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CROM Et. Al. (1991) - Guide To Certification of Shotcrete Nozzlemen (ACI 506.3R-91)
CROM Et. Al. (1991) - Guide To Certification of Shotcrete Nozzlemen (ACI 506.3R-91)
CROM Et. Al. (1991) - Guide To Certification of Shotcrete Nozzlemen (ACI 506.3R-91)
3R-91
GUIDE TO CERTIFICATION OF
SHOTCRETE NOZZLEMEN
This is a guide for a means of certifying wet mix and dry mix Chapter 2 -- Certification production, page 506.3R-2
shotcrete nozzlemen for application of several but not all types of shotcrete.
Certification procedure includes a learning and training period, a
written/oral examination, and a workmanship demonstration.
2.1 -- General
2.2 -- Training and study period
Keywords: certification; evaluation; examinations; placing; refractory 2.3 -- Certification examination
shotcrete; shotcrete; structural shotcrete; tanks (containers); training 2.4 -- Written test
courses; underground shotcrete. 2.5 -- Workmanship demonstration
2.5.1 -- General
CONTENTS 2.5.2 -- Test panel requirements
2.5.3 -- Materials for the demonstration test
Chapter 1 -- Introduction, page 506.3R-2 2.5.3.1 -- Mixture proportions
2.5.4 -- Equipment for the demonstration test
1.1 -- Purpose of nozzleman certification 2.5.5 -- Shotcrete crew
1.2 -- Available procedure for testing nozzlemen 2.5.6 -- Shooting the test panel or area
2.5.7 -- Curing
2.5.8 -- Testing and analysis of test panel or area
ACI Committee Reports, Guides, Standard Practices, and * Members of the Subcommittee which prepared the report.
Commentaries are intended for guidance in designing, This report supersedes ACI 506.3R-82, effective Nov. 1, 1991. A number of minor
planning, executing, or inspecting construction and in revisions have been made to the report. Several key references have been added
and existing references have been updated. The document has been reformatted
preparing specifications. Reference to these documents and reorganized for enhanced clarity.
shall not be made in the Project Documents. If items Copyright © 1991, American Concrete Institute.
found in these documents are desired to be part of the All rights reserved including rights of reproduction and use in any form or by any
means including the making of copies by any photo process, or by any electronic
Project Documents, they should be phrased in mandatory or mechanical device, printed or written or oral or recording for sold or visual
language and incorporated into the Project Documents. reproduction or for use in any knowledge or retrieval system or device, unless
permission in writing is obtained from the copyright proprietors.
506.3R-1
506.3R-2 MANUAL OF CONCRETE PRACTICE
Chapter 3 -- Evaluation of the certification examination, paragraph 1.6.4.2 of ACI 506.2, provides testing pro-
page 506.3R-4 cedures to be conducted prior to the start of shotcrete
construction, to check the operation of the equipment and
Chapter 4 -- Summary, page 506.3R-5 the workmanship of the application crew, particularly the
shotcrete nozzleman. Preconstruction testing may be
Chapter 5 -- References, page 506.3R-5 required for any type of shotcrete construction. It should
verify the ability of the nozzleman to apply the quality of
Appendix A -- Bibliography of shotcrete publications shotcrete specified for the particular job.
Although the procedure is available to pretest the
Appendix B -- General questions on shotcrete practice ability of a nozzleman on a shotcrete project, it may also
be desirable to require that the nozzleman be certified to
Appendix C -- Specific questions on wet mix shotcrete be knowledgeable and to have previously demonstrated
his ability to apply a specific type of shotcrete. The
Appendix D -- Specific questions on dry mix shotcrete presence of a certified nozzleman should not preclude a
degree of preconstruction testing, but should provide
Appendix E -- Specific questions on structural shotcrete increased assurance that the shotcrete applicator will be
able to apply the specified quality of shotcrete. Further-
Appendix F -- Specific questions on underground more, having a certified nozzleman available for small
shotcrete projects may justify the elimination of all or part of the
somewhat costly and time-consuming preconstruction
Appendix G -- Specific questions on refractory shotcrete testing.
Until a reasonable number of nozzlemen have been
Appendix H -- Specific questions on prestressed tank certified, the owner and specifier should carefully weigh
shotcrete the cost and time required to certify a nozzleman against
the size and cost of a shotcrete project, before specifying
that a certified nozzleman be used on the project.
CHAPTER 1 -- INTRODUCTION
CHAPTER 2 -- CERTIFICATION PROCEDURE
1.1 -- Purpose of nozzleman certification
This guide has been prepared to assist those spe- 2.1 -- General
cifiers, public agencies, shotcrete applicators, shotcrete The certification procedure should be divided into
users, testing laboratories, and others who may find it two parts: (1) a training and study period; and (2) the
desirable to broaden their own knowledge and/or to esta- certification examination, which consists of a written (or
blish a procedure for training and certification of shot- oral) examination and a field demonstration test.
crete nozzlemen. Since at this time, no official certi-
fication programs based on this guide are recognized, 2.2 -- Training and study period
modifications in procedure and questionnaires to suit local The applicable publications listed in the bibliography
requirements are encouraged. Nothing included herein is found in Appendix A should be available to certification
mandatory, this being only a guide with the goal of examiners and examinees prior to the certification ex-
eventual establishment of a uniform national certification amination. Answers to most of the questions asked in the
program for shotcrete nozzlemen. certification examination written test are in the biblio-
Training and examining personnel will find the graphy publications.
bibliography and certification procedure in the guide to be
helpful tools in any educational program to: (1) train new 2.3 -- Certification examination
nozzlemen and other members of the shotcrete crew; or The certification examination should be conducted
(2) increase the knowledge and broaden the capabilities by qualified personnel of an independent testing lab-
of their trained personnel to possibly include additional oratory, materials bureau, local ACI Chapter, or the
types of shotcrete applications. This guide does not imply testing laboratory of a public agency. The testing lab-
that an individual nozzleman is required to prepare him- oratory or materials bureau should issue the actual
self unaided for certification, although that possibility is certification, which should be valid for a stated period of
not precluded. It is the intent that qualified personnel, two or three years. The nozzleman may renew his certi-
with the aid of this guide, references included herein, and fication by repeating the entire examination or, at the
other experience, will train and prepare candidates for option of the certification examiner, by repeating the
certification. workmanship demonstration only.
The examination may be adapted to certify dry mix
1.2 - Available procedure for testing nozzlemen or wet mix shotcrete nozzlemen in the following types of
ACI 506R, Chapter 3 -- Preconstruction testing, or shotcrete applications:
CERTIFICATION OF SHOTCRETE NOZZLEMEN 506.3R-3
a) Structural proper type of shooting surface for the test panel or area,
b) Refractory the proper thickness of the shotcrete application to cor-
c) Underground relate with acceptable core or cube dimensions, mix pro-
d) Prestressed Tanks portions for dry mix or concrete proportion mix for wet
e) Special Products -- Fiber-reinforced shotcrete, mix, and normal reinforcement requirements.
latex modified shotcrete, and others as the The test panel or area should be checked by the
need develops. certification examiner to verify that the forms are ade-
quately braced, reinforcing steel bar laps are spaced 2½
It is recommended the examination consist of two bar diameters apart, mesh is lapped 1½ squares, rein-
parts, a written (or oral) test, and a field workmanship forcement is properly spaced and rigidly tied and secured
demonstration. to avoid movement during the shotcrete operation, and
shooting surfaces and reinforcement are clean and pro-
2.4 -- Written test perly prepared to receive shotcrete application.
The written test offered herein is divided into three 2.5.2 Test panel requirements -- The surface to be
sections. The questions in the first section are based on shot against, anchorages, reinforcement, panel orientation
general shotcrete practice. The second section of the test (vertical, horizontal, or overhead), total sample thickness,
presents specific questions on the particular types of shot- material, and mix shall duplicated job requirements as
crete for which the examinee may be certified. The third nearly as practical.
section of the test presents specific questions on the 2.5.3 Materials for the demonstration test -- The
particular types of shotcrete application for which the certification examiner may refer to ACI 506R-90, Chapter
examinee may be certified. 2 -- Materials, as a guide for quality requirements for
shotcrete materials. The certification examiner should
1. General Questions: Ten questions may be selected consult with the shotcrete applicator to establish the
in part or entirely from the questions listed in materials and mix proportions for the test.
Appendix B. 2.5.3.1 Mixture proportions -- If sufficient data
are available from previous tests of the materials, shot-
2. Specific Type Shotcrete Questions: Fifteen or more crete mixture proportions may be selected from such data
questions may be selected in part or entirely from to produce a given compressive strength.
the questions listed in Appendixes C (Dry Mix), or If insufficient or no previous data are available, at
D (Wet Mix). least three shotcrete control test panels with a minimum
thickness of 3 in. (75 mm) should be shot by an exper-
3. Specific Type Application Questions: Fifteen or ienced nozzleman using different proportions. Cores or
more questions may be selected in part or entirely cubes taken from the test control panels shall be removed
from the questions listed in Appendixes E, F, G, and tested in accordance with ASTM C 42. See paragraph
and H. 2.5.8 for additional requirements.
Based on the compressive strength achieved by the
The certification examiner may give this test either cores or cubes taken from the test control panels, a mix-
orally or written. ture proportion should be selected for the test which
should produce shotcrete with a 28-day compressive
2.5 -- Workmanship demonstration strength of a least 4000 psi (27.5 MPa). Core strengths
2.5.1 General -- The examinee should be required to should be corrected to an L/D of 2 in accordance with
demonstrate his ability to correctly and successfully apply ASTM C 42 and cube strengths should be reduced by 15
the type of shotcrete for which he will be certified. percent in accordance with ACI 506.2. Compressive
Effective nozzling is a skill learned from experience and strength and setting time requirements for refractory test
is physically demanding. Only persons who are physically panels differ from other mixes. Where quick-setting
able and experienced should be allowed to take the exam. additives or comments are used, compressive strength and
A test panel or test area, simulating a surface setting time may be adjusted to test for initial set time
suitable for the type of shotcrete for which the examinee and initial strength in addition to ultimate compressive
is to be certified, should be shot by the examinee using strength.
the equipment, materials, mix proportions, and rein- 2.5.4 Equipment for the demonstration test -- The test
forcement normally used for the particular type of shot- should be conducted using equipment of a design and size
crete. The test panel or area should be a minimum of 4 ft. normally used for the specified type of shotcrete. The cer-
(1.2 m) square to allow the examinee to adequately tification examiner may refer to ACI 506R, Chapter 4 --
demonstrate his ability. Provision may be made to accum- Equipment Requirements, as a guide for recommended
ulate and measure rebound from the panel or test area. equipment requirements for either the dry mix process or
Certification requirements may vary from different the wet mix process.
types of shotcrete, and the certification examiner should 2.5.5 Shotcrete crew -- A competent crew, including
consult with the shotcrete applicator to establish the an experienced gunman or pump operator, nozzle helper,
506.3R-4 MANUAL OF CONCRETE PRACTICE
and possibly a finisher, should be provided to assist the CHAPTER 3 -- EVALUATION OF THE
nozzleman examinee in his demonstration. CERTIFICATION EXAMINATION
2.5.6 Shooting the test panel or area -- The
certification examiner should carefully observe shooting of
the test panel or area, and note if the nozzleman The value of the three segments of the examination
examinee: may be weighted as follows:
1. Cleans shooting surface with air and water prior to Written or Oral Examination
shooting.
1. General Questions - 10 percent
2. Applies bonding coat on shooting surface ahead of 2. Specific Type Questions - 15 percent
heavier shotcrete applications. 3. Specific Use Questions - 15 percent
4. Workmanship Demonstration - 60 percent
3. Directs shotcrete application around reinforcement
in a manner which prevents buildup on face of
reinforcement and allows shotcrete to flow and The examinee should attain an overall 70 percent
compact tightly around back and remainder of grade to pass, with not less than a 60 percent grade in any
reinforcement. single segment of the examination.
Allow 100 points for both the general and each of
4. If applicable, directs finisher or nozzle helper to cut the specific question segments, making the value of each
out any sags or sand pockets. question correspond with the total number of questions
used to achieve 100 points.
5. If applicable, and where necessary, directed finisher The examinee shall achieve a passing grade in the
or nozzle helper to broom shotcrete surface prior to written or oral examination before he is allowed to pro-
application of additional layer of shotcrete. Notes, ceed with the workmanship demonstration.
photographs, or other documentation made by the Allow 100 points for the workmanship demon-
certification examiner during gunning of the test stration test. Deduct points for unsatisfactory parts of
panel or area will be helpful later in testing and shotcrete application as noted below. All items should be
analyzing the test panel or area. evaluated and graded.
2.5.7 Curing -- The test panel or area should be 1. Compressive strength tests -- Average strength of
properly cured in accordance with ACI 506R, Chapter 6-- three cores or modified cube results below strength
paragraph 6.4 -- Curing and Cold Weather Protection, established for test -- deduct SO points
and ACI 506.2, paragraph 3.7.
Curing requirements for refractory shotcrete panels 2. Encasement of reinforcement -- Sandy pockets or
should be in accordance with ACI 547R. voids around or behind reinforcement or sags under
2.5.8 Testing and analysis of test panel or area -- Tests horizontal reinforcement -- deduct 15 points
and observations of the test panel or area will be used to
evaluate the workmanship demonstration. 3. Sand pockets or voids in corners of panels -- deduct
A minimum of six cores or cubes should be cut from 1-7 points
the panel or test area. Three cores or cubes cut through
unreinforced sections of the test panel or area should be 4. Sags or sandy pockets apparent on stripped sides or
subjected to compressive strength tests. Test results will backs of panels -- deduct 1-7 points
be compared with the compressive strength requirement
established for the test. At least three cores or cubes 5. Sand lenses within the destroyed panel -- deduct 1-7
should be cut through the reinforcement for analysis of points
quality and extent of shotcrete encasement. All cores or
cubes should be examined for evidence of sand pockets, 6. Failure of nozzleman to clean shooting surface with
voids, and sags. air and water prior to shotcrete application --
Where applicable, the stripped side of the panel deduct 1-7 points
should also be examined for evidence of sags, sand
pockets, and lack of bonding coat. Corners and other 7. Excessive rebound -- Local shotcrete testing
sections of the panels or areas should be cut or broken requirements may make it necessary to include
open for observation of laminations, sand lenses, or other measurement of rebound from a test panel or area
defects. as part of the test. Any deductions of points for
The certification examinee should be allowed to excessive rebound should be made in accordance
examine the cores or cubes and cut or broken sections of with value established locally for allowable amount
the test panel or area. of rebound -- deduct 1-7 points
CERTIFICATION OF SHOTCRETE NOZZLEMEN 506.3R-5
11. Crom, T.R. “Dry Mix Shotcrete Nozzling,” (The 11. Curing fresh shotcrete is
Crom Corporation, 250 S.W. 36th Terrace, Gainesville, necessary to:
Florida 32607). a. Keep surface clean X
b. Minimize shrinkage cracking X
APPENDIX B -- GENERAL QUESTIONS ON c. Make shotcrete strong by
SHOTCRETE PRACTICE WHICH MAY BE USED chemical action X
FOR THE FIRST PART OF THE
SHOTCRETE NOZZLEMAN CERTIFICATION 12. When encasing reinforcing steel,
WRITTEN EXAMINATION the nozzleman should:
a. Hold nozzle closer than
(The correct answer is indicated by an X. In using the usual X
questionnaire, the examiner should recopy adding any further b. Keep the face of the bar
questions desired and omitting the X's) T F clean, so he can use steel
until buried X
1. Laitance on a layer of shotcrete
must be removed prior to the 13. Reinforcing steel fibers can be
application of the next layer added to both dry mix and wet
of shotcrete. X mix applications. X
2. In the wet mix shotcrete process 14. The following shooting surfaces
water is usually introduced at the should be damp but without
nozzle. X ponding or running free surface
water prior to application of
3. Shotcrete may be applied against shotcrete:
an overhead shooting surface. X a. Earth X
b. Concrete X
4. As the nozzleman works closer to c. Brick (masonry) X
the delivery equipment (gun or
pump), lengths of hose should be
removed. X
a. Reduce the slump by adding a you have 600 cfm (17 m3/minute)
little dry sand X air compressor or larger. X
b. Add a little more water X
c. Contact the job 19. As a general rule, shotcrete should
superintendent X be applied perpendicular to the
d. Shoot it X receiving surface. X
5. Generally, hose plugs may be caused by: 20. The nozzleman when encasing steel
a. Continuous pumping all day X should be about 7 ft from the
b. Improperly designed pump receiving surface. X
concrete mix X
21. When encasing steel against a
6. Concrete pumps should not be cycled vertical surface, the slump range
in reverse prior to disconnecting can be:
any portion of the pipeline. X a. 3 to 5 in.
(75 to 125 mm) X
7. The nozzleman should always turn b. 1 to 3 in. (25 to 75 mm) X
off the nozzle air valve whenever c. 0 to 1 in. (0 to 25 mm) X
pumping has stopped. X
22. A small aggregate mix requires
8. Hose plugs should be cleared by less cement. X
applying full forward pumping
pressure. X 23. Since air is added at the nozzle,
the concrete line does not have
9. Gradation of pump mix aggregates much pressure. X
does not matter. X
24. A nozzleman can tell that he is
10. The concrete pipeline interior is properly encasing steel when he
lubricated by the cement paste of can see shotcrete build up on the
the concrete mix. X face of reinforcing steel. X
11. Reducers should be checked 25. Overspray from wet mix is good
occasionally for wear. X material and doesn’t have to be
cleaned off bars not encased. X
12. The hopper area of the pump
should never be entered during 26. Generally, concrete should be
pumping operations. X placed within 1½ hours from the
time batched. X
13. Wall sections are best started by
shooting at the top and working 27. Corners should be shot last. X
downward. X
28. Rebound that falls into a corner
14. Extreme caution is needed when should be shot in. X
concrete hose clamps are opened. X
5. The bond strength of shotcrete to 14. A 3 in. (75 mm) thick shotcrete
brick can be stronger than the wall will produce a higher percent-
shear strength of the brick. X age of rebound than a 7 in.
(175 mm) thick shotcrete wall.
6. A 10 in. (250 mm) thick wall
should be constructed full thick-
ness from the bottom upward to
the top, with the nozzleman
keeping the upper shooting surface APPENDIX F -- SPECIFIC QUESTIONS ON
sloping down toward him at an UNDERGROUND SHOTCRETE WHICH MAY BE
angle of approximately 45 USED FOR THE SECOND PART OF THE
degrees. X SHOTCRETE NOZZLEMAN CERTIFICATION
WRITTEN EXAMINATION
7. Small core holes made in a
completed shotcrete wall should be (The correct answer is indicated by an X. In using this
filled with shotcrete. X questionnaire, the examiner should recopy adding any further
questions desired and omitting the X's.) T F
8. A shotcrete finish coat will bond to
a previously placed layer of shot- 1. If dry, the underground shooting
crete which was left properly surface should be dampened
broomed and is properly cleaned before shooting. X
with air-water blast immediately
before application of the final coat: 2. The most common type of under-
a. If final coat is applied ground shotcrete application in the
24 hr later X United States is the hand-held
b. If final coat is applied nozzle technique. X
4 days later X
3. In a tunnel, shotcrete application
9. A nozzleman should shoot a thin should start at the crown and follow
bonding coat of shotcrete slightly, down the arch to the springline. X
ahead of the application of a
heavier layer of shotcrete on the 4. It is considered good practice to
following shooting surfaces: reuse rebound in subsequent
a. Wood forms X batches. X
b. Concrete X
c. Brick (masonry) X 5. Two main advantages of remote
d. Steel X nozzling are:
a. Nozzleman is in a safer
10. To avoid sand pockets in the position to avoid rock fall X
506.3R-10 MANUAL OF CONCRETE PRACTICE