D.M.S.S.V.H.

College of Engineering
Machilipatnam

A PAPER PRESENTATION
ON

CONCEPTS OF SHOTCRETE TECHNOLOGY

BY

K.HARINADH
II/IV B.TECH (CIVIL)
Cell: 9985457977
E-mail: kharinadh@yahoo.com

CH.PRASANTH,
II/IV B.TECH (CIVIL)
Cell: 9866976721

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ABSTRACT:
Shotcrete is the sprayed concrete, which was first used in Pennsylvania, USA in
1907 by Dr.Aneley. The technology is improving giving us enhanced comforts and the
task is completed with a greater economy in terms of both time and investment. This
innovative technology of shotcrete was introduced to make the work easier and
immediate where any alterations are to be made or any architectural effects are to
be
enhanced.

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 i.e. dry mix process and wet mix process. Advantages of shotcrete and
its
applications in various fields like tunneling, canals, buildings etc. are specified
in detail.
This paper presents an overview of shotcreteing technology along with its
applications.

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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 also gives better surface finishes and reduces surface tearing on
nonlinear sections. Cementitious material containing the poly propylene fibers
resist cycles
of freezing and thawing and also reduces the chances of water and chemical
penetrations.

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. 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.

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CLASSIFICATIONS OF SHOTCRETE:
There are two classifications of shotcrete namely1. Dry process

2. Wet process

They are discussed below.

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 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. Most
applications
have production rates of 2-6 cubic yards per hour of mix. Patching and sealing are
done
at even low rates by employing 1”-1.5” hoses.
In dry process rebound and over spray should be considered.
ADVANTAGES OF DRY PROCESS: Easy start up, shutdown and clean up.
 Control of materials is on site.
 Nozzle man can be up to 1000ft horizontally or 500ft vertically from the gun.

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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 3/8" 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.

ADVANTAGES OF WET PROCESS: Little or no formwork is required.

 Cost effective method for placing concrete.
 Ideal for irregular surface applications
 Allows for easier material handling in areas with difficult access

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APPLICATIONS OF SHOTCRETE: 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

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 Arch culverts and highway culverts are other major applications of shotcrete.

Highway culvert repair and arch culvert

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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.

REFERENCES:
1. www.adfil.com
2. www.commercialshotcrete.com
3. www.allentownequipment.com