QC Issues - Contents

Comparison on Cube vs Cored samples QC issues on Spraying Application Curing QC issues on Pre-Application Test Methods Calculation on Accelerator Dosage

EUROPEAN SPECIFICATION for SPRAYED CONCRETE

Good Spraying Technique ?

Spraying Technique Hand Spraying

Spot the mistake ???

If you value your hands

State of the Art - Robotic Spraying

Application Nozzle Angle

Nozzle angle
Nozzle should always point 90 to the receiving surface For spraying onto steel arch / lattice girder exceptions will be required

90

90

Application Nozzle Distance

Nozzle distance
For Robotic application the distance should between 1 2 m

90

Influence
Incorrect nozzle angel and distance has significant influence on concrete quality like poor compaction, strength etc, and will dramatically increase rebound

90 1-2m

QC issues on Application -Layering

Consistent Sprayed Concrete quality through out the different layers

Thin passes guarantee continuity in the quality of the sprayed concrete throughout the different layers. This is essential for final linings
The surfaces must be cleaned before spraying to guarantee bond Consistent high quality concrete is essential throughout the different layers

QC issues on Application - shadow

No spray shadows behind reinforcement bars

In case of bad spraying, spray shadows form behind the

reinforcement bars
Water migrates into these voids, allowing corrosion of the reinforcing bars Corrosion reduces the diameter of the bars and there fore there strength. The lining looses its lode bearing capacity

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QC issues on Application - shadow

Application technique can be dramatic

Same concrete mix from one truck, sprayed 10 minutes apart! Sprayed by two different nozzlemen during training Compaction is important for durability

Shotcrete Applicator Training Programs

Trial Panel Spray Training Basic & Advanced Concrete Technology Training Robotic operator training

Recognized Standards

Equipment Calibration and Instruction Shotcrete Application Techniques

Hand Spraying applicator training

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Shotcrete & Nozzleman Certification

The American Concrete Institute conducted the first Shotcrete

Nozzleman Certification Scheme in Asia Kah Fai Lee ( Tam Singapore ) Alve Rutgersson ( Tam Singapore ) and Ritchard Hood ( Tam Hong Kong ) successfully completed the course, and examinations, and are now ACI certified shotcrete nozzlemen. Alve Rutgersson is to be accedited with ACI Assessor certification Alve Rutgersson , Ritchard Hood, Kah Fai Lee of Normet have recently obtained the EFNARC Shotcrete Nozzlemen Assessor certification for Robotic Shotcrete Application

Curing is essential in sprayed concrete

As with conventional concrete, permanent sprayed concrete structures need to be cured or the following may occur: Rapid moisture loss and drying resulting from the tunnel ventilation systems

Relatively high cement content in mix and early reaction temperatures due to accelerated mix may cause rapid drying and shrinkage cracking
Without proper curing, we get poor bonding, low strength and poor durability

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So why is curing important?

(Cement + water = CSH)

Original cement particle

The term hydration of cement means the reaction between the cement and the water which makes calcium silicate hydrates (CSH) The CSH is the gel or binder that gives concrete its strength If the water in the concrete evaporates too quickly, then these important hydration processes are not given a chance to create a dense, strong matrix between the aggregates Curing is needed to keep the water in the sprayed concrete as long as possible to help hydration of the cement Good curing gives: Higher compressive strengths Higher bond strengths Increased durability Less shrinkage cracking
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Hydration products ( CSH ) Water to complete the hydration

Pre-Application - Ordering of Concrete

The Nozzlemen should be informed about:
General mix design, w/c ratio, slump, with or without fibres, etc. The use of special admixtures for control of hydration (open time), etc The quality/performance requirements of the applied concrete Result from pre test, type and dosage of set accelerator Location and orientation of the area to be applied Details of reinforcement and concrete thickness to be applied Total amount of shotcrete to be applied at the location The timing for the application and supply rate for the concrete

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Pre-Application Delivery Acceptance

Control of concrete on arrival at the spraying location should be according the contract requirements
Check delivery note of each truck mixer if according to order, and note any exceptions General visual assessment of the supplied mix before transferred into the hopper Visually check presence of fibre and possible fibre balling (if applicable) Check visually for any separation of the concrete mix Measure slump or flow for each delivery Never add water to the mix for correction of slump Spraying of test panels and sampling as required according to contract QC requirement In case of interruptions longer than 15 minutes, slump to be observed and re measured

In case of exceptions, or any doubt, report to responsible site engineer for approval prior to start of application

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Vicat Test testing the reactivity of cement with accelerator Interpretation of results:
Initial set
Final set Rating

< 2 min
< 5 min Good

<4 min
< 8 min Acceptable

> 4 min
> 8 min Not acceptable

Early Strength Testing Penetrometer

Penetrometer Needle For testing of early strength from 0.2 to 1.0 MPa

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Early strength testing -Hilti Pull Out Tester V

Early Strength Testing using stud driving from 3 to 12 MPa

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Compressive Strength Testing

Test Spray Panels Coring of Spray Panels

For Compressive Strength > 10 MPa

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Pre-Application Delivery Acceptance 1 Litre Test

Calculation of Accelerator Dosage

What we need to Know ? Weight of cement in kg per m3 (Cement
kg ) Weight of Silica Fume / PFA / Slag ( Binder kg) Output of concrete pump ( Qc m3 / hr) Density of Accelerator ( D = kg /L) Dosage of Accelerator in % by weight of cement ( %)

Formula is : ( Cement kg + Binder kg ) x (m3/ hr) x (%) / 60 min/hr / D