a review of shotcrete materials, mix design and applications department of civil engineering,...
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A REVIEW OF SHOTCRETE MATERIALS, MIX DESIGN AND
APPLICATIONS
Department of Civil Engineering, University of Cape Town
Shotcrete for Africa Conference
2 – 3 March 2009
M G Alexander and R Heiyantuduwa
University of Cape Town Concrete Materials and Structural Integrity Research Group
Overview
• Introduction
• Shotcrete processes
• Applications of shotcrete
• Shotcrete materials and mix design
• Properties of shotcrete
• Conclusions
IntroductionShotcrete is a form of concrete commonly made with small
sized aggregate, pneumatically projected at high velocity from
a nozzle onto a suitable substrate to produce a dense
homogeneous mass.
Advantages of Shotcrete:• Economical • Formwork not required• Can achieve high compressive
strengths• Good bond with various substrates
Shotcrete processes – dry mix process
Transport pneumatically
Aggregate
Cementitious material
Water
Admixture: powder
Admixture: liquid
Fibres
Batch
Batch
Batch
Batch
Batch
Mix
Mix in nozzleGauge by eye
Put into mechanical
feeder
Project onto
surface
Gauge by flowmeter
Mix
Shotcrete processes – wet mix process
Aggregate
Cementitious material
Water
Admixture: conventional
Admixture: special
Fibres
Batch
Batch
Batch
Batch
Batch
Pump
Project onto surface
Inject
Batch
MixAggregate
Cementitious material
Water
Aggregate
Cementitious material
Water
Aggregate
Cementitious material
Batch
Water
Aggregate
Cementitious material
Batch
Batch
Water
Aggregate
Cementitious material
Batch
Batch
Batch
Water
Aggregate
Cementitious material
Mix
Batch
Batch
Batch
Water
Aggregate
Cementitious material
Mix
Batch
Batch
Batch
Water
Aggregate
Cementitious material
Mix
Batch
Batch
Batch
Water
Aggregate
Cementitious material
Put into delivery equipment/pump
Mix
Batch
Batch
Batch
Water
Aggregate
Cementitious material
Inject compressed air
Put into delivery equipment/pump
Mix
Batch
Batch
Batch
Water
Aggregate
Cementitious material
Pump
Inject compressed air
Put into delivery equipment/pump
Mix
Batch
Batch
Batch
Water
Aggregate
Cementitious material
Pass through nozzle
Pump
Inject compressed air
Put into delivery equipment/pump
Mix
Batch
Batch
Batch
Water
Aggregate
Cementitious material
Project onto surface
Pass through nozzle
Pump
Inject compressed air
Put into delivery equipment/pump
Mix
Batch
Batch
Batch
Water
Aggregate
Cementitious material
Aggregate
Cementitious material
Water
Aggregate
Cementitious material
BatchWater
Aggregate
Cementitious material
Batch
BatchWater
Aggregate
Cementitious material
Batch
Batch
BatchWater
Aggregate
Cementitious material
Aggregate
Cementitious material
Aggregate
Water
Cementitious material
AggregateAggregate
Cementitious material
Aggregate
Water
Cementitious material
Aggregate Batch
Water
Cementitious material
Aggregate
Batch
Batch
Water
Cementitious material
Aggregate
Batch
Batch
Batch
Water
Cementitious material
AggregateMix
Batch
Batch
Batch
Water
Cementitious material
AggregatePut into delivery equipment/pump
Mix
Batch
Batch
Batch
Water
Cementitious material
AggregatePumpPut into delivery
equipment/pumpMix
Batch
Batch
Batch
Water
Cementitious material
Aggregate
Pass through nozzle
PumpPut into delivery equipment/pumpMix
Batch
Batch
Batch
Water
Cementitious material
Aggregate
Inject compressed air
Pass through nozzle
PumpPut into delivery equipment/pump
Batch
Batch
Batch
Water
Cementitious material
Aggregate
Project onto surface
Inject compressed air
Pass through nozzle
PumpPut into delivery equipment/pump
Batch
Batch
Batch
Water
Cementitious material
Aggregate
Water
Cementitious material
Batch
Water
Cementitious material
Batch
Batch
Water
Cementitious material
Batch
Batch
Batch
Water
Cementitious material
Put into delivery equipment/pump
Batch
Batch
Batch
Water
Cementitious material
Inject compressed air
Put into delivery equipment/pump
Batch
Batch
Batch
Water
Cementitious material
Pump
Inject compressed air
Put into delivery equipment/pump
Batch
Batch
Batch
Water
Cementitious material
Pass through nozzle
Pump
Inject compressed air
Put into delivery equipment/pump
Batch
Batch
Batch
Water
Cementitious material
Project onto
surface
Pass through nozzle
Pump
Inject compressed air
Put into delivery equip. / pump
Batch
Batch
Batch
Water
Cementitious material
Comparison of dry and wet-mix processes
Dry-mix process Wet-mix processInstantaneous control over mixing water and consistence of mix at the nozzle.
Better suited for mixes containing low-density aggregates, refractory materials and shotcrete needing early strength.
Batches of mixed material are capable of being transported longer distances.
Mixing water is controlled at the point of manufacture and can be measured.
Special mixing and transporting equipment needed.
Less dust generation and cement loss.
Comparison of dry and wet-mix processes (cont‘d)
Dry-mix process Wet-mix processMinimal waste and greater placement flexibility.
Low water/cement ratio results in higher strengths.
Very operator sensitive.
Better assurance that the mixing water is thoroughly mixed with other ingredients.
Higher wastage.
Lower rebound.
Capable of greater production.
Higher cost of placed material.
Applications of shotcrete
• New structures• Linings and coatings• Repair • Strengthening and reinforcing• Support of underground openings • Refractory shotcrete• Special shotcrete
Materials and mix designCementitious materialso SABS EN 197-1 common cements of Type I and Type II o Type III cements should only be used in the 42.5 strength o class
(Above cements often contain mineral additives in the blend)o Condensed Silica Fume (CSF) o Calcium Aluminate Cement
Aggregateso Aggregate used for shotcrete should comply with
requirements for use in conventional concrete i.e. SANS 1083.
o Rounded aggregates are preferable (but are frequently crushed in SA, and therefore angular)
o Well graded aggregate is important with no fraction constituting more than 30% of the total
Materials and mix design (cont‘d)
Mixing water
The requirements for mixing water are the same as for
conventional concrete i.e. clean and potable.
Admixtures
Accelerators, air-entraining admixtures, pozzolanic additives,
plasticisers, retarders, activators
Reinforcement
Weldmesh, fibre reinforcement: polymeric or steel
Materials and mix design
Typical shotcrete mix proportions
Mass (per m3)
Cementitious content - dry mix 350 – 450 kg
- wet mix 400 – 500 kg
Silica Fume (5 – 12 % of cementitious mass) 30 – 50 kg
Water/cementitious ratio 0.35 – 0.5
Aggregate/cementitious ratio 3 – 5
Steel fibre (when present) 30 – 50 kg
Typical properties of shotcrete vs. cast concrete
Property High quality
shotcrete
Cast in situ
concreteCompress. strength, 1 d (MPa) 20 6 (estim.)
Compress. strength, 28 d ( MPa) 30-60 30-50
Elastic modulus, 28 d (GPa) 34 31 (estim.)
Poisson’s ratio, 28 d 0.18 0.15 – 0.22
Tensile strength, 28 d (MPa) > 2 (estim.) 3.8 (estim.)
Initial setting time (start-end) (min) 3 – 5 45 – 145 (estim.)
Typical properties of shotcrete vs. cast concrete (Cont’d)
Property High quality
shotcrete
Cast in situ
concreteShrinkage after 100 d (%) 0.06 – 0.12 0.03 – 0.08
Specific creep - 60 d (%/MPa) 0.01 – 0.06 0.008
Density (kg/m3) 2140 – 2235 2200 – 2450
Total porosity (%) 15 – 20 12 – 18
Permeability (m/s)
10-12 to 10-14 10-11 to 10-12
Microcracking, 28 d (cracks/m)
1300 -
Coefft. of thermal expan. (K-1) 8 – 15 x10-6 8 – 12 x10-6
Slump (estimate) (mm)
0 to 200 50 to 120
Durability of shotcrete
Particularly for linings in tunnels:o Carbonation o Infiltration through the lining of pure waters or waters
carrying aggressive agents, resulting in leaching and/or degradation
Durability testing
Can be done on mock-up panels
Should also preferably be done on in-situ samplesBoiled Absorption (BA)Volume of Permeable VoidsDurability Index tests (SA tests currently being
developed for conventional concrete)
Conclusions
• The properties and performance of shotcrete are largely dependent on the conditions under which it is placed (i.e. curing, compaction) as well as on the characteristics of the particular equipment, and ultimately on the competence and experience of the application crew.
• Based on improvements in material quality and versatility, which provide enhanced physical properties, shotcrete techniques could further replace more conventional construction procedures.