DRY&WET SHOTCRETE METHODOLOGY:

The Shotcrete works will be performed according to the following description. The method
may be adjusted during the course of the work if required to accommodate local conditions
encountered on site.
Methodology
Transportation
Transit mixers to be used for the transport of shotcrete approved exhaust filters
underground will be fitted with approved exhaust filters
Dry Shotcrete:
The dry-mix shotcrete will be applied either plain or reinforced with wire mesh. Cement
and Aggregates shall be batched in the proportions specified and designed. Measurement
shall be done by weight. At the time of batching all aggregates shall have been dried.

Mixing of cement and aggregates shall be performed mechanically. Shotcrete shall not
be used unless placing can be completed within a period of 90 minutes from the time of
mixing unless a hydration control admixture is used that is suitable to inhibit setting and
retain consistence for the time span required until placing the shotcrete.

For the dry process, powder or liquid type accelerating admixtures shall be added to the
dry mix. The powder type accelerator shall be proportioned and added just before the dry
mix enters the shotcrete machine through a mechanical device (dispenser). The liquid
accelerator, if used, shall be added at nozzle outlet point.

The optimum distance between nozzle and surface of application is 1.0 to 1.3 meters.
The nozzle shall be positioned at right angles to the surface of application.

Wet Shotcrete:
In this process, liquid type accelerators shall be used. The delivery from the accelerator
pump shall be controlled and to be proportional to the suit the output of the concrete
pump.

Accelerator pump calibration shall be periodically checked in accordance with

manufactures recommendations. The provision of nozzle shall ensure a homogenous
mixture of the accelerator with the wet mix.

Shotcrete shall not be used unless placing can be completed within a period of 120 min.
from the time of mixing unless a hydration control admixture is used that is suitable to
inhibit setting & retain consistence for the time span required until placing the shotcrete.
 The optimum distance between nozzle and surface of application is 1.0 to 1.3 metres.
The nozzle shall be positioned at right angles to the surface of application.

Preparation of Surfaces:
Before spraying of the Shotcrete following preparatory work shall be done:

Loose rock shall be removed from the surface

The rock shall be mapped so the total need for support can be clarified

Immediately prior to the application of shotcrete, all surfaces to receive shotcrete will
be cleaned with compressed air & water jet to remove all loose rocks and dust.

The surface to receive shotcrete should be damp and should not exhibit free water.

Where water is found seeping through the leaks in the rocks and the surface is wet,
the seepage water will be led off either by drainage pipes or shall be blocked by the
Use of an accelerated cement paste-mortar or by grouting.

Spraying of Shotcrete:
First Layer of Shotcrete
Pre-wetting of the surface area shall be carried out unless otherwise specified.
Big cavities shall be carefully built up with layered application of Shotcrete and layer
should not thicker than 150 mm before the main applications.

Shotcrete will be applied to the slope / vertical surface and overhead. For the fast set
process, powder or liquid accelerating admixtures shall be added to the mix. Periodic
calibration checks shall be performed in accordance with the manufacturer's
recommendation.

Dosage pump and hoses to the nozzle shall be kept in good order.
Spraying shall start from the bottom and continue upwards. This is to minimize rebound
losses. Once the columns have been constructed along the surface, both vertically and
horizontally in layers by applying the shotcrete from left to right until it has reached a
layer of not exceeding 150 mm, and thereafter repeated until final closure of the
unsupported surface is covered.

The water content of the aggregates for the dry process shall be kept above 4% in hot
weather in order to avoid cement loss at the rotor of the shotcrete machine. During
transportation, the shotcrete mix shall be effectively protected against the influence of
weather.
Hoses for delivery of shotcrete mix to the nozzle will be of uniform diameter and laid
straight or in gentle curves and will be free of any kinks between the spraying machine
and the nozzle.

Shotcrete is transported by transit mixers from the batching plant to site will be delivered
into the hopper of the Shotcrete spraying machine and transferred to the nozzle.

Second Layer of Shotcrete

Spraying Shotcrete starts from the bottom and moves the nozzle in small circles working
its way up. Care will be taken to avoid applying fresh materials on top of rebound or
over sprayed Shotcrete. It is essential that the air supply is consistent and has sufficient
capacity to ensure the delivery of a steady and uninterrupted stream of high velocity
shotcrete to the rock surface. Applying the second layer of shotcrete will not affect the
compressive strength development of the first layer.

The designed thickness of the shotcrete will be built up in layers.

The velocity and spraying distance shall be the optimum for maximum concrete
adherence and compaction.
Curing:

Sprayed concrete shall be cured in accordance with the EN 206 or in national

recommendations set out in standards any other method which has been shown to allow
continuous hydration of the cement over the curing period.

Approved curing agents maybe used where a further layer of sprayed concrete is to be
applied.

Testing of Shotcrete
Field Suitability Tests:
Field Tests shall be carried out to determine Early and Final strength and establish a
suitable range of accelerator dosage of shotcrete applied in field and adequate results
obtained prior to commencement of excavation.

For each type of accelerating and mix design a trial mix shall be sprayed into test panels
(3 nos. per trial mix). At least 3 different dosages (between 2% and 7%) of the
accelerating admixtures shall be tested following the recommendations of manufacturers.

The compressive strength shall be determined by crushing of cylindrical Shotcrete

specimens. After spraying, the test panels shall be covered and not be moved for 18
hours after spraying the cores for determination of final strength shall be stored in water
for 3 days before testing the specimen diameter of 100 mm and cut to a height of 100
mm.
Consistence
The concrete consistence required for wet spraying depends on the type of conveyance
and the application procedure. For given cement content and w/c ratio admixtures added
at the mixing plant or on site.

Working temperature
The temperature of the mix before placing shall not be below 5°C and shall not exceed
35° unless special provisions are made. Spraying shall not be undertaken when ambient
temperature is below 5°C.

Quality Control Tests

General:
The production of sprayed concrete shall be subject to quality control procedures.
Quality control is defined as a combination of actions and decisions taken in compliance
with specifications and checks to ensure that the specified requirements are satisfied.
Preconstruction tests
Composition of the sprayed concrete is determined in the course of preconstruction tests
in which the required properties of construction material can be checked. Examples of
properties to be checked:
Fresh concrete:
Workability, Pump ability,
Spray ability/Rebound
Density
Dosage of Accelerator
Hardened concrete:
In-Situ Early strength (24 hrs)
Compressive strength at 1, 7 and 28 day.
All tests are to be done on samples taken either from in-situ material or test panels. The
frequency of the tests shall be decided by the designer, bearing in mind the function of
the sprayed concrete (including structural integrity), its design life, and the difficulty of
installation, the environmental classification and the consequences of a failure.

Requirements for Durability:

To produce a durable concrete, which protects the reinforcing steel against corrosion and
withstands satisfactorily the environmental and working conditions to which it is
exposed during it lifetime, the following factors shall be taken into consideration:

Choice of suitable constituents, containing no harmful components, or those which may

interact unfavorably

Choice a concrete composition that satisfies all specified performance criteria.

Chloride content
The chloride content of the in situ sprayed concrete shall not exceed the values that are
specified in ENV 206 Section 5.5.
Alkali content
The alkali content of the aggregate shall comply with the requirements of current
National Standards to prevent alkali-silica reaction.

Requirements related to environmental conditions

The sprayed concrete shall be specified to meet the appropriate environmental exposure
classes given in Section 5 of EN 206 and related prescriptive requirements, with the
following exceptions:
The maximum water/cementations ratio shall not exceed 0.55;

The minimum cement content shall be 400 kg/m

The minimum cover requirements relate to bar and mesh reinforcement

CONSTRUCTION MATERIALS
Cement:
Cements shall comply with the requirements of EN197or alternatively with the National
standards
IS Code: 12269 or regulations of the sprayed concrete. Only cement with established
suitability for sprayed concrete applications shall be used.
Fine& Coarse Aggregate:
Aggregates shall comply with the requirements of the National standards IS Code:
383:1970 and regulations of the sprayed concrete and shall be appropriate to the
requirements of the application.

Water
Water for mixing shall comply with the requirements of EN 1008 or the National
Standards IS Code: 456:2000 and regulations.

Admixtures
Admixtures for concrete and sprayed concrete shall comply with the requirements of EN
934-2 and EN 934-5 or with the National Standards IS Code 9103:1999 or regulations
for the admixture dosages.