MethodStatement for Shotcrete

METHOD STATEMENT
FOR
Shotcrete
Table of Contents

1. PURPOSE -------------------------------------------------------------------------------------------- 2

2. SCOPE ------------------------------------------------------------------------------------------------ 2

3. RESPONSIBILITIES ------------------------------------------------------------------------------- 2

3.1 Project Manager ----------------------------------------------------------------------------------------------------------------------- 2

3.2 Station Manager ----------------------------------------------------------------------------------------------------------------------- 3

3.3 Site Engineer ---------------------------------------------------------------------------------------------------------------------------- 3

4. DEFINITIONS ---------------------------------------------------------------------------------------- 3

5. REFERENCES -------------------------------------------------------------------------------------- 3

6. METHODOLOGY: ---------------------------------------------------------------------------------- 4

6.1. Preparation of Surfaces -------------------------------------------------------------------------------------------------------------- 4

6.2. Installation of Reinforcement/ Wire mesh ------------------------------------------------------------------------------------ 4

6.3. Mixing & Transportation of concrete -------------------------------------------------------------------------------------------- 5

6.4. Spraying of Shotcrete ---------------------------------------------------------------------------------------------------------------- 5

6.5. Rebound Material --------------------------------------------------------------------------------------------------------------------- 6

6.6. Curing ------------------------------------------------------------------------------------------------------------------------------------- 6

6.7. Defects and Repairs ------------------------------------------------------------------------------------------------------------------- 6

6.8. Drainage of Slope Surface ----------------------------------------------------------------------------------------------------------- 7

7. SAFETY ----------------------------------------------------------------------------------------------- 7

8. QUALITY --------------------------------------------------------------------------------------------- 7

9. EQUIPMENTS --------------------------------------------------------------------------------------- 7

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MethodStatement for Shotcrete

1. PURPOSE
This document covers Method Statement for Shotcrete by dry mix process (dry mix shotcrete) to the
excavated slope/ vertical surface to ensure the stability of soil / rock slope, in order to carry out the works
inplanned and systematic manner.

2. SCOPE
This method covers following activities:

 Leaning of rock surface from loose particles

 Installation of wire-mesh, where required.
 Preparation of shotcrete mix
 Application of shotcrete

3. RESPONSIBILITIES

 The MS shall be followed by all personnel involved in shotcretingactivity.

 This MS may be adjusted to suit adverse site conditions subject to approval of Station
Manager.
 Action may be delegated, but responsibilities shall not be delegated.
 Use of word ‘shall’ with in this document indicates a mandatory requirement.
 Use of word ‘should’ within this document indicates a preferred requirement.
 Detailed responsibilities are set out in:
o Project Quality Management Plan
o ITPs
o Risk Assessment
o SHEVCs

3.1 Project Manager

 The approval of this MS

 Overall scope of work.
 Coordination of personnel and equipment to ensure continuous program of works during
execution.
 Receiving daily progress reports and distributing to Client’s approved representative and
Contractor’s Management, and ensuring prompt action to any matter highlighted in the
same.

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MethodStatement for Shotcrete

3.2 Station Manager

 Implementation of this MS.

 Safety to personnel, incident reporting and implementation of the Safety Management Plan
and Safety Management System.
 Ensuring that the works are carried out in accordance with approved permits and MS.
 Ensuring that all personnel are fully aware of their duties and responsibilities.
 Liaising with Client’s approved representative during the operations and during MS change,
contingency operations or mitigation works.

3.3 Site Engineer

 Ensuring construction is in accordance with approved MS and specifications.

 Ensuring that all data is recorded in accordance with this document.
 Ensuring all required as built data are recorded.
 Providing any information and field calculations that may be required during the work.

4. DEFINITIONS

For the purpose of this document the term:

 JKIL :Contractor
 QA :Quality Assurance (applies essentially to process)
 QC :Quality Control (applies essentially to works andproducts)
 ITP :Inspection& Test Plan-A document that sums up all the
information related to inspections, measurements and tests to be
carried out during execution of work in scope. For the scope, the
term ITP is used.
 Shall : Mandatory Requirement
 Should : Recommended Practice
 SHEVC : SHE verification checklist

5. REFERENCES

 Applicable Specifications - refer to Attachment 1

 Applicable Project Procedures - refer to Attachment 1
 Applicable Project MSs - refer to Attachment 1
 Applicable Drawings & Sketches – refer to Attachment 2

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MethodStatement for Shotcrete

6. METHODOLOGY:

Dry Mix Shotcrete in which dry components of shotcrete (the cement, sand, 10mm aggregate
and admixture) are thoroughly mixed and fed to the hopper of the concrete spraying machine.
Compressed air carries the dry mix to the nozzle, where water is introduced under pressure and
intimately mixed with the dry mix before being jetted onto the surface.
The dry-mix shotcrete shall be applied either plain or reinforced with wire-mesh.
Thickness of shotcrete shall be 100mm and laid in two layers. Wire mesh of size 100mm x
100mm (4mm dia) shall be installed in the middle after laying of 1st layer.

6.1. Preparation of Surfaces

Immediately prior to the application of shotcrete, all surfaces to receive shotcrete shall be
cleaned, depending upon site condition, with compressed air to remove all loose rocks and
particles. Where water is found seeping through the leaks in the rocks and the surface is wet, the
seepage water will be led off by drainage pipes.
Also, prior to the application of an ext layer of shotcrete, the previous layer of shotcrete should
have initial set (Not lessthan 12Hrs) and all Loose material and rebound will be removed. The
surface will finally be cleaned and wetted using air and water.
The surface to receive shotcrete should be damp but will not exhibit free water.

6.2. Installation of Reinforcement/ Wire mesh

The reinforcement shall consist of MS wire-mesh of 100x100mm (4mm diameter). Wire-mesh

shall be installed only where shown on the drawings or required following geological observation
of the exposed slope / vertical surface.

Wire mesh shall be installed as follows:

 First layer of shotcrete is applied to the surface and wires (at about 1.5m intervals both
horizontally and vertically) will be embedded into and protrude out from the first layer of
shotcrete to support the wire mesh.
 Nails/dowel bars will also be installed for the binding of the wire mesh.
 Wire mesh is mounted and firmly secured to the embedded wires.
 Alternatively, where rock bolts are available, the wire mesh will be securely fixed by the face
plate in the rock bolt instead of above method.
 Second layer of shotcrete is applied to the surface properly embedding the wire mesh.
 If required as per design, a second layer of wire mesh is then installed and shotcrete applied
in layers to build the total design thickness.

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MethodStatement for Shotcrete

6.3. Mixing & Transportation of concrete

 The mix proportions for the shotcrete shall be M30.

 Batching and mixing of cement, sand, aggregate & admixture shall be carried out at batching
plant and shall be transported to site by concrete transit mixers.
 The mixture is then fed into a hopper of a Shotcreting machine and moves into the delivery
hose by a feed wheel or distributor.

6.4. Spraying of Shotcrete

 Shotcrete will be applied to the slope / vertical surface of excavated rock.

 Spraying of shotcrete will be carried out by experienced nozzle man only having an
experience of at least 3 years and shall exhibit his skill in the application of shotcrete by
spraying onto test panels.
 Hoses for delivery of dry mix to the nozzle will be of uniform diameter and laid straight or in
gentle curves and will be free of any kinks between the spraying machine and the nozzle.
 Dry mix shotcrete transported by transit mixers from batching plant to site shall be loaded
onto the hopper of the spraying machine. The dry mix unloaded at site on to plastic
sheets,will be mixed up with the shovel, if required, to avoid segregation before feeding into
the spraying machine.
 Admixtures shall be added to achieve early strength and dosage shall be according to the
Manufacturer’s specifications.
 The dry mix shall be taken to lower feeding chamber and feed motor is switched on.
 The mix is allowed to flow into the delivery hose with the help of compressor and feeding by
feed motor.
 The mortar is shot on to the surface through a nozzle coupled to the delivery hose by the
nozzle man.
 Just before shooting of mix, required quantity of water as per design mix shall be added at
the nozzle tip by the nozzle man. The design mix of shotcrete shall be submitted seperately.
 The nozzle will be operated manually. The nozzle man starts spraying shotcrete from the
bottom of the bench and moves the nozzle in small circles working his way up. It is essential
that the air supply is consistent and has sufficient capacity to ensure the delivery of a steady
and uninterrupted stream of high velocity shotcrete to the rock surface. Should the flow
become intermittent for any reason, the nozzle man shall direct the nozzle away from the
work until it again becomes constant. The nozzle shall be checked for wear and replaced if
necessary.

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MethodStatement for Shotcrete

 Thickness of shotcrete will be built up in layers. Rock bolt head projecting out from the rock
surface and the nail/dowel bars will be used to monitor and ensure the thickness of shotcrete
applied ( nail bars to be placed at min. 500mm c/c staggered in both direction).
 The nozzle will be kept 1.0m ~ 1.4m away from and as perpendicular as possible to the
surface receiving the shotcrete. Holding the nozzle farther from the rock face will result in a
lower velocity of materials which leads to poor compaction and a higher proportion of
rebound. However, the nozzle will be inclined sufficiently to ensure proper embedment of the
wire-mesh.
 No mix shall be used more than 2 hours after addition of water. Rebound material shall not
be reused.
 To avoid sagging and bleeding, shotcrete shall be built-up in successive layers, each layer
not exceeding 50mm thickness. The mortar shall cover the fabric reinforcement to a depth of
atleast 30mm.
 Total thickness of shotcrete shall be 100mm.
 Prior to continuation of spraying from a joint or leading edge position where the sprayed
concrete has hardened beyond its initial set, loose material will be removed by jetting with a
compressed air nozzle. Any laitance which has taken final set will be cleaned by jetting with
air and water.
 Shotcrete shall not be stopped till all the wire mess and 100mm nails have been covered.

6.5. Rebound Material

Rebound material shall not be covered with shotcrete. All rebound material shall be removed from
the working area immediately after completion of shotcrete and shall not be used in the works.

6.6. Curing

Shotcrete shall be cured by covering it with hessian cloth & kept wet for 3 days to keep required
moisture content. During hot weather, curing shall be done for 10 days.

6.7. Defects and Repairs

Before a subsequent layer of shotcrete is applied, the preceding layer will be checked for defects.
Where defects like honeycombing, voids, dry or ‘sandy” patches, sagged or slumped material is
detected, the defects will be cut out and re-shotcrete.The area of re-spraying shall not be less
than 300mmx300mm

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MethodStatement for Shotcrete

6.8. Drainage of Slope Surface

In order to provide for drainage of slope surface, weep holes shall be drilled before the spraying
of shotcrete at 5-10m intervals in both horizontal and vertical directions depending on quantity of
seepage water expected.
If water table is below the excavation area, the above weep holes may be further reduced to meet
only seepage water during rainy season.

7. SAFETY

 Risk Assessment report attached as attachment 3 shall be used.

 Workers will wear helmets, Safety shoes/ Gum boots while working on site.
 Watchman will be available at each work site both during working and non-working
hours.

8. QUALITY

 Inspection Test Plan attached as appendix 4 shall be used.

 A test panel shall be fabricated of at least 30cm square and 75mm thick which shall be
periodically gunned and cores or cubes extracted for compression tests carried out at the
age of 7 or 28 days or both. Visual inspection from cut surfaces may be done to check
soundness & uniformity of the material.

9. EQUIPMENTS

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