SPRAYED CONCRETE

BY
NIBHA GIRIDHAR
 HISTORY
o Sprayed concrete was originated in USA.
o In 1895 at the Field Museum of Natural Science in

Chicago USA, the curator, Dr Carlton Akeley devised

a method of constructing plaster models of large animals.
He sprayed plaster on to the framework with a special gun.
He developed a single chamber pressure vessel which contained
mixture of cement and sand. When pressurized with compressed air
the mixture was forced through an opening and along a delivery
hose. At the end of the hose was a nozzle which was fitted with a
water spray. When passing through this spray the mixture was
hydrated. This equipment was known as the “Cement Gun” and the
sprayed material named “Gunite”.
The system has different names in different countries such as
Blastcrete, Blowcrete, Guncrete, Jetcrete etc.

The term “Shotcrete” is often used when describing mix whose

maximum aggregate size is more than 10mm.

“Shotcrete” – in USA
“Sprayed Concrete” - in Europe.
The acceptance and use of sprayed concrete is now worldwide.

Sprayed concrete is a mixture of cement, aggregate and water

projected pneumatically from a nozzle into place to produce a
dense homogeneous mass.
 PROPERTIES
 lower water/cement ratio than poured concrete.

 attain high compressive strengths particularly with a low

water/cement ratio. Rapid strength gain is also achieved,
Compressive strengths 30% higher than conventionally placed
concretes can be expected.

 The high velocity of placement ensures good compaction, high

density with low permeability and water absorption. This results
in a durable homogeneous material.

 bond strength is generally excellent.

 can deliver high volumes quickly and economically. Free formed

tunnel linings or retaining walls can be sprayed immediately
after excavation.
ADVANTAGES
 Less formwork -In comparison with conventionally
poured concrete, sprayed concrete requires far less
formwork.

 Ease of application - material can be applied in

restricted areas, often considerable distances from the
point of access.
 Less man force - only operator, assistant along with machines
need to be able to visit the workface. The cement and sand
mixture can be transported overlong distances from the
production plant.

 Economy – A construction method that is typically more

economical and expedient, and often produces a cosmetically
superior product.
DRAWBACK
- Loss of the constituents of the sprayed material by
rebound against the surface being sprayed because of
the high velocity of the impacting jet.
-The loss of material varies with parameters like angle
of spray, nature of the surface being sprayed, pressure
of spraying, distance from the spraying front and the
composition of the concrete itself.
-Dry mix spraying results in larger percentages of
rebound than wet mix spraying.
-Rebound can waste 40% or more of sprayed concrete
applied in a project.
 APPLICATIONSAND USES
1.New Construction
Shell roofs and domes  Blast proof structures  Retaining walls
 Piled wall facings  Caissons  Silo structures
 Barrel vaulting  Bank vaults  Diaphragm walls

2. Underground Construction
 Tunnel linings  Storage reservoirs

3. Water Retaining Structures

 Sea and river walls  Swimming pools  Canal lining
 Reservoirs and dams  Water towers  Aqueducts

4. Protective Coatings
 Fire protection to structural steelwork  Pipeline encasement
 Refractory linings  Rock and soil stabilization
5. Strengthening and Repair
Bridges
Brick arches and tunnels
 Overlays
 Fire damaged structures
 Cooling towers
reinforcement corrosion
6. Free Formed Structures
Swimming pools
Landscaping courses
Climbing walls
Theme parks
Jetties and wharves
Tunnel linings
 Cathodic Protection
 Housing
 Concrete damaged by
Sculpture
 Water sports slalom
Bobsleigh runs
Zoological structures

There are two methods used in sprayed concrete:

Dry process and wet process.
 THE DRY PROCESS
 Developed in the early 1900's.

 A predetermined ratio of cement and aggregate is batched and

mixed without adding water. The mixture is fed into the machine,
and conveyed through flexible hoses to the spraying nozzle by
introducing a high velocity air stream. At this nozzle a finely
atomised spray of clean water is added to hydrate the cement and
provide the right mix consistency and the materials are projected
at high velocity into place, where the impact compacts the
material.
 Because water or admixtures are not required to give workability
during transportation or to achieve compaction, dry process sprayed
concrete with suitable aggregates and aggregate/cement ratios can
be placed at low water/cement ratios, with no slump characteristics.
Advantages of the dry-process
 Easy setup, shutdown and cleanup.
 On-site control of materials.
 Nozzle man can be up to 1,000 ft horizontally or 500 ft vertically
from the gun.
Disadvantages of the dry-process
 The large amount of compressed air required for high volume
placement.
 Control of rebound.
Dry process equipment
Most dry mix machines today are the rotor type, a design
whereby the dry mix is fed into an open hopper, dropping
by gravity into a revolving barrel and is blown by
compressed air into the spraying hose and to the water
injection nozzle where the water is applied by the nozzle
man’s judgment. The nozzle can be a great distance from
the machine.
If the feed rate of materials is not constant the nozzle
man will experience great difficulty in maintaining the
correct water/cement ratio.
Dry spray machines have been used for applications
ranging from structural repairs due to fire damage,
cooling tower and bridge strengthening to new
construction in housing, tunneling, mining, swimming
pools etc
Typical dry spray
machine
THE WET PROCESS
- Developed in 1960s.
- A mixture of cement and aggregate, are mixed with water prior
to being pumped through a hose or pipe to the nozzle. High
velocity air is used to propel the mix into position and this
supply of high pressure air is introduced at the nozzle and the
resultant velocity propels the concrete into position where it is
compacted by its own momentum.
Advantages of the 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.
Disadvantages of the wet-process
 Equipment is more costly.
 Wet concrete requires special handling.
 Cleanup must be a consideration.
 WET PROCESS EQUIPMENT
Wet process sprayed concrete pumps include machines with
piston and worm pumps where the concrete is delivered to
the nozzle as a dense stream. At the nozzle, air and
accelerator (if required) are added to project and compact
the material to the substrate.
Worm pump machines can deliver concrete with maximum
aggregate sizes of 4mm, and are typically used for repair and
surface finishing projects. Double piston pump based
machines also supply a dense stream of concrete to the
nozzle. Accelerator dosing units are usually fitted to these
pumps allowing synchronized dosing with the concrete
output.
These wet process sprayed concrete pumps may take mixes
with up to 20mm aggregate.
Typical worm
pump
 SPRAYING PROCEDURES
1. Surface preparation -the substrate must be clean before spraying
concrete. Proper surface preparation is critical to achieve good
mechanical bond between the freshly placed Concrete and the
substrate.
2. At start-up the nozzle man should direct spray away from the
works until he judges that the concrete coming out of the nozzle is
of an acceptance quality.
3. Velocity of spray - should remain consistent from start to finish,
ensuring even compaction and uniform quality.
4. Layers are built by making several passes of the nozzle over the
area, generally in an overlapping oval configuration.
5. The nozzle should be right angles to the substrate and at the
correct distance from it. (600mm -1m for the dry process and
between 250 - 500 mm for the wet process.) When reinforcing
steel is encountered, the angle is varied slightly to ensure proper
encasement of the steel.
 Rebound: too much A lot little
6. Application should start at the bottom of a vertical or sloping
surface.
7. Removal of any rebound material that might become
encased in the works should be done by the nozzle man’s
assistant and this rebound should be discarded.
8. Steel must be cleaned to of loose mill scale or rust and be
free of surface contaminants such as paints and form oil.
Care must be taken when placing steel reinforcing bar to
ensure that it is properly spaced, so that when the concrete is
applied, proper encasement around the bar does not present
a problem.
9. Thorough and consistent blending of aggregates and cement
prior to and during application is important for both the
processes.
SURFACE FINISHES
In both processes it is usual for the concrete to be placed
slightly different of that of required alignment. On thin
coatings (less then 25mm) toweling is undesirable as it can
disturb the impaction bond. If required this surface can be
finished, preferably with a wooden trowel or, if absolutely
necessary, steel float. No additional water should be used to
aid finishing. A very thin flash coat is preferable. Typically,
the finer the aggregate, the easier it will be to float and the
better the end product.
 HEALTH AND SAFETY
Like all activities in construction, spraying concrete needs to be
planned and executed with due regard to Health and safety.

 Construction Design and Management Regulations

A safe work site must be maintained. This will include security to
prevent unauthorized visitors, especially children, a safe means of
access to the works (scaffolding etc) and the elimination of risk to
passers-by.

 Personal Protective Equipment (PPE)

The nozzle man, mixing gang and those adjacent to them must be
issued with appropriate PPE. This will include overalls, gloves and
safety helmet with full face visor or specialized helmet with
breathing apparatus and safety boots. This equipment must be
maintained and replaced when damaged or worn out.
 Plant
Sprayed concrete plant is essentially fairly simple. Plant must be
maintained and serviced properly. Unsafe/improperly maintained
plant should never be used until it is repaired and checked by
competent persons.

 Working Environment
A safe working environment should be created and maintained
- leveled ground ,proper access to the work area.
- Proper lighting ,ventilation especially for dust extraction or when
working in a confined space.
-Protection against overspray and airborne dust should be provided
where necessary.
The workforce must enjoy proper welfare facilities. These will
include accommodation where they can change and dry clothes,
washing facilities, WC facilities, and a separate clean area for
taking breaks and eating.
Safety equipments is required, including facing shields or
goggles, respiratory protections and water proof gloves.
PICTURES SHOWING THE SPRAYED CONCRETE
CONCLUSION
The technique of sprayed concrete has been in use for over
50 years in construction, structural repairs and a variety of
other applications.
The use of properly applied sprayed concrete is recognized
as being a technically sound and economic method of
applying concrete both for effective repairs and for new
constructions.
Sprayed concrete provides the combined features of high
productivity, increased quality and low cost in work which
concerns repairs, preservations, and general work which
requires support.
THANK YOU