SHOTCRETE TECHNOLOGY

Shortcreting has proved to be the best method for construction of curved surfaces. Domes are now much
easier to construct with the advent of with this shotcrete technology. Tunnel linings are also becoming
easy technology.
DEFINITION OF SHOTCRETE
Applied mixture of cement, aggregate, and water conveyed through a hose and projected at high velocity
onto the application 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.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.
HISTORY
Shotcrete, then known as gunite (/ˈgənīt/), was invented in 1907 by American taxidermi Carl Akeley to
repair of Columbian Museum in Chicago (the old Palace of Fine Arts from the World's Columbian
Exposition). He used the method of blowing dry material out of a hose with compressed air, injecting
water at the nozzle as it was released. In 1911, he was granted a patent for his inventions, the "cement
gun", the equipment used, and "gunite", the material that was produced.
SHOTCRETE MATERIALS
The shortcrete materials are same as cement like portland cement, water, sand, admixture, fiber etc. The
main difference with concrete is that it is provided via compressed air.
NOVEL SHOTCRETE MATERIALS
 Polymer modification
 Pozzolanic admixtures
 Fiber reinforcement
 Low velocity shotcrete
 Steel fibre reinforced micro silica shotcrete

EQUIPMENTS USED IN SHOTCRETE

 Batching and mixing equipment
 Admixture dispensers
 Air COMPRESSOR
 Nozzles
 Shotcrete accelerator
SHOTCRETE VERSUS CONVENTIONAL CONCRETE
 Unlike conventional concrete, which is first placed and then compacted in 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.
 Shotcrete is not placed or contained by forms. It can be impacted onto any type or shape of surface,
including vertical or overhead areas.

Working of dry process

 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.
 The maximum production achievable with dry process equipment ranges from 10-12 yards per hour of
dry mix depending on the conditions.
 Most applications have production rates of 2-6 cubic yards per hour of mix.

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.
Definition of Wet Mix Shotcrete
• Shotcrete in which all of the ingredients, except accelerator, are mixed before introduction into the
delivery hose. Accelerator, if used, is added to the shotcrete mixture at the nozzle in such a way that the
quantity can be properly regulated and monitored.
Working of wet process
 Step 1: Wet material is pumped to the nozzle where compressed air is introduced to
 Step2: All ingredients, including water, are thoroughly mixed and introduced into the shotcrete
equipment.
 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 same as for the dry process and for coarse aggregate mixes; 20-30 percent of
20mm aggregate is added. Cement content will vary according to age.
 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
APPLICATION OF SHOTCRETE
 Support of underground openings in tunnel, mines, drainage.
 Rock slope stabilization and support for excavated foundations, often in conjuction with rock and soil
anchor systems.
 Channel linings, protection of bridge abutments and stabilization of debris-flow prone area.
 Rehabilitation of reinforced concrete structures such as bridges, chemical processing and handling
plants.
 Rehabilitation of deteriorated marine structures such as bulkheads, piers etc.
ADVANTAGES
 Little or no framework is required.
 Cost effective method for placing concrete.
 Ideal for irregular surfaces application.
 Allows for easier material handling in areas with difficult access.
 Easy start up, shutdown and clean up.
 An increase in load bearing capacity due to redistribution of stresses.
 Excellent corrosion resistance
DISADVANTAGES
 Rain may wash out the cement leaving a sandy surface, or it may saturate the shotcrete and cause
sloughing or sagging
 Strong wind will separate the material between the nozzle and the point of deposit, reducing the
strength
 It requires skilled and experienced labours.
 A greater degree of geotechnical knowledge is required
 Improperly applied shotcrete may create conditions much worse than the untreated condition