Introduction to Shotcrete Applications

1 Introduction to Shotcrete Applications Course No: C04-002 Credit: 4 PDH Gilbert Gedeon, Continuing Education and Development, Inc. 9 Greyridge Farm Court Stony Point, NY 10980 P: (877) 322-5800 F: (877) 322-4774 EM 1110-2-200531 January 1993US Army Corpsof EngineersENGINEERING AND DESIGNS tandard Practice for ShotcreteENGINEER MANUALDEPARTMENT OF THE ARMYEM 1110-2-2005US Army Corps of EngineersCECW-EGWashington, DC 20314-1000 Engineer ManualNo. 1110-2-200531 January 1993 Engineering and DesignSTANDARD PRACTICE FOR SHOTCRETE1. manual provides information and guidance on the selection, proportioning, andapplication of Shotcrete as a construction manual applies to all HQUSACE/OCE elements, major subordinate commands,districts, laboratories, and field operating activities (FOA) having civil works manual describes general construction procedures using Shotcrete .

2 It includesboth the dry-mix process, in which most of the mixing water is added at the nozzle and the wet-mixprocess, in which all of the materials are mixed before entering the delivery hose. Additionalinformation on concrete properties and mixing proportioning are available in EM 1110-2-2000,"Standard Practice for Concrete."FOR THE COMMANDER:WILLIAM D. BROWNC olonel, Corps of EngineersChief of StaffThis manual supersedes EM 1110-2-2005, dated 10 September OF THE ARMYEM 1110-2-2005US Army Corps of EngineersCECW-EGWashington, DC 20314-1000 Engineer ManualNo. 1110-2-200531 January 1993 Engineering and DesignSTANDARD PRACTICE FOR SHOTCRETET able of ContentsSubjectParagraphPageSubjectParag raphPageChapter 1-51-1 Activities and 1-61-1 Point of 1-71-2 Chapter 2 Types of Shotcrete and ApplicationsWhy 2-22-1 Shotcrete 2-32-2 Fiber-Reinforced 2-42-4 Silica-Fume 2-52-4 Polymer-Modified 2-62-4 Accelerated 2-72-5 Chapter 3 Materials, Proportioning.

3 And PropertiesCementitious 3-33-2 Chemical 3-43-2 Reinforcing 3-53-3 Fiber 3-63-4 Proportioning 3-73-4 Properties of 3-83-6 Chapter 4 Equipment and CrewGeneral 4-14-1 Dry-Mix 4-24-1 Wet-Mix 4-34-1 Auxiliary 4-44-1 Special 4-54-7 Crew 4-64-7 Chapter 5 Preconstruction Testingand 5-15-1 Nozzleman 5-25-1 Mixture Proportioning Evaluation .. 5-35-1 Preconstruction Demonstration 5-45-1 Alternate 5-55-6 Chapter 6-16-1 Batching and 6-26-2 Shotcrete 6-56-8 Curing and 6-66-9 Repair of Surface 6-76-9iEM 1110-2-200531 Jan 93 SubjectParagraphPageChapter 7 Quality ControlGeneral 7-17-1 Preproduction 7-27-1 Production 7-37-2 Corrective 7-47-4 Chapter 8 Quality AssuranceGeneral 8-18-1 Preproduction 8-28-1 Production 8-38-1 AppendicesAppendix AReferencesAppendix BGlossaryAppendix CCorps of Engineers ProjectsAppendix DMixture Proportioning SampleSubmittaliiEM 1110-2-200531 Jan 93 Chapter 1

4 Introduction1-1. PurposeThis manual provides information and guidance on theselection, proportioning, and application of Shotcrete . Itis intended for use by engineers and technical stafftasked with the planning, design, contract preparation,and construction management phases of a shotcreteproject. A quality assurance chapter is included whichdetailsnecessarytechnicalactivities duringtheconstruction phase. Subjects discussed include shotcreteandapplications,materials,equip mentandcrew,preconstruction testing and evaluation, placement, qualitycontrol, and quality manual does notprovide guidelines for structural analysis of to EM 1110-2-2000 for additionalgeneral guidance on ApplicabilityThis manual is applicable to all HQUSACE/OCEelements,majorsubordinatecomm ands,districts,laboratories, and field operating activities (FOA)

5 Havingcivil works ReferencesAppendix A consists of a list of cited references thatappear in the body of the text as well as a selectedbibliography pertaining to the use of is encouraged to study applicable references tosupplement the guidance provided by this , the reader is encouraged to refer to AmericanConcrete Institute (ACI) Committee Report 506R-90,"Guide to Shotcrete " (paragraph A-1, ACI (1991d)), andother ACI 506 documents (paragraph A-1, ACI (1991e),paragraph A-2, ACI (1991c and 1991d)).1-4.

6 GlossaryAppendix B consists of definitions of terms commonlyused in Backgrounda. Special equipment and forpneumatically applying a fine aggregate cement mixturewas first introduced in that time, manyimprovements have been made in the equipment and inthe specialized techniques required for application ofpneumatically applied mortar or concrete. The wideacceptance of Shotcrete for slope and surface protection,swimming pool construction, tunnel lining, specialarchitectural features, and renovating existing structureshas resulted in the availability of a wide variety ofmanufactured pneumatic placement Shotcrete denotes various hasbeen referred to by such terms as Gunite, formerly atradename for pneumatically applied mortar or concrete,sprayed concrete, spraycrete, air-blown mortar andconcrete, gunned concrete.

7 And some areas"gunite" has been used to denote small-aggregateshotcrete and mortar mixtures, and " Shotcrete " to denotelarge-aggregate mixtures. The preferred term today forall gunned material is Shotcrete , regardless of theaggregate Specialty most Shotcrete placedis the traditional dry-mix and wet-mix Shotcrete , the useof specialty shotcretes has become of accelerators, fibers, and silica fume Varied Applications forCorps of Engineers (Corps) projects further discussed inChapter 2 include slope protection and stabilization,temporary excavation protection, tunnel support, andvarious structural and remedial Applications .

8 Appendix Cprovides a listing of some Corps projects that have usedshotcrete for various Activities and DocumentationInvolvementinshotcreteactiv itiesrangesfrompreliminary planning studies through the engineering anddesign phases, preparation of contract documents, toconstruction these activities theengineerorotherprofessionalmustperfor minvestigations, prepare documents, and review activities often result in theproduction of the following documents:- Shotcrete Investigation Report- Technical Specifications- Engineering Considerations and Instructions forField Personnela.

9 Shotcrete investigation informationlisted is to be included in a Shotcrete investigation reportand prepared either as a separate report or part of adesign memorandum, as a preparatory step to the1-1EM 1110-2-200531 Jan 93production of technical specifications. The formalizationof such a report depends on the size and complexity ofthe Shotcrete project.(1) Shotcrete quantity to be used and qualityrequired.(2) Climatic and service conditions to which theshotcrete will be subjected.(3) Types of Shotcrete processes and deliveryequipment to be used.

10 (4) Types, kinds, and sources of cementitiousmaterials to be specified, including special requirements.(5) Potentialaggregatesources,quality,andcon stituents.(6) Grading of aggregate to be specified.(7) Types and kinds of admixtures to be specified,including test CW 03361 provides a basis for preparationof a specification for Engineering considerations and instruction forfield accordance with EM 1110-2-2000,the designer should provide explanation of the intent ofthe Shotcrete application, special precautions, criticalitems to monitor, and any other information that may bebeneficial to the field Point of ContactQuestions or discussion concerning this manual should bedirected through Headquarters.