-
Association 1992). forcements must be prevented, as this
i m p o r t a n t in the s u p p o r t i n g or
strengthening process to obtain good would lead to serious defects in the
6.0 Preparation for Shotcreting sprayed layer.
bonding of the shotcrete onto its sub-
6. 1 Genera/ strate, spraying should be preceded, if
Recommendations regarding pre- necessary, by surface demolition or 8.0 Shotcrete Equipment
cautions before shotcreting involve ac- picking in order to dislodge the large 8. 1 Dry Mix Process
tivitie s to control leaking water by drain unstable elements. The subsequent
systems and cleaning of rock surfaces Below are given the recommenda-
preparation of the wall for cleaning
by compressed air and water, as well as and stripping generally consists of a tions from the various countries con-
dampening of surfaces that are too dry. mechanical action obtained by high- cerning shotcrete equipment used in
In general, according to AFTES the dry-mix process.
pressure water or blasting.
(1992), whatever the nature of the sub- Machine types:
strate, it is recommended that the sur- Bell-type machines or Rotor-type
6.5 Drainage of Water
face be wetted just before spraying so machines.
that it does not absorb the water of the According to AFTES (1992), it is
Delivery line:
freshly sprayed concrete. This precau- essential to make arrangements to I n n e r d i a m e t e r : 5 0 - 6 5 mm
tionary measure is absolutely essen- avoid any water underpressure on the (AFTES 1992).
tial if the surface to be treated is dry; newly treated surface.
Spraying lance:
and it also eliminates dust that has Metal or rubber nozzle.
recently settled on the surface. 7.0 Reinforcements Pre-wetting lance: should allow
This section concerns the applica- annular distribution of liquids
6.2 Direct Spraying on the Work tion of normal bar reinforcement of (water, admixtures) 1-3 m from
Sudace shotcrete. Recommendations on this the discharge end (AFTES 1992).
For direct spraying on the work sur- process are given in Table 31. Admixture proportioning:
face, AFTES (1992) recommends that The EFNARC draft (1992) relates
Should be controlled by the op-
the wall be treated as soon as possible the requirements concerning the con-
crete cover to the environment class, as eration rate (AFTES 1992).
after excavation. The preparation of Powdery admixtures: should be
the excavation is limited to removal of shown in Table 32.
Where two layers of reinforcement added by machine mounted on
unstable elements. If some time has feed conveyor (AFTES 1992).
passed since the baring of the wall, are incorporated, the bars on the front
face should be in line with those on the Equipment must be protected
surface stripping may be necessary.
Minimum distance between reinforcement layers: 50 mm DIN 18551. 1992, AFTES 1992
Minimum cover between existing structure and 35 or 40 mm Sprayed Concrete Association 1990
reinforcement in the shotcrete:
from dripped water, dirt, atmo- tional 8 m nozzle above the gun. 2. Removable robots--also include
spheric influences, and dust - Air pressure for hose diameter a boom, in which the operating
(EFNARC draft 1992). 65 mm, according to Japanese platform is attached to a carrier.
Liquid admixtures: should be recommendations (Japan Tun- The following operating conditions
added in lance di ssolved in water nellingAssociation 1991),given are recommended in the EFNARC draft
(AFTES 1992). in Table 33. (1992):
Water supply: Compressor capacity and hose The operator must be able to
P r e f e r a b l y an i n d e p e n d e n t diameter, according to Table 34. watch the nozzle.
booster allowing overpressure of The robot should be capable ofas
1-2 MPa. For higher pressure 8.2 Wet-Mix Process long a reach as possible.
(5-10 MPa), a special lance with
Recommendations for the wet-mix The operator must be able to ad-
small holes should be used
process are given in Table 35. just the movement function.
(AFTES 1992).
Air supply: The operator must be able to con-
8.3 Spray Robots trol/adjust the amounts of water,
Air rate, low output: 7m3/min. concrete, accelerator/additives,
Air rate, other cases: 10 m3/min. Spray robots are recommended for
use in large-section tunnels, i.e., > 30 and air.
(AFTES 1992)
m 2 (AFTES 1992).
Air pressure: Two types of robots are used: 9.0 Health and Safety
- Operating pressures < 175 kPa
when 30 m or less of material
1. Complete robots--self-contained German documents give regulations
operations that comprise a car- and limits for dust concentration at
hose is used (Vandewalle 1991).
Increased 35 kPa for each addi- Tier with a boom, operating sta- work sites (Tiefbau-Berufsgenossen-
tion, and pump. schaft 1985 and 1988). The limits are
tional 15 m of hose or addi-
PUMP TYPES:
Screw pump:
Maximum pressure: 1.6 MPa AFTES 1992
Rotation speed: 0-170 rev/min. AFTES 1992
Maximum rate: 286 I/rain. = 17 m3/h AFTES 1992
Maximum aggregate size: 8mm Austrian Concrete Society 1990
Piston pump:
Maximum delivery: 24 m3/h AFTES 1992
Maximum aggregate size: 12 mm Austrian Concrete Society 1990
Consistency, normal slump: 160-200 mm Norwegian Concrete Assoc. 1992
< 100 mm possible, but increased
rebound
AIR SUPPLY:
Required amount 5 m3/min. AFTES 1992
> 3 m3/min. at 700 kPa Vandewalle 1991
ADMIXTURE PROPORTIONING:
Liquid admixtures: Added by built-in proportioning pump AFTES 1992
controlled by the pump delivery rate.
Changes in bulk density and viscosity Austrian Concrete Society 1990;
must be taken into account. Swedish Railroad Dept. 1991 a
Total consumption of accelerators P6ll& 1991
should be measured.
Thickness: 1 test (5 points of measure)/50 rn3 Stockholm City Streets & Traffic Admin. 1990
1 point of measure/m 2 JC11991
1 test (7 points)/20 m Japan Tunnelling Association 1991
Aggregate content: < 0.25 mm; no frequency stated DIN 18551, 1992
*The scatter is great, depending on experience, when testing in place, due to the influence of deviated traction, peelings,
placement difficulties, and weight of equipment. Therefore, testing in laboratory is recommended.
Minus tolerance 1.5 in. (40 ram) 2.5 in. (65 mm) 13.0 Test Methods
13.1 Test Panels
When testing shotcrete from test
Table 49. Acceptable tolerances for workability of wet-mix fibre-reinforced panels, there are different recommen-
shotcrete for slump not specified as "maximum" or =not to exceed ~. dations concerning the dimensions of
the test panels. Some recommended
examples are given in Table 53.
Tolerances for Nominal Slumps The choice of panel dimensions is
important--both from the practical
For Specified Slump of Tolerance point of view, because of the difficulty
of handling the panels; and from the
2 in. (50 mm) and less + .5 in. (15 mm) technical point of view, because of the
necessity of obtaining a realistic mea-
2 to 4 in. (50 to 1 O0 mm) + 1 in. (25 mm)
sure of the actual concrete structure.
More than 4 in. (100 mm) + 1.5 in. (40 mm) When using robots, the test panels
should be made by spraying on a load-
ing stool, without the normal inclined
sides, provided with a laminate plate
Table 50. Acceptable tolerances for workability of wet-mix fibre-reinforced shot- (Norwegian Concrete Association 1992).
crete when measured for time of flow specified as "maximum" or "not to exceed: According to the 1992 EFNARC
draft, the filling of receptacles by robot
Specified Time of Flow is difficult because of the high rate of
Type of filling (10-20 m3/hr). Therefore, sam-
Tolerance If 15 s or less If more than 15 s pling by in-place coring is recom-
mended.
In making test panels, the following
Plus tolerance 5s 10 s guidelines should be observed (Norwe-
gian Concrete Association 1992):
Minus tolerance 0s 0s The mold shall be placed against
the tunnel wall with inclination
< 45 to the vertical plane.
Table51. Acceptable tolerances for workability of wet-mix fibre-reinforced shot- The panels should be sprayed to
crete when measured for time of flow not specified as "rnaximum ~ or =not to exceed~ a minimum thickness of 120 mm.
A concrete thickness > 170 mm
Tolerances for Time of Flow shall be removed immediately.
The panel shall be cured similarly
Tolerance to the lining, and shall remain at
For Specified Time of Flow of I the test place for 12-18 hours.
The concrete surface shall be pro-
8to15s +3s tected by a plastic sheet or moist
More than 15 s +5s cloth before transport to the test
Table 53. Examples of recommended dimensions for test panels for testing shotcrete.
600 x 600 x 100 mm for dry-mix shotcrete Sprayed Concrete Association 1990
750 x 750 x 100 mm for wet-mix shotcrete
450 x 450 x 100 m for construction test; Specification for Lesotho Highlands Project 1991
750 x 750 x 100 for preconstruction test
DRILLED CORES:
Diameter: 60-100 m
RI'3xf,
100
~ ........
average stress level in the deflection
range correspondingto toughness in-
dices Izoand 13o.(f, = first crack stress)
Accordingto the JCI (1991)standard,
flexuralstrengthis definedwithreference
to the maximumload. As a measure of
toughness,an =equivalentf]exuralstrength
~erived from an average load value over a
"is defined,matchingaflexuralstrength
,B
I
I
',D
_
I
F
15.55
%
I
I
I
H/
mum deflection equal to 1/150 of the span
(see Fig. 5). DEFLECTION
This absolute description neglects
the resemblance of the material to an OACD OAEF OAGH
15 =
elastic-plastic ideal material. While it OAB I1 = OAB I3- OAB
tells how much energy must be used for
a certain standard specimen to be de-
formed to a certain extent, the form of Figure 4. Load-deflection curve and toughness indices, according to ASTM
destruction (brittle or ductile) is not C1018 (Vandewalle 1991).
indicated (Kasperkiewicz and
Skarendahl 1990).
Table 55. Recommendations regarding beam dimensions for test beams.
13.4.3 Other properties
Recommendations of Beam Dlmenslons Reference Source
Splitting tensile strength: The "Bra-
zilian" test on cores 60 mm. It is
important that the surfaces are straight, 100 x 100 x 350 mm (thick sections) ASTM C1018, 1989
without undulations (AFTES 1992). Equal to the actual thickness used (thin Norwegian Concrete
Direct tensile test: sections) Association 1992
On cores ~60-80 mm (preferably
80 mm to reduce the scatter) 7 5 x 1 2 5 x m i n . 550mm EFNARC 1992
[AFTES 1992]. 75x125x600mm EFNARC 1992
On samples 100 x 100 x 600 mm
(28d) [EFNARC draft 1992].
Density: by weighing and hydrostatic Bond: Controlled by knocking. If there
weighing after application of paraffin Preferably performed in a labo- are non-bonded areas, the reason
(AFTES 1992). ratory on cores 80 mm (AFTES shall be investigated and the need
Thickness: 1992). of additional support evaluated
Tested by drilling holes. The Measured on a random 1-m 2 (Norwegian Concrete Association
placing may be specified using a surface area of the tunnel lining. 1992).
template, according to Swedish Six cores are tested, at the
earliest, after 10 days. The cores Watertightness shall be tested on
standard (see Fig. 6).
are wrapped in plastic sheeting cores ( 150 mm and h = 120 mm) from
Alternatively, the Norwegian Con- before being taken to a labora- shotcrete panels, according to DIN 1048
crete Association draft (1992) states tory. The mean centric tensile (1989). []
that thickness can be tested: strengths are measured at age
By sticking a pricker through the 14 days (Maidl 1992). References
fresh shotcrete; or Measurement of bond may be AC1506-66. 1983. Recommended Practice
By applying distance pins in the stopped if the bond strength > for Shotcrcting. American Concrete
first shotcrete layer. 1.5 MPa (DIN 18551, 1992). Institute.