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SHOTCRETE
(NTS: This section is written to accommodate the special tests and inspections. Confer
with Chief Structural Engineer and coordinate local building code requirements for the
particular project and its locale.
PART 1 - GENERAL
1.01 DESCRIPTION:
(NTS: Select and list specification sections for inserting into this subsection based on
the following:
1. Specification sections that contain products and construction that the reader might
expect to find in this section BUT are specified elsewhere.
2. Specification sections referenced in the body of this section.)
A. Section 03100: Concrete Formwork.
1.03 REFERENCES:
(NTS: Select the appropriate references to be included in the project. Add or edit
references as appropriate. Delete those references that are not applicable.)
A. American Concrete Institute (ACI):
3. ACI 304: Guide for Measuring, Mixing, Transporting, and Placing Concrete.
1. A 185: Standard Specifications for Wire Fabric, Plain, Welded Steel for
Concrete Reinforcement.
2. A 615: Standard Specifications for Bars, Deformed and Plain, Billet-Steel, for
Concrete Reinforcement.
3. A 820: Standard Specifications for Steel Fivers for Fiver Reinforced Concrete.
4. C 31: Standard Practice for Making and Curing Concrete Test Specimens in
the Field.
6. C 42: Standard Test Method for Obtaining and Testing Drilled Cores and
Sawed Beams of Concrete.
10. C 171: Standard Specification for Sheet Materials for Curing Concrete.
(NTS: Include the next reference when fly ash or pozzolans are specified.)
12. C 311: Standard Test Methods for Sampling and Testing Fly Ash or Natural
Pozzolans for Use as a Mineral Admixture in Portland Cement Concrete.
(NTS: Include the next reference when fly ash or pozzolans are specified.)
15. C 618: Standard Specification for Coal Fly Ash and Raw or Calcined Natural
Pozzolan for Use as a Mineral Admixture in Portland Cement Concrete.
16. C 642: Standard Test Method for Specific Gravity, Absorption, and Voids in
Hardened Concrete.
17. C 685: Standard Specification for Concrete made by Volumetric Batching and
Continuous Mixing.
19. C 1140: Standard Practice for Preparing and Testing Specimens from
Shotcrete Test Panels.
22. E 154: Test Methods for Water Vapor Retarders Used in Contact with Earth
Under Concrete Slabs, on Walls, or as Ground Cover.
23. E 329: Standard Specification for Agencies Engaged in the Testing and/or
Inspection of Materials used in Construction.
1.04 SUBMITTALS:
1. Name and address of proposed Contractor's testing laboratory firm and a brief
description of prior work which is similar to that proposed for this project.
Provide prior work owner's full name, address and telephone number. ASTM
E 329 will also be used as one of the basis for evaluating the testing laboratory
firm.
4. Mill test reports for each shipment of cement, regardless of quantity, prior to
incorporation into the work.
(NTS: Include the next paragraph when fly ash or pozzolans are specified. Do not use
pozzolan for liquid retention structures, including exterior foundation walls below
groundwater.)
6. Manufacturer's fly ash or pozzolan chemical analysis and results of physical
test reports in conformance with ASTM C 311 and as specified herein for each
shipment of fly ash or pozzolan, prior to incorporation into the work.
C. Do not use admixtures, including calcium chloride, which will cause accelerated
setting of cement in shotcrete.
D. Do not place shotcrete into the work until design mix, material tests and trial shotcrete
batch mix compression test results are approved by the CM/CS. Approvals are
required at least 30 days before placing any production shotcrete.
E. The Contractor shall employ an independent testing laboratory firm, acceptable to the
CM/CS, to test conformity of materials to specifications and to design shotcrete
mixes.
F. Furnish, pay for and deliver representative samples of sufficient quantity of cement,
aggregates and admixtures required for trial shotcrete batch mixes to the testing
laboratory. Obtain materials from the shotcrete batching plant that will be supplying
production shotcrete in conformance with ASTM D 75.
H. Preconstruction Testing:
2. Produce test panels for each proposed mix proportion, each anticipated
shooting orientation, and each proposed nozzleman. Mixes shall meet
requirements as specified herein. In half of the test panels provide
reinforcement of the same size and spacing required for the work.
3. Obtain six test specimens from each panel, three nonreinforced specimens and
three with reinforcing steel.
4. Test the nonreinforced specimens for compliance with the specified physical
properties in accordance with ASTM C 42.
5. Visually grade the reinforced specimens for compliance with specified core
grade in accordance with ACI 506.2. The core grade of each core shall not be
greater than grade 2 as defined in ACI 506.2.
7. Only nozzlemen with a test panel mean core grade less than or equal to 2.5
shall be allowed to place job shotcrete. When the prequalification test panel is
rejected, a second panel may be shot. If the nozzlemans second mean core
grade is greater than 2.5, the nozzleman shall not be permitted to shoot on the
project.
A. Do not place shotcrete until conditions and facilities for making and curing control
test specimens are in compliance with ASTM C 1140 and as specified herein.
PART 2 - PRODUCTS
(NTS: Use the following paragraph on projects where structures are to contain potable
water.)
A. All materials used in shotcrete or the curing and repair of shotcrete, which can contact
potable water, shall be certified as meeting requirements of ANSI/NSF 61 for contact
with potable water when in the finished shotcrete.
B. Furnish Portland cement conforming to ASTM C 150. Use one approved brand from
one mill throughout the contract term unless otherwise approved by the CM/CS. Use
cement of uniform color.
1. Reject the entire shipment when cement is lumpy, wetted, partially or wholly
set.
(NTS: Next item shall be used or modified to suit the project when fly ash and
pozzolans are specified.)
2. For mix designs containing fly ash or pozzolans, use ASTM C 150 Type II
cement with fly ash or pozzolan as a cement replacement.
C. Water:
1. Use water for shotcrete that is potable and free from injurious amounts of oil,
acid, alkali, organic matter or other deleterious substances, and conforms to
the requirements for water in ASTM C 94, and as specified herein.
2. The maximum water-soluble chloride ion in the water shall not exceed 0.060
percent by weight of cement.
D. Aggregates:
1. Use fine aggregates for normal weight shotcrete consisting of well graded
natural sand conforming to ASTM C 33 and to the following requirements:
E. Admixtures:
1. General Requirements:
2. Air-Entrainment:
(1) 7 percent for shotcrete using 3/8 inch [9.5 mm] or less
nominal maximum aggregate size.
(2) 6 percent for shotcrete using greater than 3/8 inch [9.5 mm]
nominal maximum aggregate size.
(NTS: Include the next item when fly ash and pozzolans are specified.)
d. Adjust the admixture content to accommodate the fly ash or pozzolan
requirements, and other admixtures when used, in order to obtain the
specified air content.
(NTS: Delete, use or modify the next item to suit the project.)
4. High Range Water Reducer (Super Plasticizer): Use admixture conforming to
ASTM C 1194.
F. Curing Compound: Liquid form, which will form impervious membrane over,
exposed surface of shotcrete when applied to fresh shotcrete by means of spray gun.
Apply twice the coverage (double the application rate) recommended by
manufacturer. Compound not to prevent future bond of shotcrete layers, coverings, or
surface treatment. Use Type I-D compound with red fugitive dye, Class B, having 18
percent minimum solids conforming to ASTM C 309.
G. Curing Sheet materials: Curing sheet materials that cause stains on surface shall not
be used. Use materials conforming to ASTM C 171.
1. Class F fly ash conforming to ASTM C 618 for chemical and physical
properties.
2.02 MIXES:
A. Use 4000 psi [28 MPa] shotcrete for all shotcrete, unless otherwise indicated or
specified.
B. Secure, for every part of work, shotcrete of homogeneous structure having required
strength, water tightness, and durability. Give careful attention to selection of
materials, mixtures, transporting to discharge locations, shooting, and curing.
(NTS: Include the next paragraph when fly ash or pozzolans are specified.)
D. Fly ash or pozzolan not to exceed 15 percent of the combined weight of fly ash or
pozzolan and cement.
A. Conform to the requirements specified in Section 03100 for finish tolerances for
formed surfaces.
B. Maximum deviation in shotcrete structures not to exceed 1/4 inch [6 mm] in 10 feet [3
meters] as determined by a 10 foot [3 meter] straight edge placed anywhere on the
surface in any direction.
PART 3 - EXECUTION
A. Weight batching shall comply with the accuracy specified in ASTM C 94.
B. Volume batching shall comply with the accuracy specified in ASTM C 685.
A. Verify that surfaces are acceptable and are ready to receive shotcrete.
B. Verify that forms are to line and grade, braced against vibration, and constructed to
permit escape of air and rebound.
A. Earth: prepare surfaces to line and grade. Do not apply shotcrete to frozen surface.
Dampen surface immediately prior to shooting.
B. Concrete, Masonry, and Shotcrete: When bonding is required, remove all deteriorated,
loose unsound material or contaminants that may inhibit bonding. Chip areas to be
repaired to remove offsets causing abrupt changes in thickness. Taper edges to
eliminate square shoulders at the perimeter of a cavity. Surface shall be saturated
surface dry immediately prior to shooting.
D. Rock: Remove loose material, mud or other foreign material that will prevent
bonding. Clean surface and pre-wet surface immediately prior to shooting.
A. Conform to ACI 305R and as specified herein for hot weather concreting. Do not
place shotcrete when material temperature is above 90 degrees Fahrenheit [32 deg. C]
for wet-mix; 100 degrees Fahrenheit [38 deg. C] for dry-mix. Lower temperature of
reinforcement and receiving surfaces below 100 degrees Fahrenheit [38 deg. C]
immediately prior to shooting. Do not add retarder admixture to any shotcrete.
B. Conform to ACI 306R and as specified herein for cold weather concreting. Do not
shoot when ambient temperature is 40 degrees Fahrenheit [4 deg. C] and falling
unless measures are taken to protect shotcrete. Shotcrete material temperature when
shot shall not be less than 50 degrees Fahrenheit [10 deg. C]or more than 90 degrees
C. Do not place shotcrete containing pozzolan during cold weather concreting, as defined
in ACI 306R.
3.05 JOINTS:
B. Install inserts, anchors, sleeves and other items indicated or specified under other
sections of these specifications in formwork. Close ends of conduits, piping and
sleeves embedded in shotcrete with caps or plugs.
D. Check location and support of piping, electrical conduits and other embedded items
before depositing shotcrete. Correct locations as required and secure supports.
Maintain three-diameter minimum clear spacing between parallel runs of piping and
conduit. Do not install runs of piping and conduit between formwork and
reinforcement.
A. General: Conform to concreting procedures set forth in ACI 304R and as specified
herein.
C. Remove and replace shotcrete that is delaminated, exhibits laminations, voids, or sand
pockets exceeding the limits for the specified grade.
D. Remove and replace shotcrete that does not comply with the specified material
properties.
E. Repair core holes in accordance with ACI 301. Do not fill core holes by shooting.
F. Shotcrete work that has previously failed to meet one or more requirements, but
which has been repaired to bring it into compliance to the satisfaction of the CM/CS,
will be accepted.
3.09 PLACING:
A. Install taut ground wires or other means to establish thickness and plane of required
surface. Install taut ground wires or other means at corners or offsets not established
by forms.
D. Apply shotcrete so sags or sloughing do not occur. Discontinue shooting or shield the
nozzle stream if wind causes separation of ingredients during shooting.
G. Remove hardened overspray and rebound from adjacent surfaces, including exposed
reinforcement.
I. Protect surfaces not intended for shotcrete placement against deposit of rebound and
overspray or impact from nozzle stream. Remove rebound and hardened overspray
from final shotcrete surfaces and from areas not intended for shotcrete placement.
3.10 TESTING:
1. Produce a material test panel for each mix and each work day or every 50
cubic yards [40 cubic meters] placed, whichever is less. Test panel shall be
kept moist and at 70 F 10 degrees Fahrenheit [21 C + 5 deg. C] until moved
to test laboratory. Obtain test specimens either from job site material test
panel or from in-place shotcrete. Test specimens from test panels in
compliance with ASTM C 1140.
4. The mean compressive strength of a set of three cores shall equal or exceed
0.85 times the specified compressive strength with no individual core less than
0.75 times the specified compressive strength. The mean of a set of three
cubes shall equal or exceed the specified compressive strength with no
individual cube less than 0.88 times the specified compressive strength.
2. Comply with curing procedures set forth in ACI 301, applicable portions of
ACI 308 and as specified herein.
B. Duration:
C. Curing Requirements:
1. Unformed Surfaces: Cover and cure entire surface of newly placed shotcrete
immediately after completing finishing operations and water film has
evaporated from surface or as soon as marring of shotcrete will not occur.
Protect finished slabs from direct rays of the sun to prevent checking, crazing
and plastic shrinkage.
2. Water retaining and below Grade Structures: Moist cure by the addition of
water to maintain the surface in a continually wet condition. Use water that is
free of impurities that could etch or discolor exposed shotcrete surfaces. Other
shotcrete shall be cured by moist curing, by moisture-retaining cover curing,
or by the use of curing compound. Use curing compound at water retaining
and below grade structures only in cold weather after the initial curing period
and only when approved by the CM/CS, in writing.
D. Curing Methods.
2. Sealing Materials:
b. Lap adjacent sheets a minimum of 12 inches [300 mm]. Seal edges with
waterproof tape or adhesive. Use sheets of sufficient length to cover
sides of shotcrete member.
d. Maintain the continuity of the coating and repair damage to the coating
during the entire curing period.
(NTS: Use the following paragraph on projects where structures are to contain potable
water.)
e. Provide a copy of manufacturers certification that the curing compound
meets the requirements of ANSI/NSF 61 for shotcrete surfaces that will
be in contact with potable water,
4. Natural Curing:
F. Protection from physical injury: Protect shotcrete from physical disturbances such as
shock and vibration during curing period. Protect finished shotcrete surfaces from
damage by construction equipment, materials, application of curing procedures and
rain or running water. Do not load shotcrete in such a manner as to overstress
shotcrete.
3.12 REPAIR:
B. Surface defects in all shotcrete surfaces that adversely affect the durability of the
shotcrete shall be repaired per the requirements of this section. Such surface defects
that require repair include all visible cracks in tank floors and walls and the exterior
envelope of structures below grade, regardless of width. Cracks in all other areas in
excess of 0.02-inch [0.5 mm] wide, honeycomb, rock pockets, and spalls.
C. Repair of Cracks:
1. Cracks, which have resulted from overstress conditions and are structural in
nature, shall be pressure grouted using an injectable epoxy.
2. Cracks in water retaining or below grade members, which have resulted from
shrinkage stresses and show any sign of leakage, or are positioned such that
leakage cannot be observed, shall be pressure grouted using hydrophilic resin.
3. Cracks in other members, which have resulted from shrinkage stresses and
exceed 0.020 inch [0.05 mm] in width shall be pressure grouted using
hydrophilic resin.
a. Compressive strength at one day: 2000 psi [14 MPa] (ASTM C 109).
(NTS: Use the following paragraph on projects where structures are to contain potable
water.)
d. NSF Standard 61 potable water approved when used in water treatment
and related facilities.
4. Use no more mixing water than necessary for handling and placing. Mix
patching mortar and allow to stand with frequent manipulation with a trowel,
without addition of water, until it has reached stiffest consistency that will
permit placing.
5. Brush bond coat of neat cement well into surface after surface water has
evaporated from area to be patched. Consolidate mortar into place and strike
off so as to leave patch slightly higher than surrounding surface to permit
initial shrinkage. Leave patch undisturbed for at least 1 hour before final
finish. Keep patched area damp for a minimum of 7 days.
3.13 FINISHES:
B. Broom or roughen the surface of freshly placed shotcrete after shotcrete has reached
initial set when subsequent layers are to be applied.
C. Descriptions of finish:
3. Smooth Form Finish: Remove fins, finish flush with parent shotcrete and
make necessary repairs. Wet and rub finned and repaired areas with
carborundum stone or other abrasive until uniform color and texture are
produced. Complete rubbing not later than 24 hours after the curing period.
A. Secure castings, inserts, conduits and other metalwork encased in shotcrete to prevent
metalwork from being displaced or deformed during shotcrete work.
C. Build dovetail anchor slots into new shotcrete against which facing brick, shotcrete
masonry units, tile, stone or any type ashlar is to be installed. Provide vertically at
24-in. [600 mm] centers where facing brick, etc., passes by shotcrete. Provide one
continuous anchor slot where facing brick, etc., abuts the shotcrete work.
END OF SECTION