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SikaShotcrete Systems PDF
SikaShotcrete Systems PDF
®
Sika Shotcrete Systems
Your local Sika Company
Technology and
Sika Services AG
Corporate Construction
Concepts for Shotcrete
CH-8048 Zürich
Switzerland
Phone +41 44 436 40 40
Fax +41 44 436 46 86
www.sika.com
S&W 04.05 / 05SIC 21.17 / © Sika Services AG
a nagemen
d Qu lity Sy Ma
fie d t
st
rti
Sy
ie
em
Ce
Certif
stem
1
IS
00
IS
O
90
01 / E N 2
9 O 14 0 0 1
since 1986 since 1997
Sika Shotcrete Technology
Sika – The Leader by permanent Innovation
The high reputation enjoyed by Sika in tunnelling is so wi- always clearly marked by the development of shotcrete
dely known because the Company’s activities always loo- technology. To cite just one example from this success
ked towards the future of tunnelling from its beginnings in story, the decision was made to use Sika products
1910. The first patent for a spraying machine was for the waterproofing to all the structures for the electrifi-
registered in the year that Sika was founded, a symbolic cation of the railway line through the 1st Gotthard Alpine
Introduction 1920
In 1933 the Sigunite® Brand was born
For reasons of flexibility, speed and economy, In powder form,
shotcrete has grown continuously in importance added by hand
over recent decades, especially for heading sup- Quantity added 3 – 7 %
port in tunnelling. The main basis for this was
new developments or improvements in shotcrete
and process technology.
1940 Spribag BS-12/MS-12 Naphthalene Sulphonate
New developments in concrete additives and First dry-mix machines Melamine Sulphonate
fillers, cements and methods of application are (compressed air process) Sikament®, still a reliable flow control agent in tunnelling
leading to innovative new applications and with a spraying capacity Working time up to 2 hours
enabling shotcrete to be produced by the wet of up to 3 m3/hr.
spraying process which can meet the highest
strength and durability requirements. This poten-
tial has yet to be utilized to the full worldwide, as
shotcrete is often used as temporary support 1960 Alkaline Aluminates Cement particle
concrete that only has to meet quite low quality The first liquid setting accelerators
requirements. More recently, however, the fullest for shotcrete, Sigunite®-L Liquid
possible know-how on wet-mix shotcrete has Quantity added 3 – 6 %
been developed in a wide variety of projects and
for many different applications.
2000 Sika®-PM500
Highly-mechanized
shotcretingsystems for dry or
wet mix shotcrete
Aluminium Hydroxide Modified
Aluminium Sulphate Polycarboxylates
Sigunite® AF Liquid EQ Sika® ViscoCrete®, the latest
E
Conforms to the EFCA envi-
ronmental quality standard
Konform mit den Umwelt-
richtlinien der EFCA
Cement particle
of
s
nc uro p
Co
on
r e t e a n F e d e r a t i o n c i a ti
eA
d m ixture s A sso
Conforme aux directives
écologiques de l’EFCA
branes and eyes can be avoided. Sigunite AF Liquid specifications: < 0.55 70
60
W/C ratio for wet shotcrete for average
50
The spraying capacity is the main factor specifications: < 0.50 40
Pump pressure during concrete delivery
influencing the economics of the wet W/C ratio for wet shotcrete for high 30
spraying process. Depending on the appli- bar specifications: < 0.46 20
160 10
cation, up to 30 m3/hour can be achieved.
120 0
To obtain a high output, it is important Durability,
to find the best shotcrete formulation, layer 80 Watertightness 3 3 days 7 days 28 days
thickness and type and quantity of accel- 40 Durability means high watertightness. W/C ratio 0.40 W/C ratio 0.46 W/C ratio 0.50
erator. A high output cannot be obtained 0 Low capillary porosity is essential for 3
Without SikaPump: jerky feed pressure Effect of W/C ratio on depth
unless the concrete is easily pumpable. high watertightness and is obtained by of water penetration
If the concrete mixes are unsuitable, spe- bar correctly applied shotcrete with a low
cial additives help to prevent separation 160 W/C ratio and correct curing. 140
Formulations for shotcrete must always Examples of Concrete Formulations During the prequalification procedure
be adapted to the specifications of the client or project designer normally
the aggregate components and cement Dry-mix shotcrete 0 – 8 mm requires suitability tests to be car-
available so that the required early ried out to verify that the quality speci-
strength and workability can be obtained. Cement 280 kg fications are met. These tests have
Preliminary tests in the concrete laboratory ®
SikaFume - HR/-TU 20 kg to be done at the start of construction
make the site operations easier. ® and the locally available raw materials
Retarder SikaTard - 930 0.3 %
0 – 4 mm with 4% inherent moisture 55 % ca. 680 kg (cement and aggregate) and the plant Flow-table spread testing of fresh concrete 1
The cement grade has a strong influence and equipment planned for the works
4 – 8 mm with 2% inherent moisture 45 % ca. 560 kg
on both strength development in the must be used.
3
early stages and the final strength and Dry mix moist m * ca. 1540 kg
properties of the hardened concrete. *Must be checked by a yield test During construction the quality of the
SikaFume® is used for much higher Cement content shotcrete must be controlled in accord-
watertightness (durability) and reduced For 1000 litres dry mix, 280 kg cement is added to 800 litres aggregate ance with current standards or the
rebound. SikaTard ® (retarder) is For 1250 litres dry mix, 350 kg cement is added to 1000 litres aggregate tender documents.
used for long-time retarded shotcrete Shotcrete from 1 m3 dry mix gives on the wall
and SikaTard ® or ViscoCrete® Accelerated with Sigunite® AF Powder (rebound 16 – 20 %) 0.58 – 0.61 m3
(flow control agents) for better Accelerated with Sigunite® AF Liquid (rebound 20 – 25 %) 0.55 – 0.58 m3 Concrete spraying, spraying shadow/rebound 2
Cement content in the shotcrete ca. 450 – 460 kg/m3
workability at a reduced water content.
Steel fiber increase the load-bearing
capacity and ductile bearing properties of Wet-mix shotcrete 0 – 8 mm
the shotcrete. Polypropylene fiber is
Concrete
used for improved early shrinkage proper- Cement 425 kg 135 l formulation
ties and higher fire resistance of the SikaFume®- HR/TU 20 kg 9l
shotcrete. The air void content of the fresh ®
Flow control SikaTard /
shotcrete is increased, which improves
Sika® ViscoCrete® 1.2 % Concrete
the workability and spraying result. 1
Retarder SikaTard - 930 ®
0.3 % production
Early strength of 0 – 1 N/mm2 3
Penetrometer method
The maximum aggregate particle size Aggregate:
depends on the layer thickness and the 0 – 4 mm with 4% inherent moisture 60 % 967 kg 358 l
surface finish required for the shotcrete 4 – 8 mm with 2% inherent moisture 40 % 791 kg 293 l Concrete
Added water (W/C = 0.47) 155 kg 155 l delivery
layer. Approximately 95% of the aggre- Air voids (4.5 %) 45 l
gate surface is supplied by the 0 – 4 mm Steel fiber 40 kg 5l
sand fraction and variations in the sand
Shotcrete 1000 l
component have a massive effect on the Density per m3 2398 kg Concrete
fresh concrete properties, the W/C ratio 3
pumping
and therefore the properties of the 1 m of applied shotcrete gives set on the wall
Accelerated with Sigunite® AF Liquid (rebound 6 – 10 %) 0.90 – 0.94 m3
hardened concrete. The sand fraction Cement content in shotcrete 450 – 470 kg/m3 Early strength of 1 – 15 N/mm2 4
Stud-shooting method
must be analyzed with extreme care Steel fiber content in shotcrete 30 – 36 kg/m3
during the quality control process. We Spraying 2
distinguish between round and broken Sufficient fines ≤ 0.125 mm are important
aggregate. The best particle form is for pumpability. Recommended fines content
cubic/spherical: it is very important for (total aggregate + cement + additional fine
workability. The aggregate must be hard, aggregates): Shotcrete
clean and not weathered.
Aggregate 0 – 8 mm 0 – 16 mm
3
Round 500 kg/m 450 kg/m3
Early strength
3 4
Compressive strength of core sample 5
Broken 525 kg/m3 475 kg/m3 testing Compression press
Hardened concrete
5 6
testing
Curing
Water impermeability 6
Testing with water under pressure 6|7
Shotcrete Application
Compressed air
Compressed air
Wet mix Wet mix Dry mix
Repair of High durability in thin layers
concrete dams Low elastic modulus
Pneumatic feed
Hydraulic feed
Low rebound
(dense flow)
(fine flow)
Pneumatic feed Pneumatic feed
(fine flow) (fine flow)
Repair of High mechanical resistance Concrete pump Concrete spraying machine Concrete spraying machine
harbour walls High resistance to chemical effects
Air
100 cm – 150 cm
Current transformer
alkali-free
100 cm – 150 cm
Sigunite,
80 cm – 120 cm
alkaline
Air
alkali-free
alkali-free
Sigunite,
Sigunite,
Sigunite,
Sigunite,
alkaline
alkaline
Air for current transformer Water
Bridge New concrete not susceptible
reconstruction to vibration from traffic
Frost and freeze/thaw resistance Accelerator Accelerator Accelerator + water
8|9
Shotcrete Additives Shotcrete Accelerators
Workability Time of wet Shotcrete Mixes Table of the various Accelerator Types Elutability of the Calcium Hydroxide Ca(OH)2
and their main Properties
Property Accelerator type Calcium hydroxide content
in mmol / L m2
60 cm
Alkaline Alkaline Alkali-free
Aluminate-based Silicate-based
50 cm 30
Dosing range 3–6% 12 – 15 % 4–7%
Long-time retarded 25
wet-mix shotcrete with pH value 13 – 14 11 – 13 3
40 cm SikaTard-930 and 20
Sika ViscoCrete Na2O equivalent 20 % 12 % <1 %
Wet-mix shotcrete with 15
basic retarding of 3 hours with
30 cm
SikaTard-203
Very early strength ++++ ++++ +++ 10
at same dosage
5
Consistency, flow
Flow control SikaTard® High water reduction Optimum effect when added
agent (FM) Sika® ViscoCrete® Better workability after the mix water
High-performance Time controlled workability Optimum dosage depends
flow agent Rapid increase in strength on cement type
Better shrinkage and creep properties For specific properties, Liquid, alkali-free Sigunite® AF Heading stabilization in tunnelling For the dry or wet spraying process
Higher watertightness preliminary tests with the setting accelerator Liquid Rock and slope stabilization Non-corrosive
cement and aggregates to High-quality lining shotcrete Low final strength reduction compared
be used are essential Very high early strength with the non-accelerated original
Increased watertightness concrete
Retarder (VZ) SikaTard®- 930 Adjustable workability Reduced eluate quantity Not compatible with alkaline
No cleaning of pumps and hoses Better health and safety accelerators
necessary during the retarding phase Metal parts in contact with this
accelerator must be of stainless steel
Silicafume slurries Sikacrete®- L Improved fresh concrete homogeneity Added at the batching plant
Silicafume powder SikaFume® Much higher watertightness Optimum curing is necessary
Improved adhesion between aggregate because silicafume concrete Powder, alkali-free Sigunite® AF
and hardened cement dries out very quickly on setting accelerator Powder
High frost and freeze/thaw resistance the surface
Lower rebound Liquid, alkaline Sigunite® Heading stabilization in tunnelling For the dry or wet spraying process
setting accelerator Liquid Rock and slope stabilization Corrosive
Polymer-modified Sikacrete®- PP1 As for SikaFume,® plus: As for SikaFume® Very high early strength Final strength reduction compared with
silicafume powder Significant water reduction Lower rebound the non-accelerated
For very high quality specifications Can be sprayed on a original concrete
wet substrate
Pumping agents SikaPump® Improvement in homogeneity and internal Addition increases the power
and stabilizers Sika® Stabilizer cohesion for unsuitable concrete mixes input of the mixer and the concrete
Increase in spraying output with lower consistency – do not adjust by Powder, alkaline Sigunite®
energy consumption, even for mixes with adding water setting accelerator Powder
broken aggregate
10 | 11
Dry and Wet Mix Spray Mortars Machines for Shotcreting
SikaCrete®- Gunite®
Sealing gunite High durability Concrete Spraying Machines Aliva®- 246/Aliva®- 252/Aliva®- 263/
Silicafume-modified High frost and Aliva®- 285
freeze/thaw resistance Concrete spraying machines for
Sulphate-resistant dry and wet spraying
Good adhesion to substrate Low to medium outputs
Dry spraying process Mobile and multi-purpose
For spray mortar and shotcrete
SikaCem®- Gunite®
Sealing gunite Can be applied in thin layers
Polymer-modified High frost and
freeze/thaw resistance
Sulphate-resistant
Good adhesion to substrate Spraying Robots for TBM Aliva®- TBM Spraying Robots
Dry spraying process Heading Shotcreting robot for immediate
stabilization and lining by shotcreting
Sika® MonoTop® Medium to high outputs
Repair mortar Repair of concrete structures
Silicafume and High frost and
polymer-modified freeze/thaw resistance
Good adhesion to substrate
Ideal surface workability
Wet spraying process
1-component ready-mix mortar
12 | 13
Uses of Shotcrete
Shotcrete Stabilization in conventional Heading Excavation Slope Stabilization with Wet or Dry Mix Shotcrete
Sika-PM500 shotcreting system for large sections Aliva-503 shotcreting system for small sections Slope stabilization Excavation stabilization
Shotcrete Stabilization in TBM Heading Concrete Repair with Dry Mix Spray Mortars
14 | 15
®
Sika Shotcrete Systems
Technology and Concepts for Shotcrete
®
Sika Shotcrete Systems
Your local Sika Company
Technology and
Sika Services AG
Corporate Construction
Concepts for Shotcrete
CH-8048 Zürich
Switzerland
Phone +41 44 436 40 40
Fax +41 44 436 46 86
www.sika.com
S&W 04.05 / 05SIC 21.17 / © Sika Services AG
a nagemen
d Qu lity Sy Ma
fie d t
st
rti
Sy
ie
em
Ce
Certif
stem
1
IS
00
IS
O
90
01 / E N 2
9 O 14 0 0 1
since 1986 since 1997