Professional Documents
Culture Documents
2-95)
Reported by ACI Committee 506
Steven H. Gebler
Chairman
Jon B. Ardahl
Bruce K. Langson
Ernest K. Schrader
Seymour A. Bortz
Paul D. Carter
Albert Litvin
Kristian Loevlie
Vern Schultheis
Raymond J. Schutz
Gary L. Chynoweth
Dudley R. Morgan
Philip T. Seabrook
W. L. Snow, Sr.
John R. Fichter
Dirk E. Nemegeer
I. Leon Glassgold
H. Celik Ozyildirim
Curt E. Straub
Jill E. Glassgold
Harvey W. Parker
Lawrence J. Totten
Warren L. Harrison
Dale A. Pearcey
Gary L. Vondran
Charles H. Henager
Merlyn Isaak
Richard A. Kaden
Thomas J. Reading
This specification contains the construction requirements for the application of shotcrete. Both wet-mix and dry-mix shotcrete are specified, and the
minimum standards for testing, materials, and execution are provided.
Keywords: dry-mix shotcrete; fiber reinforced shotcrete; nozzleman;
shooting; shotcrete; wet-mix shotcrete.
CONTENTS
Foreword, p. 506.2-2
Preface to specification checklist, p. 506.2-2
Mandatory requirements checklist, p. 506.2-2
Optional requirements checklist, p. 506.2-2
Submittals checklist, p. 506.2-3
Section 1General, p. 506.2-4
1.1Scope
1.2Definitions
1.3Reference organizations
1.4Reference standards
1.5Submittals
1.6Quality assurance
1.7Shotcrete core grades
1.8Evaluation of in-place shotcrete
1.9Acceptance
ACI 506.2-95 supercedes ACI 506.2-90 and became effective October 1, 1995.
Copyright 1995, American Concrete Institute.
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 electronic or
mechanical device, printed, written, or oral, or recording for sound or visual reproduction or for use in any knowledge or retrieval system or device, unless permission in
writing is obtained from the copyright proprietors.
506.2-1
506.2-2
ACI STANDARD
Section/Part/Article
2.7Proportioning
3.3Surface preparation
3.12Tolerance
Section/Part/Article
1.4Reference standards
1.5Submittals
506.2-3
1.6Quality assurance
Specify whether preconstruction testing is required. Specify compatibility for admixtures for wet-mix shotcrete.
Specify type and frequency of additional tests if needed.
Preconstruction testing is not always justified or practical. Examples are: noncritical applications or small jobs,
temporary construction, when job conditions do not allow enough time, and when the contractor has recently completed
similar acceptable work with similar materials, personnel, and equipment. The cost of testing should be weighed against
potential benefits.
If the contractor can show satisfactory results on previous jobs with the same materials, personnel and equipment, the
engineer should give consideration to eliminating the requirement of preconstruction testing.
Flexural strength in accordance with ASTM C 78 and toughness in accordance with ASTM C 1018 in addition to
compression tests are usually required as prequalification of fiber reinforced shotcrete. When prequalification testing is
required, a ratio of compressive to flexural strength is to be established for quality assurance purposes, then compressive
design strength would govern as acceptance. Specify the frequency of testing and acceptance criteria.
Concrete design strength is based on cast concrete cylinders. Shotcrete design strength, however, is based on cores or
sawed cubes taken from a sample panel. Core sample strength, however, is expected to be 0.85 of cast cylinder strength
(ACI 318 paragraph 5.6) since core samples are disturbed due to the coring or cutting process.
Quality shotcrete is highly dependent on the contractor and the workmanship of the nozzleman. The nozzleman should
demonstrate his ability and knowledge or have proven his ability through nozzleman testing. At the present time,
Nozzleman Certification ACI 506.3R is a report (not a standard) and may not be referenced in the ACI Shotcrete
Specification. The specifying authority, however, can specify nozzleman certification in accordance with 506.3R or
other suitable requirement. Language, however, must be mandatory.
1.7Shotcrete core grades
Specify core grade of shotcrete required. Grade 1 cores are optimum, however, Grade 1 cores cannot be consistently
shot. Grade 2 cores are used for most structural members.
1.8Evaluation of in-place shotcrete Specify acceptance/rejection criteria.
2.1Cement
Specify if other type of cement is allowable If required, specify blended hydraulic cement in accordance with ASTM
C 595. Base selection of cement type on sulfate exposure conditions or other conditions.
2.2Aggregate
Specify if other grading, type or tests are required. Specify criteria for acceptance. Other gradings proposed by the
contractor may be acceptable if the contractor can demonstrate satisfactory performance under similar conditions of
use.
2.3Reinforcement
Specify type, size, configuration, minimum content, tests required, or required testing frequency and acceptance criteria.
2.5Admixtures
A concrete mix doesn't become shotcrete until it is placed at a high velocity. Measuring air content at the pump hopper, measures concrete air content not shotcrete air content. Shotcrete air content can be measured by taking samples
from in-place material. If air content is to be tested, specify where the sample is to be taken.
Wet-mix shotcrete exposed to moderate or severe freeze/thaw conditions should have air entrainment in the concrete
prior to shooting. Six to seven percent (6 - 7 percent) air content in the concrete is required prior to shooting. Entrained
air is lost during shotcreting. Obtaining greater than 4 percent entrained air in in-place wet-mix is difficult. If a greater
percent is required, test practicality.
Specifying air entrainment for dry-mix is not recommended.
Specify limits and types of other acceptable admixtures. Specify dosage if important.
Calcium chloride is not recommended in reinforced shotcrete structures. Tables in ACI 201 or ACI 318 provide limits. If specified, it shall conform to ASTM D 98. Specify if other admixtures are allowable.
2.8Fiber
ACI 506.1RState-of-the-Art Report on Fiber Reinforced Shotcrete provides guidance for fiber shotcrete.
3.3.3Surface preparation
It is recommended that steel surfaces should comply with SSPC-SP6 3.3.3.2.
3.3.5Forms
High velocity air transporting the shotcrete mix, if not allowed to escape, may create voids at form corners.
3.4.1Joints
Specify square joints for construction joints subject to compression loads.
3.5Alignment control
For long spans (over 30 ft), devices that permit tightening of ground wires, such as springs or turnbuckles can be used.
3.6.1Application
Do not place subsequent lifts until the previous lift has hardened enough to support the new shotcrete. Vertical walls
should be gunned from the bottom up unless it can be demonstrated that another method will work successfully.
3.6.2Encasement of reinforcement Voids behind bars are not easily evident by inspection. Limiting the maximum size reinforcement bar to a No. 5 bar
increases the likelihood of complete encasement, especially with limited experienced crews. Encasing larger bars
requires great care, along with high impact velocity and plasticity. Close inspection is also needed. See Guide to Shotcrete, 506R-85 Section 5.4.1.2.
3.7Finishing
Specify type of finish. If other than a gun finish is required, specify finish types such as rod, broom, wood float, rubber
float, or steel trowel. Disturbance of the shotcrete surface by finishing may reduce the durability of the surface.
Material to correct small flaws may be added if the material is fresh and properly proportioned.
3.8Curing
Caution must be exercised when using curing compounds. Curing compounds can interfere with the bond of
subsequent layers of shotcrete. If curing compounds are used and additional layers of shotcrete are to be applied, the
curing material must be removed by either water blasting or sand blasting.
Steam curing is acceptable provided the steam temperature is less than 150 F.
3.10Cold weather
ACI 306.1 standard specification should be reviewed.
SUBMITTALS CHECKLIST
Section/Part/Article
1.5Submittals
506.2-4
ACI STANDARD
SECTION 1GENERAL
1.1Scope
This Standard Specification describes the requirements for
materials, proportioning, and application of shotcrete.
1.2Definitions
AcceptedAccepted by or acceptable to the Architect/Engineer.
Architect/EngineerThe architect, engineer, architectural
firm, engineering firm or architectural and engineering firm
issuing project drawings and specifications or administering
the work under the Contract Documents.
Contract DocumentsDocuments covering the required
work and including the project drawings and project specifications.
ContractorThe person, firm, or corporation that the
owner enters into an agreement with for construction of the
work.
Core gradeQuality ranking of a shotcrete core.
Dry-mix shotcreteShotcrete in which most of the water
is added at the nozzle.
Fiber-reinforced shotcrete (FRS)Shotcrete mixed with
discrete discontinuous fibers commonly made of steel, plastic, or alkali resistant (AR) glass.
Finish coatFinal thin coat of shotcrete preparatory to
hand finishing.
Flash coatThin shotcrete coat applied from a distance
greater than normal for use as a final coat or for finishing.
Ground wireWire used to establish line and grade for
shotcrete work.
GunDry-mix shotcrete delivery equipment.
Gun finishUndisturbed final layer of shotcrete as applied from nozzle without hand finishing; also known as natural or nozzle finish.
NozzleAttachment at end of delivery hose from where
shotcrete is projected.
NozzlemanWorker on shotcrete crew who manipulates
the nozzle, controls consistency of dry-mix shotcrete, and
controls final disposition of the material.
OversprayShotcrete material deposited away from the
intended receiving surface by air blast.
OwnerThe corporation, association, partnership, individual, or public body or authority with whom the contractor
enters into agreement and for whom the work is provided.
ReboundShotcrete material that ricochets off the receiving surface.
Sand/rock pocketA porous zone in the shotcrete containing aggregate with reduced mortar content.
ShootingAct of applying shotcrete.
ShotcreteMortar or concrete pneumatically projected
onto a surface at high velocity.
SloughingSubsidence of shotcrete, due generally to excessive water in mixture or to vibration of continuous reinforcement or formwork.
SubmittedSubmitted to the Architect/Engineer for review.
Wet-mix shotcreteShotcrete in which plastic concrete
506.2-5
C 642
1.5Submittals
Submit proposed mix characteristics including:
Strength
Proportions
Test results
Submit preconstruction test panel results when required.
1.6Quality assurance
1.6.1 Preconstruction testing
1.6.1.1 Prepare preconstruction test panels for examination by Architect/Engineer prior to job shotcrete placement.
Preparation and testing shall comply with ASTM C 1140.
1.6.1.2 Produce test panels for each proposed mix proportion, each anticipated shooting orientation, and each proposed nozzleman. Mixes shall meet requirements of section
2.7Proportioning. In half of the test panels provide reinforcement of the same size and spacing required for the
work. Obtain six test specimens from each panel, three nonreinforced specimens and three with reinforcing steel.
1.6.1.3 Test the nonreinforced specimens for compliance with the specified physical properties in accordance
with ASTM C 42.
1.6.1.4 Visually grade the reinforced specimens for
compliance with specified core grade (Section 1.7Shotcrete core grades).
1.6.1.5 Test admixtures for compatibility with cement in
accordance with ASTM C 1141.
1.6.1.6 Unless otherwise specified, only nozzlemen
with a test panel mean core grade less than or equal to 2.5
(section 1.7) shall be allowed to place job shotcrete. When
the prequalification test panel is rejected, a second panel may
be shot. When the nozzleman's second mean core grade is
greater than 2.5, the nozzleman shall not be permitted to
shoot on the project.
1.6.2 Construction testing
Grade 1
506.2-6
Grade 2
ACI STANDARD
Grade 3
Grade 4
maximum dimension of 1 in. (25 mm) perpendicular to the
face of the core with a maximum width of 11/2 in. The end of
the core that was shot against the form may be sandy and
with voids containing overspray to a depth of 1/8 in.
1.7.5 Grade 5 core: A core that does not meet the criteria
of core grades 1 through 4, by being of poorer quality, shall
be classified as Grade 5.
1.7.6 Determination of grade shall be by computing the
mean of a minimum of three test specimens.
1.7.7 A mean grade of 2.5 or less is acceptable unless otherwise specified. Individual shotcrete cores with a grade
greater than 3 are unacceptable.
1.7.8 The above core grades are based on cores with a surface area of 50 in.2 For cores with greater or lesser area than
50 in.2, adjust allowable flaws relative to 50 in.2
Grade 5
ceeding 3/16 in. thick by 11/4 in. long, or one major void, sand
pocket, or lamination containing loosely bonded sand not to
exceed 5/8 in. thick and 11/4 in. in width. The surface against
the form or bond plane may be sandy with voids containing
overspray to a depth of 1/16 in.
1.7.4 Grade 4 core: The core shall meet in general the requirements of Grade 3 cores, but may have two major flaws
such as described for Grade 3 or may have one flaw with a
506.2-7
See ASTM C 33 for tolerances for various nominal maximum size designations.
2.8Fiber-reinforced shotcrete
ASTM C 1116
2.9Prebagged materials
Are allowable with predampening.
2.10Delivery, storage, and handling
Deliver, store, and handle materials to prevent contamination, segregation, corrosion or damage. Store liquid admixtures in order to prevent evaporation and freezing.
SECTION 3EXECUTION
3.1Examination
Verify that surfaces are acceptable and are ready to receive work.
Verify that forms are to line and grade, braced against
vibration, and constructed to permit escape of air and
rebound.
Verify that placement and clearance around reinforcement permits complete encasement.
Verify that surfaces to receive shotcrete have been
properly prepared according to the Contract Documents.
3.2Batching and mixing
Weight batching shall comply with the accuracy specified
in ASTM C 94.
Volume batching shall comply with the accuracy specified
in ASTM C 685. Volume batching shall be verified once a
week by a weight batching check.
Use batching and mixing equipment capable of proportioning and mixing the required materials.
Shoot dry-mix shotcrete material within 45 min after
batching or predampening. This requirement does not include dry, prebagged material unless prebagged material is
predampened.
Shoot wet-mix shotcrete material within 90 min after
batching.
3.3Surface preparation
3.3.1 EarthPrepare surfaces to line and grade. Do not
apply shotcrete to frozen surface. Dampen surface immediately prior to shooting.
3.3.2 Concrete, masonry, and shotcreteWhen bonding
is required, remove all deteriorated, loose unsound material
or contaminants that may inhibit bonding. Chip areas to be
repaired to remove offsets causing abrupt changes in thick-
506.2-8
ACI STANDARD
Place shotcrete to provide the cover over reinforcement required by ACI 301.
Minimum slump of wet-mix shotcrete is 1 in.
3.7Finishing
Gun finish or as specified.
Broom or roughen the surface of freshly placed shotcrete
after shotcrete has reached initial set when subsequent layers
are to be applied.
3.8Curing
Immediately after finishing, cure shotcrete continuously
by maintaining in a moist condition for seven days or until
specified strength is attained or until succeeding shotcrete
layers are placed.
Cure by one of the following methods:
Ponding or continuous sprinkling
Covering with an absorptive mat or sand that is kept
continuously wet
Covering with impervious sheet material
Curing compounds
Natural curing shall be permitted if ambient relative humidity is maintained above 95 percent.
3.9Hot weather shotcreting
Do not place shotcrete when material temperature is above
90 F for wet mix; 100 F for dry mix. Lower temperature of
reinforcement and receiving surfaces below 100 F prior to
shooting.
3.10Cold weather shotcreting
Shooting may proceed when ambient temperature is 40 F
and rising. 50 F for latex-modified shotcrete. Shooting shall
discontinue when ambient temperature is 40 F and falling
unless protective measures are taken to protect shotcrete.
Shotcrete material temperature, when shot, shall not be less
than 50 F or more than 90 F. Shotcrete shall not be placed
against frozen surfaces. Applicable procedures used for cold
weather concreting may be used for cold weather shot-creting.
3.11Protection
Protect surfaces not intended for shotcrete placement
against deposit of rebound and overspray or impact from
nozzle stream.
Remove rebound and hardened overspray from final shotcrete surfaces and from areas not intended for shotcrete
placement.
3.12Tolerances
Tolerances of shotcrete shall comply as specified.
ACI 506.2-95 was submitted to letter ballot of the committee and approved in accordance with ACI standardization procedures.