Shotcrete and its Potential

Applications on Ontario
Construction Projects
Webinar
September 19th, 2018
Housekeeping
 45 minute webinar with 15 minutes Q & A
 All attendees are muted
 Questions? Use ‘Questions’ Pane
 Webinar will be recorded and posted on the Concrete
Ontario YouTube channel. www.ConcreteOntario.org
Presenter
Ryan Regier, MASc., EIT
Contracts Manager
HCM Shotcrete
RyanR@hcgroup.ca
 Civil Engineering Degree
 Structural Graduate Degree
• SHM Reinforced Concrete Bridges
 5+ years of Heavy Civil PM Experience
Webinar Outline
• Definition of Shotcrete
• History of Shotcrete
• Shotcrete Processes
• Shotcrete Specification
• What’s in the mix?
• Applications of Shotcrete
• Shotcrete Advantages
Definition of Shotcrete
• ACI CT-13 Concrete Terminology:
“Concrete placed by a high
velocity pneumatic projection
from a nozzle.”

• Shotcrete is not a product, it is

simply a method of placing
concrete
History of Shotcrete
• 1895 – Development of the original
cement gun
• 1905-10 - Original Shotcrete Gun
patented in the USA
• 1915 - Trade name “Gunite”
• 1920 – Patented in Germany
History of Shotcrete
• 1930 - American Railway Association
introduced “shotcrete” terminology
• 1940 – Coarse aggregate introduced
• 1945 – ACI adopts the term “shotcrete”
• 1950 – Inception of ACI 506
• 1955 – Wet Mix method introduced
• 1970 – Steel fibre reinforced shotcrete
• 1975 – Silica Fume shotcrete
History of Shotcrete
• 1983 – Introduction of pre-bagged dry
mix shotcrete
• 1985 – Air entrainment in dry-mix
• 1998 – American Shotcrete Association
• 2000 – ACI Nozzleman Certification
established
• Now - Shotcrete being rapidly used in
the construction industry
Shotcrete Processes
• The two processes describe the material prior to entering a machine:
• Wet Process
• Dry Process
• Material exits nozzle at high velocity
• Velocity decreases as stream fans out
• Lower impact velocity produces less compaction
• ~1,000-1,500 psi compaction on receiving surface
• Importance of consistency of material & nozzle angle
Dry Mix Process
• Dry-mix shotcrete process:
• The dry material is conveyed through a hose in an air stream at high velocity; water is
added at the nozzle to produce plastic material on impact. Mixing of water and the dry
material occurs at the nozzle and on the receiving surface.
Dry Mix Process
Dry Mix Process
• Dry-mix shotcrete Nozzle:
• Dry Mix nozzle tips help with
material mixing.
• Removable tips increase the
material velocity.
• Tip lengths and shapes will change
the material spray pattern.
• Hydro-mix nozzle eliminates pre-
dampening
Wet Mix Process
• Wet-mix shotcrete process
• Concrete is pumped through a
hose and air is added at the nozzle
to accelerate the mixture to a high
velocity.
Wet Mix Process
Wet Mix Process
Dry vs Wet Process?
Shotcrete Placement
• Performed by ACI certified Nozzleman
• Proper placement requires:
• Good compaction
• High Velocity
• Receiving surface free of overspray and
rebound
Shotcrete Placement
• Generally the same basic shooting principles apply for both wet-mix and
dry-mix shotcrete

• Sufficient impact velocity and proper plasticity

• Nozzle at 90° to receiving surface to maximize

compaction and minimize rebound
Shotcrete Placement
• Fill corners, voids & holes first
• Continuously move the nozzle with small
circular motion to build up uniform layers

Elevation view
Shotcrete Placement
Correct Method

Incorrect
Shotcrete Placement – Typical Set-up
Shotcrete Placement – Typical Set-up
Shotcrete Placement – Typical Set-up
Shotcrete Placement – Typical Set-up
Shotcrete Placement – Typical Set-up
 Shotcrete Specification
• ACI 506R - Guide to Shotcrete • OPSS 931 Structure Rehabilitation
- Shotcrete
Shotcrete Specification
• Environmental Conditions
• Surface Preparation
• Reinforcement
• Shotcrete Mix Components
• Quality Assurance
• Shotcrete Application
• Finishing and Curing
Shotcrete Specification
• What’s in the Mix
• Cement Content: shotcrete mixes are typically high cementitious mixes
(420kg/m3to 450kg/m3) with silica fume.

• Water to Cement Ratio: due to the nature of placing shotcrete, mixes are
typically designed with a low water to cement ratio (maximum 0.5) to
maintain a high degree of plastic material cohesion.
Shotcrete Specification
• What’s in the Mix
• Aggregate: Shotcrete differs from conventional mixes in aggregate makeup.

• Shotcrete mixes contain relatively high volumes of sand (40% to 60% volume/volume
shotcrete) and moderate volumes of course aggregate (10% to 20% volume/volume
shotcrete).

• Course aggregate size is generally limited to nominal maximum size of 13mm.

Shotcrete Specification
• What’s in the Mix
• Air-Entraining Admixtures: Improve pumpability and adhesion in wet-mix
shotcrete and freeze-thaw durability

• Fibres: Control cracking, increase toughness values, improve impact

resistance and energy adsorption

• Accelerators: improve placement characteristics in adverse conditions,

allow for thicker single pass applications, larger productions, and reduce the
occurrence of fallouts on structures subject to vibration
Shotcrete Specification
• What’s in the Mix – Wet-Mix – Foundation Wall
• Cement content with 8% Silica Fume 420 -450 kg/m3
• Coarse Aggregate 450-550 kg/m3
• Fine Aggregate (Fineness Modulus 2.5) 1150-1250 kg/m3
• Total Water (corrected for sand moisture) 155-165 kg/m3
• Water Reducer 250-350 ml/100kg
• Air Entraining 50-100 ml/100kg

• Slump range max 70mm +/- 20mm

Shotcrete Applications
• Shotcrete Advantages:
• Wet process shotcrete with a focus in structural shotcrete as a substitute
for formed construction in blind wall applications, structural liners (silos,
tanks, tunnels), and architectural concrete.

• Dry process shotcrete with a focus in rehabilitation of existing structures

and remote access concrete placement (mines, dams, work at heights).
Shotcrete Applications
• Shotcrete Advantages:
• Elimination of crane lifts related to concrete placement and delivery
• Elimination of time, labour, and materials related to formwork construction,
erection, stripping, and re-finishing;
• Increased daily production of finished concrete elements per day resulting
in schedule savings;
• Increased compressive strength, high grade finish, durability, and quality;
Shotcrete Applications
• Shotcrete Advantages:
• Improved resistance to waste washout, and sulphate attack.
• Superior resistance to freeze-thaw cycling and salt scaling resistance;
• Ability to review and verify wall conditions (embeds, reinforcing steel,
waterproofing, water stops, etc.) until concrete is placed;
• Ability to visually review concrete placement at all wall areas unlike “blind
wall” construction, and;
• Seamless and/or architectural finishing without the use of form liners;
Shotcrete Applications
• New Construction – Foundation Walls
Shotcrete Applications
• New Construction – Retaining Walls
Shotcrete Applications
• New Construction – Architectural Retaining Walls
Shotcrete Applications
• Infrastructure Rehabilitation – Parking Garages
Shotcrete Applications
• Infrastructure Rehabilitation - Tunnels
Shotcrete Applications
• Infrastructure Rehabilitation - Tunnels
Shotcrete Applications
• Infrastructure Rehabilitation - Bridges
Shotcrete Applications
• Infrastructure Rehabilitation - Bridges
Shotcrete Applications
• Infrastructure Rehabilitation - Bridges
Shotcrete Applications
• Infrastructure Rehabilitation – Water reservoirs, Canals, and Spillways
Shotcrete Applications
• Infrastructure Rehabilitation - Culverts
Shotcrete Applications
• Infrastructure Rehabilitation - Culverts
Shotcrete Applications
• Infrastructure Rehabilitation – Marine Structures
Shotcrete Applications
• Infrastructure Rehabilitation – Storage Tanks
Shotcrete Applications
• Infrastructure Rehabilitation – Dam’s and Silo’s
Shotcrete Applications
• Infrastructure Rehabilitation – WWTP’s
Shotcrete Applications
• Infrastructure Rehabilitation – Sewers
Shotcrete Applications
• Ground Support – Tunneling and Mining
Shotcrete Applications
• Ground Support – Soil Nailing
Shotcrete Applications
• Ground Support – Rock Protection
Shotcrete Applications
• Ground Support – Slope Stability
Shotcrete Applications
• Architectural – Subway Entrance
Shotcrete Applications
• Architectural – Landscapes / Zoos
Shotcrete Applications
• Recreation – Pools/ Water-features / Skateparks
Shotcrete Applications
• Luge Tracks
References
• CSA 23.3 and 23.4
• OPSS 931
• ACI 506 R
• ASA – Shotcrete Specifications Introduction
• HCM Shotcrete Past Projects
Questions
Upcoming Webinars
1. October 23 – MTO Specification Updates
2. November 14 – Concrete Chute Secondary
Restraint Methods
3. December 12 – Seasonal Loads
4. January 17 – Preparing for MOE plant
inspections