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    Aftes - Recommendations On Sprayed Concrete - Technology and Practice

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    Brian

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    of 11
    A.F.T.E.S. WORKING GROUP N° 6 RECOMMANDATIONS ON SPRAYED CONCRETE Technology and pratice Prepared by M. LEGRAND, chairman, assisted by MM. 8. BUZET. 8. CAZENAVE G, DURAND P. FAUVEL H. FORGERIT R. FOURCAUD M. GURTLER J. LAUNAY ¢. LOUIS. J. PROST ©. RESSE G. RIVALLAIN FOREWORD 6.1.2. — Spraying over a layer of early-age sprayed concrete 1. — STATEMENT OF PROBLEM AND DEFINITIONS. 2.— SPRAYED CONCRETE PRINCIPLES. ‘AND eure ix process spraying principle —MIX DESIGN -~ Characteristics of tresh concrete 427 —Eanyage srongth 122 = flechatleal properties 422.1 —Comprossive strongth 4222 = Splting tense strength 42.2.3. — Direct tonsile strength 4224. — Densiy 4.22'5.— Bonding DESIGN AND SUITABILITY TRIALS lan ae trial 52.) — Sutaolly tna crtera 2.2, — Dato of suitability tial 5.2.5. — Consistency of suitability tial 6. — PREPARATION OF SUSBSTRATE 6.1. — Proparation of wall to be treated 1.1. — Diet spraying on work surlace 6.1.3, — Spraying over an existing structure 114. — General remarks .2. — Drainage of water on wall to be trested '3. — Reinforcements 7. MANUFACTURE - TRANSPORT 8. — SPRAYING 8:1 — General practice = Surtace finish 8.3. — Sprayed concrete curing 8.4. — Cold weather 8.5. — Thickness check — QUALITY CONTROL — Intrinsic quality of sprayed concrewe — Analysis of fresh concrete = Compression tost ‘Spliting or “Brazilian” tensil test = Direct tonsile fost Caleulation of compactness Boning oat — Bvauaton of uniformity in mass and contnuty at the locaion of no vanous inerfacas $12. Characteriates, sampling method and conserva- tion of samples subjected to me sutanty tals ana the queltycontrl iets 32:11, — Boveretion of ocoptacts 221.1“ Boverption of ecoptactes 321.2 — Speci casoin whch a obo is used 322 Sample charactors and samping method 3221, ~Froan conrare 2222 —Harsored concrete 825. ~ Sample consrvation condos 10, SAMPLING NUMBER AND FREQUENCY. TEST SCHEDULE 41. HYGIENE AND SAFETY STANDARDS IN FORCE OW 1 JUNE 1992 NOTICE ‘The present recommendations relative to sprayed Concrete technology and practice supersede those publ shed in the special issue of “Tunnels at Ouvrages Sou- terrains" of July 1982, They are to be completed by recommendations relative to the technology and practice for metallic fibre reinfor ‘ced sprayed concrete. ‘The excessively partial and recent use of new ranges of additives and agents for sprayed concrete has not made It possible to arrive at conclusions regarding the utiliza tion conditions for these products. It is however probable that they will lead to better sprayed concrete utilisation ‘conditions and mechanical properties. Their testing with the support of a competent laboratory can thus be va- lable. ‘The appended list of current standards has the date of June 1992. European integration is presently leading to the rapid development of standardization texts. The rea der is thus requested to check the latest lists drawn up by AFNOR. FOREWORD ‘These recommendations cover the basic practice in the Use of sprayed concrete in underground engineering in all its aspects, ‘Schematically, the function of sprayed concrete in under- (ground works may be summarized as follows : — As a means of preliminary support, alone or in com= bination with other methods, involving prior spraying on the working face in a groove according to the pre-arch ‘method — As a means of support, alone or in combination with ‘other methods, involving application immediately after the excavation of the working face, in one or more phases. Sprayed on the ground, the concrete acts as “masonry” for joints, as protection against the action of ‘moisture and as a “flexible confinement curtain” which ‘must be placed continuously. — As a lining, when shotcreting takes place in a subse- ‘quent phase after excavation. The shotereting operation is then timed according to the work scheduling, Shotcrating is carried out on any support or on the ‘ground itself, when the latter is stablo without any sup- porting device. — As a means of local repaits or general strengthening of existing tunnels. ‘The present recommendations do not make this distinc- tion explicitly. tis up to the designer to state clearly in the contractual technical specifications, the requirements that he feels are best suited to the particular job. ‘When used in connection with the reconditioning ot exis- ting underground works, shotereting can be applied in va- rious ways depending on whether itis used for very loca- lized repaire or for large-scale strengthening by the provi sion of a continuous shell with possible reinforcement, The recommendations set forth below have been drawn up fram the viewpoint of the application of shoteroto in underground works. With some rectifications or adapta- tions, these recommendations may however be applied to any other use of shoterete, and in particular for surtace works, whether for new construction or repairs. STATEMENT OF PROBLEM AND DEFINITIONS, ‘Sprayed concrete is placed by spraying it through a pipe ‘against a wall under the action of compressed air. The sprayed mortar is a material in which the aggregates have a maximum particle size of § mm (AFNOR module 38). This definition is given here basically to allow this distinction between sprayed mortar and sprayed concrete which is the subject of the presant recommendations. There are presently two concrete spraying techniques — dry-mix process (with or without pre-wetting), —wet-mix process, 2s shown schematically in figure 1. The distinction has to do with the point at which the concrete mixing water is added in the spraying system. ‘The dry-mix process is presently used to a greater extent in the following cases. — For intermittent or small-scale projects. Using aggre- gates with a correct water content, the dry-mix process allows frequent and extended interruptions in spraying without any loss of mix and without requiring the system to be emptied. Also, equipement cleaning is tast and simple between each basic operation ; — When access to the spraying machine is difficult, itis possible to supply the site with dry pre-portioned concrete — When there is a very long transport distance between the sprayed concrete machine and the nozzle (more than 100 metres or so depending on the type and power of the machine). Whatever the spraying method adopted (dry-process or wot-process, manual or mechanized spraying), the quali fication of operators in charge of this task is essential for obtaining satisfactory results. The qualification of the va- ‘Aggregate, cement, pondered adixures Compressed air 2 —Dry-mix process ‘Wet concrate mix Concrete pump —— remix suspended in stoam of 4 'b— Wotunix process (compressed tlow) flux dense Premixnozlo 1 Water + ossible saul adsives Shotrthg Processes tious persons involved must consequently be checked during suitablity tests. 2.— SPRAYING CONCRETE PRINCIPLES AND EQuipMENT 2.1. — Dry-mix process 2.1.1. — Spraying principle The spraying equipment consists of: (figure 1a) —the concrete spraying machine ; —the stifener proportioning device =the mix delivery line : —the nozzle at the end of the delivery line. ‘At the inlet of the nozzie there are two pipes used to sup- ply water and possibly liquid stiffening admixtures, Compressed air ig introduced into the machine and cat ries the dry-mix (aggregates, cement and stiffening ad- mixtures, if any, in powder form) along the delivery line to the nozzie where the water is introduced. 2.1.2. — Equipment ‘Belliyae machine (figure 2) This double-lock machine, historically the fist, is compo- sed of two chambers connected by an airlack : a top chamber receiving the ingredients (1) and a bottom mixing chamber (2). The latter is equipped with a pocket wheel (3) driven by a compressed air motor. It leads to the delivery hose (4). Successive pressurizing of the two chambers closed by a cup valve (5) enables the dry mix Introduced into the top chamber to reach the delivery hose and be entrained by compresse¢ air flow (6). Figure 2 ‘Twin chamber shotcrete machine ‘Rotor ivpe machine (figure 3) In this type of machine, the dry mix is poured into a hop- per (1) generally by means of a belt conveyor. From this hopper, the concrete falls through a "loading orifice” into the cylinders of a vertically rotating barrel (2). After a half-turn of the barrel, the cylindrical chambers line up with the outlet port (5) where the concrete is driven by two compressed air streams (3 and 4), Variations in the discharge rate can be obtained by chan- ging the barrel (chango in unit volume of the cylindrical chambers) and by varying its rotating speed. Rotary todd shoteiete machine Delivery ine ‘Tho delivery lines, generally consisting of rubber hose, have an inner dlameter which Is often between 50 and 65 mm. Allowance must be made for the fact that the amounts of air required to carry the mix vary in propor- tion to the transport distance and the desired flow rate, After a certain distance, it is preferable to move the ss- prayed concrete machine, ‘Spraying tance Tne lance is placed at the end of the delivery hose. It in- cludes : — a metal or rubber nozzle which is interchangeable for replacement when worn. The speed of the concrete as it leaves the nozzle reaches several tens of metres per so- cond, up to 100 mvs, — annular distribution of fluids required for spraying, water or additives if any, placed 1 to 3 m back from the discharge end (pre-wetting lance). ‘Admixture proportioning Proportioning systems are controlled by the rate at which the sprayed concrete machine operates to guarantee re- ular and predetermined distribution. Proportioning ma- chines for admixtures in powder form are generally mounted on the feed conveyor. Liquid admixtures can be introduced into the lance dissoived in the wetting water. Water supaly In the dry-mix process, the water introduced In the lance ‘must have a sutticient pressure and a regular ‘low cate. ‘The use of an independent booster is thus recommen- ded, whose delivery rate allows effective wetting of the ix delivered by the sprayed concrete machine at its ‘maximum efficiency, Boosters usually delivery + 1 to 2 MPa. For highor pres: sures (5 to 10 MPa) a special lance (with small holes) must be used, Aicsupoly ‘The air rate required is of the order of 7 m/min for low ‘output repairs and higher than 10 m¥min for other appii- cations. 2.2. — Wet process 2.2.1. — Spraying principle (figure 1b) Tho concrete used is prepared and mixed in the plant using a conventional process. Delivered to a hopper, the concrete is then pumped through the wet mix feed line up to the spray lance. pumped in a dense flow is combined with compressed air which diffuses and acce- lerates the movement of the mix. The liquid admixture is introduced at th lance. inlet of the 222. — Equipment ‘Soraw pump (figure 4) ‘Screw pumps consist of a reception hopper (1) at the bottom of which an articulated horizontal shaft, agitator ‘and conveyor (2) carries the concrete fo the pump by ro tation (3) ‘The pump body is composed of a rubber stator and a steel rotor. ‘The rotation of the shatt and of the rotor imparts a trans- {ational movement to the concrete which is thus pushed towards the discharge line with a pressure capable of reaching 1,6 MPa. ‘The rotating speed is from 0 to 170 revolutions per mi- rule, corresponding to a theoretical maximum rate of 286 litres per minute {or 17 mém). Pumping Is continuous, Piston pump (figure 5) In piston pumps, the concrete is alternately sucked and then discharged by two pistons placed in two cylinders (1) in relation with the hopper (2) ‘The back and forth movement of a slide between the two cylinders makes it possible to achieve simultaneous mo- vements in the discharge towards the delivery lines, on the one hand, and filing by the translation of the opposite irections of the two pistons. Certain pumps operate by direct swivelling of the two cylinders of the pump. ‘The theoretical maximum delivery can reach 24 m/h, ‘Crushed nine" puma (figure 6) In this type of pump, a series of rollers crush the flexible hose and thus suck the concrete from the waiting hopper and discharge it to the lance. Aicsupaly ‘Tho amount of air required for spraying is of the order of 5 mimi. Delivery hose Delivery hose are generally made of rubber but can be ‘metallic on fixed and straight parts, in particular for lon- ger transport lengths. It is preferable to avoid right-angie bends, as these tend to favour clogging Certain delivery lines begin with a diameter of 100 mm at the outlet of the pump and end in 65 mm near the lance. In this case, the reduction in diameter should be distribu ted over different tapered reductions of sevoral metres. Lange ‘The lance itself is tapered, metalic or in rubber. The out- lat diameter is 50 mm. The annular distribution of the air and of admixtures is integrated in the lance 20 cm back from the discharge end, Admixture proportioning The liquid admixture proportioners are proportioning ‘pumps built into the machine and controled by the pump delivery rate. The nozzleman can control the regulation. 2.3. — Spray robots (figure 7) Robots replace the “nozzleman” with a remote-controted mechanized spraying boom. Their use is recommended in tunnels with large sections (larger than 30 m). Tho health and safety of shotereting personnel is then signif cantly improved. This approach obviates the need for hoavy liting equipment ofthe type with an elevating plat form or cradle and allows access to ditficut zo Figure 7 It also allows an increase in the projection rates owing to the use of larger piping diameters. The operating personnel located at a distance, near the boom attachment or on the ground with remote contro, has a better overall view of the work. This personnel controls the starting and stopping of the pump. The regular rotating and back and forth movement of the lance guarantees uniform spraying and better thicknoss control ‘There are two types of robot : — Complete robots consisting of the cartier with boom, ‘operating station and pumps. The advantage of this de- sign is the self-contained oparation of the machine. — Removable robots consisting of a boom and possibly ‘of an operating platform, which can be attached to a car- rier during the concrate spraying phase. This carrier can de used for other tasks (loading, localized face working machines). ‘The use of metallic fibras to strengthen the sprayed concrete will be dealt with in future recommendations is- susd by the ATES. 3. — MATERIALS 3.1. — Aggregate Aggregate must comply with applicable standards. The water content of the aggregate mix must be uniform and must remain low in the dry-mix process. The opti- mum water content in this case is betwaen 2 and 4% and, in any case, should romain lower than 7 %. Its the- rofore essential to store shotcrete aggregate under cover. Its preferable to use a sand containing the fewest pos- sible fat grains and a gravel having a mean volume coef- ficient, measured in accordance with French standard NF P 18-561, lower than 25 % for aggregates between 5 and 16 mm. 3.2. — Cement ‘The cement used should comply with the relevant stan- dards and appear in the NF VP or VP lists. In the presence of acid water, or water which is not highly mineralized or polluted water, the validity of the ‘chosen coment shall be demonstrated. 3.3, — Water The water used shall comply with Fronch standard NF P 18-303. 3.4. — Admixtures The products that may be used to faciltate the placement ‘of shotcrete and/or improve its quality in place are — Either concrete admixture (accelerators or superplasti- cizers, for example) ; — Or stiffening agents whose main function is to ensure immediate adhesion and stabilty, without concrete flow ‘when sprayed on the substrate, whatever the inclination of the substrate ; — Or adaitives : filers, fash, silica fumes used for par- tile size correction and sometimes to obtain a pozzola- nic effect. When the use of several admixtures is contemplated, a compatibility study shall be carried out before the suitabl- ‘hy teal 3.5. — Fibres Fibres currently used with shotcrete are elther synthetic, fibres (polypropylene) or metallic fibres. ‘By modifying the rheological behaviour of the fresh cconerete and of the concrete during hardening (Improve- ‘ment of cohesion and shearing resistance), synthetic fibres may contribute to the stability of a layer of shot- ‘rete on a material having excessively low mechanical properties. Their contribution to the improvement of hardened concrete strength is negligible. The proportioning cur- rently used Is between 1 and 2 kg/m? of produced ‘concrete. 4. — MIX DESIGN 1. — Characteristics of fresh concrete 4.1.1. — Composition ‘The initial proportioning of sprayed concrete components ‘must allow for the fact that after spraying, the proportions, in the mix willbe different from the initial proportions be- ‘cause of rebound and fall-off (except when spraying downwards). Rebound and fall-off affect the large aggre- gate sizes more particularly. ‘The result is an avarage increase of the-order of 10 to 20 % in cement proportioning for spraying of the ordor of 7 em in thickness and a transfer towards the fine aggre- Figure 6 gates of 10 10 20 % (relative value of the undrsize) on (graniat maxe 8 mm) the grading curve of the concrete in place. The thinner 8 Tamis mm the applied layer the greator wil this increase in propor- 22 $$ 8&8 9 tioning be, for ceiling application. 5 3 a Ls ° 10 2 Envelopes of grading for the aggregate-cement mix for ry-process and wet-process sprayed concrete are given by way of example in figure 8. A percentage of fine par- ticles (< 80 ) equal to or higher than 17 % in weight of the mix is necessary for spraying, For the same reasons, a continuous grading curve will be sought. ‘A constant water content is important in the dry process (see article 2.1.2. Equioment). 4.1.2, —Consistence In the wet process, consistence can be.monitored by slump tests before the stiffener is added. ‘Considering the current technology ot the pumping and spraying equipment for the wet process, a very plastic. ‘consistence will be sought. For example the slump value will be 10 to 18 cm according to Franch standard NFP 18-481 Bese eae es B* Tamisats % (oranuiat max 0 12,8 mm) Tams mm one oats ose 128 28 4.2, — Characteristics of hardened concrete « 2 4.2.1. — Early-age strength 00 T When the design requires very early age strength, cur- * rent coring techniques make it possible to evaluate volar Diy the mechanical properties of a concrete whase com- pressive strength is highar than 5 MPa For very special cases and for compressive strengths between 1 MPa and § MPa, itis possible to saw 10 cm: 4.2.2. — Mechanical properties Specitications detine the properties to be obtained at ait- ferent ages of the concrete according to the specific ap- plication requirements. z 5 422.1. — Compressive strangth E the following minimum values may be i Figure ‘Age of concrete ‘Strength {in MPa) (Granutat max 9 16 mm) 7a* 17 2¢ (oe 2 animate mean ‘characteristic strength 4.2.2.2, — Spitting tensile strangth By way of information, the following minimum values may be considered : ‘Age of concrete Strength in MPa 74 2 28d 27 Be see23 8 8 * 4.2.2.3. — Direct tensile strength When continuity between layers is desired, itis possible to evaluate it using the direct tensile test. The recom- Mended minimum 28 day value is 2 MPa, Tamisats % 1 4.2.2.4.— Density ‘The guarantee sprayed concrete durability, density mea sured on the core samples before mechanical testing shall not deviate by more than 2 % from that evaluated during design and suitability trials 4.2.2.5. — Bonding In connection with repair works, inasmuch as the sub- strate is considered to piay a supporting role, the bonding of the sprayed concrete into the substrate material shall be at feast equal to the tensile strength of tho weakest, material, measured to 28 days. 5.— DESIGN AND SUITABILITY TRIALS 5.1, —Design trial IK the contractor cannot provide a concrete composition offering references from the viewpoint of mechanical pro- erties as wall as placement conditions, a design trial will de necessary. Sprayed concrete design trials make it possible to esta- lish a nominal mix design and to check the consistence of the fresh concrete. Mechanical properties can be esti- mated knowing that the addition of stiffeners generally ‘causes a drop in strength. There are laboratory simula- tion methods which make it possible to approach these properties. Only the suitability trial will allow the valida- tion of the final mix design 5.2. —Sultability trial 5.2.1. — Suitability trial criteria ‘The suitability tral is always necessary whatever the si- tuation regarding the following two cases : a) The mix design is known and has references : the trial | requirad in order to check the capability of the contrac- tor to apply the sprayed concrete, from the viewpoint of Personnel as well as equipment. ) A prior study has been carried cut on the mix design in connection with the project but it has never been applied. Inthis case, the sultabilty trial is essential to ensure —the feasibility of concreted placement, — compliance with specifications, — capability of contractor to place the concrete. In both cases, it Is highly advised that a trial section be carried out on the site under placement conditions as close as possible as those of the future surface on which are to be carried out the tests provided for in the table of chapter 10. 5.2.2. — Date of suitability trial The suitability trial should be carried out sufficiently early in relation to the start of the works in order to have the ‘assurance that the resources used make it possible to comply with the requirements of the specifications. It is Fecommended that this trial be carried out at least 10 ‘days before the start of spraying. 5.2.3. — Consistency of suitability trial The sutabilty trial must be carried out with the person- nel, concrete ingredients, mixing and discharge installa- tions to be used for the actual works. The tests to be carried out are those called for in the quality control procedure for the concrete as defined in chapter 10. — PREPARATION OF SUBSTRATE 6.1. — Preparation of wall to be treated 6.1.1. — Direct spraying on work surface For direct spraying on the work surface, itis recommen- ded that the wall be treated as soon as possible alter ex- cavation. The preparation is limited to the removal of unstable elements. If some time has passed since the baring of the wall, surface stripping may be necessary. In very bad formations (lack of cohesion, intense fractu- ring), it may be necessary to consider a ‘special mix de- sign for the sprayed concrete to be used in the primary layer called the “safety layer 6.1.2. — Spraying over a layer of early-age sprayed concrete The spraying have to take in 72 hours afer the hardening of the preceding layer of sprayed concrete. In that case. ‘no surface preparation is necessary, provided the lattar has nat boon soiled, Hardening of the concrate oan be chacked by inserting a nail into the freshly sprayed concrete layer. 6.1.3. — Spraying over an oxisting structure (On a masonry or concrete substrate where itis important in the supporting or strengthening process to obtain good. bonding of the shotcrete onto its substrate, spraying will be preceded if necessary by surface demolition or pic- king in order to dislodge the large unstable elements. ‘Subsequently, the preparation af the wall for cleaning and stripping consist generally in a mechanical action ob- tained by spraying a steam of fluid (water at high pres- sure) or solid partcies (sanding, griting) 6.1.4. — General remarks In gonoral, whatever the nature of the substrate, itis re: ‘commended that it be wet just before spraying so that it does not absorb the water of the freshly sprayed concrete, This precaution is absolutely essential if the surtace 10 be treated is dry. This also allows the ellmina- tion of dust recently settied on the surface. 6.2, — Drainage of water on wall to be treated It is essential to make arragements to avoid any water underpressure at the interface support and sprayed coneret 6.3. — Reinforcements. It is possible to reinforce the sprayed conerete when its thickness exceeds 5 cm. In gonoral, it is preferable to use small diamoter roinforcament bars (3 mm being a mi- ‘nimum). The distance botween two parallel bars in a siven layer should (it possible) be greater than or equal to 10 om, whatever the nature of the reinforcement (concrete bars, welded mesh, centering, ‘The distance between two reinforcement layers shall be ‘greater than 5 cm. ‘The concrete covering of all metallic parts shall be at Teast 2 om. ‘The attachment of twisted grid panels in deployed metal, mesh or reinforcement bars is necessary in arder to avoid their movement during spraying. These movements contri- bute to the percentage of fall-off during spraying. Itis dest- rable that reinforcement panels be fixed rapidly on a first layer of sprayed concrete of at least 2 cm thickness. 401 In any case, several attachment points ara to be provided per square meter on the working face or on a sublayer of the shoterete. The distance botwoon a reinforcement layer and the wall on which the sprayed concrete is ap- plied shail be as small as possible. The minimum is 2 om. Aiter spraying, any movement or shitting of the rainforce- ments must be prevented, as this would lead to serious detects in the sprayed layer. 7. — MANUFACTURE - TRANSPORT ‘The manufacture of the sprayed concrete does not ditfer essentially {rom the manufacture of conventional ‘concrete. Reference may thus be made to article 24.3.2 and Technical Appendix T 24.3 of fascicle 65 of the cota. For same reasons, the transport of the shoterete is detine to anlcle 24.3.4 of fascicle 65 of the CCTG. @. — SPRAYING 8.1. — General practice To the extent possible, itis recommended that the spray lance be kept perpendicular to the surface to be treated and that care be taken to obtain, with limited rebound losses, a regular coaling with a properly compacted laysr of correct thickness. Downard vertical spraying 1s diff cout : there are also no losses, but uncoated aggregates ‘and rebounds are then mixed with the concrote. This may result in a lowering of the strength of the concrete. The distance between the lance and the suiface to be treated is adjusted according to the discharge velocity of the product to be sprayed. This velocity depends on the discharge pressure and the length of the discharge line. In general, the distance between the lance and the sur- taces to be treated should remain within the limits of 0.50 - 1.50 m. ‘The number of passes required to obtain a given thick- ness of sprayed concrete will be the smallest possible, {t would be desirable for the spraying to remote controlled rather. For manual spraying, the nozzieman will be equip- ped with appropriate means of protection. 8.2, — Surface finish Sprayed concrate linings are left as sprayed, without floating or other finishing in order to avoid any distur- bance to its structure or any effect on its qualily. If ano- ther texture is required for this surface, an additional layer will be placed (called the finishing layer) which can then be treated in conformity with the recommendations. of articie 6.1. 8.3. — Sprayed concrete curing For proper curing, sprayed concrete should be kept suti- ciently wet : it is thus recommended that it be sprayed frequently with water ; however, under certain circum- stances, curing products may be used. The conditions for the application of such products are the same as for in- situ concrete. 8.4. — Cold weather All cements set slower when temperatures drop below 5° C. The same rules as for the pouring of concrete in ‘cold weather ara to be applied. Moreover, shotorete must not be sprayed over a very cold or ica covered surtace, Special trials are required under such circumstances. 8.5. — Thickness check Complianco with the thickness of the sprayed conerate shell is essontial if it is so fulfil its confinement function. ‘The checking of this thickness is a delicate point in parti- cular when driving of a tunnel involving predominant sa- fety problems near the face. Itig often only after the spraying of a first “safety* coat of sprayed concrete, that itis possible to work in this zon The procedures used for checking the sprayed concrate thickness must consequently be suited to each specific ‘case. These procedures may include the following — Profilometer reading before and after spraying ; accu- racy is of the order of the centimetre ; — Implantation of the pegs in the facing ‘core sampling and driling in the sprayed — QUALITY CONTROL 9.1. — Consistency of quality control tests Quality control tests are based upon the following criteria — intrinsic concrete quality characterized by its compact- ness and Its short and very long term mechanical strength, — sprayed concrete bond strength on substrate, — uniformity in mass and continuity over various intor- faces (substrate, reinforcements and joints). 9.1.1. — Intrinsic quality of sprayed concrete This appl concrete. 's to fresh concret as well as hardened 9.1.1.1. — Analysis of frash concrete lt may be important to determine in certain cases the real ‘composition of the concrete placed. To accomplish this, it fs possible to carry out a “tresh concrete analysis" based upon samples made just after spraying and treated im- mediately, ‘may be taken during spraying in the receptacles defined in paragraph 9.2 andlor during spraying on the substrate, 9.1.1.2. — Compression test ‘The compression test is the basic test. Its carried out on core samples of 60 mm diameter in accordance with the provisions of French standards NF P 18-405 and 18-406, 9.1.1.3. — Spitting or “Brazilian” tensile test This tost allows the detormination of the average tensile strength of the concrete because it may affect several layers of the concrete which do not necessarily have the ‘same properties. The results are generally more scattered than in the compression test. The test is carried out on ‘core samples of 60 mm diameter in accordance with the provisions of French standards NF P 18-405 and 18-408. Procautions to be taken ‘The surfaces of the core samples must be perfectly straight without any undulation. During the test, such un- ulations constitute hard points favouring stress concen- trations and the appearance of cracks. Under such condi- 102 tions, the results do not in any way represent the proper- ties of the concrete. 9.1.1.4. — Direct tensile test ‘This test is valuable for determining the “bonding” bet- ween layers. It is carried out on core samples of 60 to 80 mm diameter (preferably 80 mm because this diame ter allows a reduction in the scattering of results). ‘The test procedure is as described below = marking the direction of the test in rel spraying direction, ion to the — sawing of faces perpendicular to the surfaces of the samples, — gluing a metal chip on each end with epoxy resin, — application of a tensile force through a system of ts, as in the following diagram. 1 Specimen Figure 9 Direct tonsiio The expression of the results includes the F/S stress as well as the location and the description on the fracture plan 9.1.1.5. — Calculation of compactness Compactness is evaluated an core samples by a density ‘measuring either by weighing and measurement or by hhydrostatic weighing atter the application of paraffin. 9.1.2. — Bonding test Experience has shown that the results of this in-place test are highly scattered and altered by secondary phe nomena such as deviated traction, peeling and even pla- ‘cement difficulties related to the surface condition of the Concrete and to the weight of the equioment. It is recommended that the test be carried out in the labo- ratory using samples of 80 mm diameter taken in situ and Containing the entire thickness of the sprayed concrete and part of the substrate, as shown in the following diagram (figure 10) The test is then cartied out using the direct tensile test procedure described in the figure 9. The results should include the failure stress F/S, the jo- cation and the description of the fracture plane. This stress will be called the bonding siress if the fracture takes place at the interface between the sprayed Concrete and the substrate material. In the particular case in which the rocky formation is cracked, it is recommended that a sprayed concrete bon- ding test also be carried out at the location of the cracks and joints. This requires precise and exhaustive prior no- tation of cracks and joints. 9.1.3. — Evaluation of uniformity in mass and conti- ‘uity at the location of the various interfaces. ‘This evaluation is carried out firstly on the basis of a vi sual examination of core samples (cores and imprints ge- erally made within the framework of the preceding tests). In the exceptional case in which in-place tests are const- dered to be unnecessary, it will be desirable to take a ‘ew core samples for visual examination. Also, it is possible to use nondestructive methods such as the sclerometer and sonic examination, if possible Using as reference the test section completed during the suitability trial. 9.2. — Characteristics, sampling method and conservation of samples subjected to the suitability trlals and to the quality control tests 9.2.1. — General Fresh concrete or hardened concrate samples can be taken from receptacles as described below or from a layer of the shoterete on its substrate. 9.2.1.1. — Description of receptacles tis recommended that the receptacies used are as des- ‘ribed in the figure 11 (offering a minimal surface, of the ‘order of 0,25 m), into which the concrete will be sprayad Perpendicular to the bottom placed vertically. However, a tolerance of 0 to 20° will be allowed on the vertically. ‘The thickness of the concrete will be at least 15 cm after spraying. Spraying will be carried out under rigorously 1 Shotcrete 2 Support Figure 10 103 the same conditions as recommended for the works constituents, machine, lance holding and mothods in par- ticular. 92. — Special case in which a robot is used ‘Considering the spraying rates currently observed when ‘a robot is usad (10 to 20 m°h}, the filling of the recep- tacles may be difficult. In this case, sampling by in-place coring maybe realized, 9.2.2. ~ Sample characteristics and sampling method 9.2.2.1. — Fresh concrete ‘A sample is to be taken after spraying, in three aifferent zones, The samples interested all of the thickness of the layer for tests. ‘One analysis of the fresh concret will be carried out on a fraction of the sample, each of one litre, .... in accor- dance with French standard NF P 18-560. 9.2.22. — Hardened concrete ‘Samples will be taken from the recoptacies or in situ by ccore sampling when the age of the concrete has reached at least 3 days ; except for the samples tested with the Previous ages. The diameter of the core samples shall be between 60 and 80 mm depending on the type of test to be carried out, The ends of the spocimens intended for the mechanical tests (compressive strength and splitting tensile strength) will be sawn perpendicular to the sur- face and then ground for the compression tests. After this operation, the slenderness ratio of the specimens will be equal to 2. 92. = Sample conservation conditions Tho receptacles will be kept on the site until the day of their transport to the test laboratory, 48 hours after th manufacture. Upon reception at the laboratory, the ‘samples will be cored. The cores will then be kept under laboratory conditions in accordance with French stan- dard NF P 18-408. in sity sampling will follow the same procedure. Number and scheduling oftests vay S0m* sping | 2107 cape ; tensile ‘Sto 28 days Srey ee tect | stozscine | once | every #0008 ony | ratte | once | on at ne coves very 1 coo Bonding + | ace elisa Vester |g Vga hack at rah cae union lan sonny Tests card out on recoptablas andlor tast sections {ed wisn he fameworkorihe utaoy ais, POP ‘Samating onthe test section, + Sampings on be tnng 5 B o Min. thickness In coring area 15 6m Pd Figure 11 104 10. — SAMPLING NUMBER AND FREQUENCY - TEST SCHEDULE These tests are sot by the main contractor. itis however recommended that sampling corresponding to the suita- bilty trials and to the quality control test series be carried ‘out in accordance with the conditions of the following table. 11. — HYGIENE AND SAFETY When sprayed concrete is used on an underground works site, and before dealing with problems relating ‘specifically to spraying concrete, the “hygiene and safety Plan* must first indicate all existing rules taking into ac count the situation and type of structure. ‘These rules have to do mainly with : — works in contined atmosphere, in aggressive, hazar-

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