Method statement for Shotcreting works

What is Shotcrete or Gunite or Spray concrete

Shotcrete and Gunite are one and the same. Indian and American standards term this concrete as
shotcrete. European standards term the same as sprayed concrete. IS 9012 defines shotcrete as “mortar
or concrete (conveyed through a hose) and pneumatically projected at high velocity onto a surface.

Purpose of this Method Statement

This method statement describes the procedure and resources required to do the work. Use any other
resources and methods not referred to in this method statement to suit the project requirement.
Always execute the work safely complying with the required standard.

This method statement summarizes suggested method of executing works safely within any constraints.
This method statement offers advice and guidance to the personnel involved in this activity to:
a) Carry works in a manner that’s safe at all times;

b) Know the hazards involved in the activity;

c) Ensure controls to steer clear of hazard exposure are in place.

The sequence of activities is a repetitive process and many aspects are common to distinct sites. Include
with detail, any crucial aspects specific to the project. Always follow the approved checklists prior to the
start of the activity.

Materials for Shotcrete

Cement: Portland slag cement or Portland pozzolana cement

Fine aggregate: Zone II and Zone III grading of IS 383-1970

Coarse aggregate: 10 mm size

Water: A water cement ratio of 0.4 to 0.5

Reinforcement: Reinforcing bars or welded wire fabric

Equipment & Tools for shotcrete

Batching and mixing equipment

Delivery equipment like Shotcrete gun, nozzle, pump

Air supply arrangement

Hosepipe

Water supply arrangement

Health, Safety, and Environment

Execute all activities with due regard to Health, Safety & Environment of all the employees and third
parties.

Perform safety checks on all pressurized lines before usage

Shotcrete spray from the nozzle is potentially hazardous if not handled cautiously

Maintain adequate visibility at all times by providing appropriate lighting

Safety clamp all material hoses and airlines

The nozzle should not be casually put down until pressure is offline.

Review Material Safety Data Sheets (MSDS) for all materials in use.

Carry the work under the strict guidance and supervision

Personal Protective Equipment (PPE)

Below are the suggested PPE for shotcrete works:

Safety-Goggles
Safety-Helmet- "Safety Footwear"

Safety-Ear-Plugs Safety Gloves Safety Vest

Quality

Compressive strength: cubes or cores shall be taken from the panel of size 75 x 75 cm. Maintain a
thickness same as that of the structure but not less than 7.5cm. Alternatively, cores can be taken having
a minimum diameter of 7.5 cm and a length-diameter ratio of at least 1.

Other materials: Same testing requirements as cast-in-situ concrete testing

Slump tests

Maintenance of Batch records with details of contents in each batch

Procedure for shotcrete or gunite

Thoroughly clean all surfaces to receive shotcrete by removing loose materials and dust and pressure
washing. Dampen the surface to a saturated surface dry condition.

Fix wire mesh to the concrete surface. The steel wire mesh has to be placed in position keeping the
mesh within 10-15 mm from the surface. Suitable fixing pins are to be inserted to keep the mesh in
proper position and to ensure that the weld mesh is not disturbed during concrete spray.

Prepare a cement/water mix. Pour this mix into Pump hose for lubrication before starting to pump the
production mixture.

When the pumped mixture reaches the nozzle, turn on the compressed air.

Apply shotcrete evenly to targeted surfaces. Built-up the desired thickness of shotcrete in layers of
about 30 mm thick each. The presence of voids can be found by hollow hammering sound after the
shotcrete has attained strength after around 3 days.

Clean all discharge lines with a through water flush