22 Shotcrete Magazine Fall 2000

I
n 1989, the Austrian Concrete Society pub-
lished a Guideline on Shotcrete that subse-
quently served as a reference work and a con-
tractual basis for shotcrete works in tunnel con-
struction in Austria and abroad. Other standards,
such as DIN 18551, focused more strongly on
shotcrete for concrete repair works. At the end of
1998, after several revisions, a new edition of the
Austrian Guideline was published that also con-
siders recent developments in the field of shot-
crete technology. Dealing with a
whole range of issues, from base ma-
terials for sprayed concrete produc-
tion to contractual aspects, the 80-
page guideline will retain its value as
a document of topical importance,
even after publication of a European
Standard (Working Group TC 104/
WG 10). The text of the guideline is
also available in English.
1
NlKl0f0
The mixture is the base product for
dry-mix and wet-mix sprayed con-
crete. Depending on the procedure
applied, three types of mixture can be
used for dry-mix sprayed concrete
(Table 1). Due to environmental con-
siderations and efforts to increase
shotcrete quality, only non-alkaline
accelerators or special binders, called
spray cements, with short setting time
are now used in tunnelling. Dry-mix
is still frequently used in central Eu-
rope as many tunnels are constructed
in poor rock conditions.
In dry-mix production, the risk of
segregation during material transport
should be kept in mind; a maximum
temperature of 40 C (104 F) must not
be exceeded. Moist-mix for immedi-
ate placing is produced in a continu-
ous mixing plant upstream of the
spraying machine. Accurate dosages,
a uniform moisture content of the ag-
gregate, and a short working time are
important. Both moist-mix and wet-
mix have to be used within no more
than 1.5 h of mixing.
$f8l Ff00000f08
The Guideline on Sprayed Concrete
provides a reliable basis for every
construction site to select and apply
ll08ll0 80 108ll 0l $00l0f0l0
000f0l l0 l00 08lfl8 60l00ll0
0 $f800 000f0l0
By Wolfgang
Kusterle
e t e r c t o h s x i m - y r D
x i m - t e W
e t e r c t o h s
f o t n e t n o c r e t a W
s e t a g e r g g a
y b % 2 . 0 < W
s s a m
r e t t a c S % 0 . 4 o t 0 . 2 = W d r a d n a t S
s s a m y b % 0 . 5 o t 5 . 1
y b % 0 . 8 < W
s s a m
n o i t a n g i s e D x i m - y r d
x i m - t s i o m
e l b a r o t s
r o f x i m - t s i o m
g n i c a l p e t a i d e m m i
x i m - t e w
d e p m u p ( e t e r c n o c )
, n o i t a n g i s e D
. r b b a
M T L - M F S - M F M N
r e d n i B
t n e m e c l e n n u T
d n a Z T
r o r o t a r e l e c c a
T F , T - M B S
t n e m e c l e n n u T
d n a Z T
r o t a r e l e c c a
T F - M B S
t n e m e c l e n n u T
d n a Z T
r o t a r e l e c c a
f o n o i t i d d A
F A - B E
n i y r a s s e c e n f I
t n a l p g n i x i m
g n i k r o w g n i r u D
y r a s s e c e n f I (
) g n i k r o w g n i r u d
g n i k r o w g n i r u D
n o i t c u d o r P
e t i s r o t n a l P
g n i x i m
e t i s r o t n a l P
g n i x i m
s u o u n i t n o C
g n i r u d g n i x i m
g n i k r o w
e t i s r o t n a l P
g n i x i m
e g a r o t S
d e s o l C
, e l p m a x e r o f (
) g a b , n i b
d e r e t l e h S d e r e t l e h S
y t i l i b a l i a v A d e t i m i l n U d e t i m i L d e t i m i l n U d e t i m i L
e m i t e g a r o t S
- g n o l t u o h t i w (
) r e d r a t e r m r e t
e g a r o t S
o t g n i d r o c c a
s t n e m e r i u q e r
n i d e c u d o r P
e b o t , e c n a v d a
n i h t i w d e s u
e m i t e g a r o t s
) h 5 . 1 m u m i x a m (
r o f d e c u d o r P
e s u e t a i d e m m i
n i d e c u d o r P
e b o t , e c n a v d a
n i h t i w d e s u
e m i t e g a r o t s
) h 5 . 1 m u m i x a m (
Table 1
Shotcrete mixture classification, abbreviations:
TM: dry-mix for the dry-mix process with oven-dry aggregates
FM-L: moist-mix, storable, for the use in dry-mix process (conventional dry-mix process)
FM-S: moist-mix, for immediate application in dry-mix process (for use with spray cement)
NM: mixture for the wet-mix process
TZ: tunnel cement, portland cement particularly suited for tunnelling
SBM: spray cement general term used to designate fast-setting binders that ensure the required rate of setting
and strength development in fresh sprayed concrete without addition of accelerator
SBM-T: spray cement for sprayed concrete with dry aggregates
SBM-FT: spray cement for sprayed concrete with moist aggregates (short contact time)
EB-AF: non-alkaline accelerator
Shotcrete Magazine Fall 2000 23
the most suitable spraying method. The advan-
tages and disadvantages of non-alkaline sprayed
concrete technologies are summarized in Table 3.
Descriptions of the individual procedures are ac-
companied by instructions for proper application.
These are quite similar to North American guide-
lines, so there is no need to go into detail. It should
only be mentioned that special emphasis is laid
on the proper metering of the accelerator. There
is also experience in spraying shotcrete onto fro-
zen substrates, requiring an increase in the sprayed
concrete layer thickness of 20 to 30 mm (0.8 to
1.2 in.), and using a mixture with a minimum tem-
perature of 13C (55.4 F).
e t e r c t o h s x i m - y r D e t e r c t o h s x i m - t e W
t n e m e C
) h s a y l f , e l p m a x e r o f ( s e v i t i d d a
* * m / g k 0 6 3 o t 0 1 3
m / g k 0 5 o t 0 3
m / g k 0 8 3 o t 0 6 3
m / g k 0 8 o t 0 5
d n a B M S , Z T ( e s o d r e d n i B
) s e v i t i d d a
m / g k 0 8 3 o t 0 4 3 m / g k 0 5 4 o t 0 0 4
o i t a r r e d n i b - r e t a W 3 J r o / d n a 2 J s t n e m e r i u q e r h t g n e r t s r o f 0 5 . 0
) x e d n i g n i d a e r p s ( e c n e t s i s n o C m c 5 5 o t 8 4
s e t a g e r g g A 1 1 K G , 8 K G 1 1 K G . x a m , 8 K G
d n a r e d n i b ( t n e t n o c d e n i a r g - e n i F
m m 5 2 . 0 < s e n i f , ) e t a g e r g g a
m / g k 0 7 4 . n i m
t n e m e c . l c n i
m / g k 0 5 5 . n i m
t n e m e c . l c n i
Unfortunately, the guideline does not give any
detailed specifications on nozzleman training or
qualification.
80@0lf0M0l8 l0 00 N0l 0
$f800 000f0l0
Depending on the application and the structural
functions to be fulfilled, sprayed concrete is clas-
sified as follows: sprayed concrete without struc-
tural functions (Class SpB I), sprayed concrete
with structural functions (Class SpB II), and
sprayed concrete with special structural functions
(Class SpB III).
Table 2: Indicative values for mix composition for SpB II and SpB III.*
*SpB = sprayed concrete; GK = maximum grain size; I,II,III = sprayed concrete classes; II being normally used for rock support uses, III,
for example, for repair works).

With binder doses of less than 340 kg/m, adhesion of the sprayed concrete to the substrate is noticeably diminished.
**10 kg/m
3
is approximately equal to 17 lb/y
3
( 16.86 lb/y
3
).
e r u d e c o r p x i m - y r D e r u d e c o r p x i m - t e W
e r u t x i M M T S - M F M N
r e d n i B T t n e m e c y a r p S T F t n e m e c y a r p S t n e m e c l e n n u T
r o t a r e l e c c A e n i l a k l a - n o N
s e g a t n a v d A
n i e c a p s e l t t i l s e r i u q e R
, y t i l i b o m h g i h , l e n n u t
t n e l l e c x e , y t i l i b a i l e r h g i h
o n , h t g n e r t s y l r a e
, r e t n i w n i s m e l b o r p
e c n a t s i d g n i y e v n o c
. ) t f 5 8 9 ( m 0 0 3 o t p u
, s t s o c l a i r e t a m w o L
, e m i t y n a e l b a l i a v a
, s e i t i t n a u q l a u d i s e r o n
, s a l u m r o f x i m l a r e v e s
e c n a t s i d g n i y e v n o c
. ) t f 5 5 6 ( m 0 0 2 o t p u
e l t t i l , t u p t u o h g i H
, e l i b o m t s u d d n a d n u o b e r
r i a d e s s e r p m o c w o l
r o t a r e l e c c a , t n e m e r i u q e r
o t e l b a t s u j d a e s o d
. s t n e m e r i u q e r
s e g a t n a v d a s i D
, n o i t a g e r g e s , s t s o c g n i y r D
t s u d , s e r u t a r e p m e t h g i h
. t u p t u o w o l , d n u o b e r d n a
y v a e h , t n e m e r i u q e r e c a p S
, t n e m p i u q e e l i b o m m i d n a
. t u p t u o w o l
h g i h , h t g n e r t s y l r a e w o L
t r o p s n a r t , s t s o c l a i r e t a m
g n i p m u p d e t i m i l , s c i t s i g o l
, g n i n a e l c t l u c i f f i d , e c n a t s i d
l a u d i s e r , n o i t a r d y h e r p
o t y a w d a o r , s e i t i t n a u q
. d e r i u q e r e c a f g n i k r o w
Table 3: Comparison of non-alkaline sprayed concrete technologies.*
*The moist-mix procedure using a non-alkaline accelerator has not been included (this table is not part of the guideline).
24 Shotcrete Magazine Fall 2000
This classification also determines the fre-
quency of testing for quality control purposes. Fur-
thermore, fresh sprayed concrete is classified on
the basis of early strength classes, J
2
being the
regular requirement for tunnelling with about 200
mm (8 in.) layer thickness, J
3
being necessary only
under very difficult ground conditions or strong
water ingress.
The strength requirements and other proper-
ties are based on the provisions of the existing
concrete standards.
$00l8l Ff00000f08
Special procedures dealt with in the Guideline in-
clude sprayed concrete under compressed air (un-
changed from 1st edition), and steel-fiber sprayed
concrete. In Austria, steel-fiber concrete is not
yet used very widely; hence, the requirements
have been used from other countries. An evalua-
tion of the results obtained in the bending-beam
test according to R. Morgan has been included
in the Guideline.
By means of this method, the strength of
sprayed concrete can be evaluated even at an early
age, which is essential for the use of sprayed con-
crete for support in difficult rock conditions.
108ll
A large part of the Guideline deals with testing
and testing requirements. The tests referred to are
shown in Table 4.
Tests are to be performed in in-
dividual steps, starting with base
materials, up to and including in-
spection of mixing and metering
equipment. Non-compliance with
the quality criteria to be met by
hardened sprayed concrete is to be
avoided through systematic estab-
lishment of important parameters
before and during production.
Table 11 of the Guideline con-
tains a clear overview and a bind-
ing list of the testing requirements
to be met. The individual tables
only refer to the relevant require-
ments for each spraying method.
In regards to the testing of base ma-
terials, the tables refer to prelimi-
nary testing, self-inspection and in-
ternal inspection on the construc-
Figure 1: Hand application of dry-mix shotcrete
without keeping nozzle within correct distance
to substrate.
Figure 2: Early strength requirements to be met by fresh sprayed concrete (between A
and B: class J
1
, between B and C: class J
2
, above C: class J
3
).
Figure 3: Bound-
aries of flexural
toughness ranges
for fiber-reinforced
sprayed concrete
(example).
Shotcrete Magazine Fall 2000 25
tion site. Information on preconstruction testing,
production testing, and structural testing is pro-
vided (Table 5).
108ll Ff00000f08
Many test procedures for base materials follow
the national specifications, but it is very impor-
tant to provide a reliable indication of the interac-
tion of cement and accelerator on the behaviour
of spray cement. This testing is done using a modi-
fied Vicat test and tests on small cylinders or
prisms [40 x 40 x 160 mm (1.6 x 1.6 x 6.3 in.)].
Special instructions are given to ensure fast
mixing and placing of the samples. Moreover, an
identification test of the accelerator, including
chemical properties, is obligatory.
Testing of base materials for concrete produc-
tion, though a meaningful approach, will never
be able to simulate the spraying procedure com-
pletely. Hence, testing of the reference sprayed
concrete, in addition to laboratory testing as speci-
fied above, is provided for. A reference formula
for sprayed concrete for small laboratory spray-
ing equipment is specified.
Following a tradition established in the first
edition, the Guideline devotes considerable atten-
tion to the testing of fresh sprayed concrete. It
specifies the needle penetration test for a strength
of up to 1.2 MPa (174 psi), and the stud-driving
method for the range of strength from
1.0 to 16 MPa (145 to 2320 psi)
(Fig. 4). The penetration needle is
used to measure the force required to
push a needle of 3 mm (0.12 in.) di-
ameter and a tip with a taper angle of
60 degrees to penetrate into the shot-
crete to a depth of 15 mm (0.6 in.).
The instrument indicates the resist-
ing force through compression of a
spring, from which an estimated com-
pressive strength can be derived from a conver-
sion curve (Fig. 5).
For the stud-driving method, a threaded stud
is driven into the shotcrete and the depth of pen-
etration is determined. Then, the stud is extracted
and the pullout force measured. The ratio of pull-
out force to penetration depth (or for low-strength,
only penetration depth) can be used to obtain an
estimated strength from conversion curves for dif-
ferent maximum aggregate grain size (Fig. 6).
The stud-driving method has been extended to
cover the entire range of strength development.
However, values above 16 MPa (2320 psi) can only
be estimated. For aggregates other than those nor-
mally used in central Europe, mixture calibration
is recommended, which can be performed quickly
in any testing laboratory.
Testing of sprayed concrete after 28 days is
performed on test cores according to the concrete
standards. Special tests for sulfate resistance and
leaching of sprayed concrete are referred to. Sul-
fate attack is more common in the Alps than al-
kali aggregate reactivity. Leaching may be a prob-
lem when using alkali aluminates or silicates as
accelerators. During sprayed concrete production,
inspections of dosages (cement content, accelera-
tor dosage), rebound, fine-dust concentration,
thickness of the sprayed concrete layer, and fiber
content are essential. Fine-dust concentration is
s l a i r e t a m e s a b f o g n i t s e T
e r u t x i m f o g n i t s e T
) s r u o h 4 2 < ( e t e r c n o c d e y a r p s h s e r f f o g n i t s e T
) e t e r c n o c d e n e d r a h ( e t e r c n o c d e y a r p s f o g n i t s e T
s n o i t i d n o c n o i t c u d o r p f o g n i t s e T
t n e m p i u q e g n i r e t e m d n a g n i x i m f o g n i t s e T
t s e T r e r u t c a f u n a M e t i s n o i t c u r t s n o C
f o t s e t y r a n i m i l e r P n o i t c e p s n i - f l e S
l a n r e t x E
n o i t c e p s n i
n o i t c u r t s n o c e r P
t s e T
n o i t c u d o r P
t s e T
t s e t l a r u t c u r t S
t n e u t i t s n o C
s l a i r e t a m

+ e r u t x i m c i s a B
d e y a r p s
e t e r c n o c
n o i t c e p s n i l a n r e t x e h t i w x i m - y r d f o e s a c n I
d e y a r p s - h s e r F
y l n o e t e r c n o c
e p o c s d e c u d e R
d e r i u q e r f I
7 0 3 3 B M R O N o t g n i d r o c c a n o i t c u d o r P
) e t e r c n o c x i m - y d a e r (

d n a g n i x i M
g n i r e t e m
t n e m p i u q e
y d o b n o i t c e p s n i y b t s e t e c n a t p e c c A n o i t c e p s n i - f l e S
Table 4: Reference to testing in the guideline
Table 5: Overview of Table 11 in the Guideline: Testing of base materials, mix and sprayed concrete, inspection of
mixing and metering equipment
26 Shotcrete Magazine Fall 2000
measured by light-scattering instru-
ments. Conversion of the relative
dust concentration into fine-dust con-
centrations obtained by gravity-
based samplers can be done by con-
version factors ranging from 1.1
to1.5.
References
1. Austrian Concrete Society,
Guideline on Sprayed
Concrete, Vienna 3/99,
e-mail: beton@netway.at.
Wolfgang Kusterle received his
diploma in civil engineering at
the University of Innsbruck in
1980. He then worked for 2 years
with a consulting engineer
designing bridges and other
reinforced concrete structures. In
1983, he started working on his
doctoral thesis at the University
of Innsbruck, which he finished in 1984 with a PhD in
civil engineering. He stayed at the Institute for Build-
ing Materials and Building Physics as assistant pro-
fessor and later as associate professor. His main
research areas are sprayed concrete and concrete
repair. He is involved in national and international
research programs and has published more than 60
papers. Consulting in concrete technology, product
development, and the organization of conferences are
some of his other areas of work.
Figure 4 : Measuring procedures for the testing of fresh-sprayed concrete (Hilti 450L being the
stud-setting unit used).
Figure 6: Testing equipment for stud-driving method. Figure 5: Penetration needle in use.