Both types of pneumatically applied concrete dry-mix and wet-mix processesare discussed

Mix Design Hints for SHOTCRETE

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hotecrete is both a material and a method. The material is concrete, mortar or grout. The method is the application of this material by pneumatic pressure through a specially adapted hose. The concrete is literally shot into the forms or around the reinforcement network in the location where it is to harden. The method has also been used to apply the finished surface. Although not a new development, shotcrete has seen increased use in recent years, with equipment and techniques improving concomitantly. There are two basic types of shotcrete: in one, the materials are combined in a central mixer and then transported through a hose, out the nozzle and into place; in the other, the dry ingredients are combined, t ra n s p o rted through a hose and mixed with water at the nozzle. The former is referred to as the wet-mix process; the latter, the dry-mix process. watertightness as the placement of the concrete progresses. To determine the mix proportions that will best suit the job at hand, it is advisable to test about three different mixtures falling within the range of 1 part cement to 3 to 4 1/2 parts sand. The sand pumped in the dry-mix process should be damp but its water content should be kept reasonably uniform (usually 3 to 6 percent). If it is allowed to vary widely, the nozzle man will have a difficult time maintaining acceptable slump and uniformity of the shotcrete in place. Because water content is so important in this work, it is necessary that test panels be made in advance of the job to ascertain the proficiency of the operator and the acceptability of the mix proportions. Such test panels also enable the specifier to define the quality required of the shotcrete in place. The test panel should be examined to determine if its physical pro p e rt i e s, such as strength, shrinkage and watertightness, will be acceptable. It is advisable to batch the cement and sand by weight rather than by volume. The sand particles must be thoroughly coated with cement; this takes at least one minute in a drumtype mixer. Application of the shotcrete should be closely supervised to guard against an overabundance of rebound (which could indicate an overly dry mix or aggregate problems) or slumping of the concrete in place (which might mean too high a water content). The stream of shotcrete emitted from the nozzle also should be watched to make sure that it is consistently conical. Distortion of the stream may point to a malfunctioning water injection system. The dry-mix process is ordinarily limited to a grout mixture. Howe ve r, concrete containing aggregate up to a maximum size of 1 inch has seen limited application in the United States. Such problems as controlling cement and water content and limiting rebound to a practical amount have curtailed its use on a large scale.

Wet-mix process
This technique permits better control and more versatile mix designs than the dry-mix process. Any type of admixture such as an air-entraining, water-reducing and/or setcontrolling agent can be used. Thorough mixing of the ingredients is easier to achieve. More accurate control of the mix proportions is possible. The mix proportions for the wetmix process are about the same as for the dry-mix process. The entire mix is premixed to a slump suitable for the work. The slump is usually in the range from 0 to 4 inches. The proper mix is determined by trial when it is desirable to use coarse aggregate. Start with 20- to 40-percent coarse aggregate and adjust subsequent mixes on the basis of trials. Because there is good control of water content and mixing, dust and rebound are kept at a minimum. Thus, there is less wasted material and cleanup. On the other hand, this technique is not accompanied

Dry-mix process
In this method, there is a wide range of control over the amount of mixing water used to adjust mix consistency as the job progresses. It also allows transportation of the mix through a longer length of hose than is possible with wet-mix. The drymix process is better suited for concrete containing lightweight porous aggregates than it is for a mixture with normal weight aggregate. It also requires that the operator of the nozzle be exceptionally skilled in controlling water content and, therefore, consistency, strength and

by the ready control of concrete consistency that is provided by the dry-mix process. Materials should be measured by weight rather than by volume. If aggregates must be measured volum e t ri c a l l y, their weight should be ascertained regularly to maintain a reasonably uniform water content. The efficiency of the two basic types of wet-mix equipment (pneumatic feed and positive displacement ) will vary with the brand and its operating condition. Ge n e ra l l y speaking, it is possible to design mortar or concrete to a lower slump with the pneumatic-feed type. The proposed equipment should be tested before the start of a job to determine its ability to place the concrete acceptably; this is especially important for vertical or ove rh e a d applications.

CHART I
Inclination of Surface Floor or slabs Sloping and vertical walls O ve rhead work Percentage of Rebound 5 -15 percent 15 -30 percent 25-30 percent

Materials
Requirements for materials used for shotcrete are basically the same as those used in conventionally placed concrete. Because of the nature of shotcrete, in some cases it is necessary to exercise greater control over physical and chemical properties. Cements ordinarily used in conventional concrete are also used in shotcrete. Type I portland cement is most commonly employed, although Type II is sometimes used for specific exposure requirements. Type III is employed where high early strength is needed. A cement that exhibits a tendency toward flash setting or rapid hardening should be avoided. Premature stiffening of the concrete could entail great loss of time in freeing shotcrete equipment and lines of hardened grout, mortar or concrete. Occasionally it is possible to use aggregates that do not meet appropriate ASTM specifications, but it will usually be found that sand finer than that called for will result in increased drying shrinkage; coarser sand will result in increased rebound. Especially when using coarse aggregate, it is necessary to

eliminate ove r- s i ze particles from the aggregates; over-size aggregates increase the possibility of clogging the lines. The safe procedure is to thoroughly screen all aggregates used. Sand should be sound and hard; soft sand particles break down on discharge through the nozzle, undermining the bonding strength of the cement. This condition is agg ra vated by long hose lengths. Admixtures are especially helpful in shotcrete work. The four types most often used are set controllers, air-entraining agents, water reducers and mineral admixtures. Accelerators or retarders will often be helpful in controlling both the setting and strength-developing characteristics of shotcrete. Rate of set is especially important in this procedure. Air entrainment, which is possible only with the wet-mix process, will be of value both in promoting cohesiveness and in increasing durability. As a rule of thumb, about twice the air content desired should be produced in the mix, since the gunning operation will generally cut air content in half. Water-reducing admixtures are commonly used for the improvements in strength, cohesiveness and reduction in shrinkage that they afford. Fly ash has been occasionally employed in shotcrete to increase plasticity and reduce sagging. Soluble admixtures are introduced into the concrete or mortar in the usual way in the wetmix process. In the dry-mix process, soluble admixtures can be dissolved in the mix water, but this will result in variations in the admixture quantity as the nozzle man varies the content.

Mix design evaluation

In the wet-mix process, the slump o rd i n a rily will range from 0 to 4 inches. The water/cement ratio for either type usually is from 0.50 to 0.35 by weight. It is recommended that from 20 to 40 percent of the coarse aggregate be tried initially and subsequent mixes adjusted to achieve the desired results. To obtain a sample of a given mix for evaluation, gun shotcrete onto a back form of plywood. The shotcrete should be at least 30 inches square in area and 3 inches thick. A separate panel should be made for each mix design and for each inclination to be encountered on the job. Cores are obtained from the panels and tested. These cores should be at least 3 inches in diameter and have a length-to-diameter ratio of at least 1. One gauge of the suitability of a mix design is the amount of rebound. A number of variables (besides materials and mix design) will affect rebound; these include inclination of the work, equipment used, nozzle operators technique, amount of reinforcement and thickness of the section. All should be kept under reasonable control. Generally speaking, the values shown in Chart I can be expected. If rebound substantially exceeds the limits shown in the chart, it is time to check cement content, water content, and maximum size and grading of the aggregates. It is recommended that rebound material should not be collected and used since its quality is highly variable. PUBLICATION #C700112
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