Sprayed Concrete, Shotcrete

SPRAYED CONCRETE,
SHOTCRETE
This work is to the scientiﬁc program of the
Development of quality-oriented and harmonized
R+D+I strategy and functional model at BME.
This project is supported by the New Széchenyi Plan
(Project ID: TÁMOP-4.2.1/B-09/1/KMR-2010-0002)
Dr. Salem Georges NEHME

assoc. Prof.
Contents
• DESIGN AND SPECIFICATION
• IN-SITU TESTS
• LABORATORY TESTS
AGGREGATES
• MSZ EN 12620:2002+A1:2008
• MSZ 4794:1:2004
• Aggregates shall comply with the requirements

of the national standards and regulations valid
in the place of use of the sprayed concrete and
shall be appropriate to the requirements of the
application.
• For dry mixes the natural moisture content in
the aggregate must be as constant as possible
and should not be more than 6%.
Aggregate grading curves for the wet
and dry-mix sprayed concrete process
100 100,0 100,0 100,0
90,0
Dry-mix process grading envelope
90
88,0 90,0
80 Wet-mix process grading envelope
72,0
73,0 73,0
70
Percentage passing, %
60 62,0 60,0
50,0 55,0
50 49,0
40
37,0 35,0
30 26,0 34,0
20 22,0 21,0
12,0 18,0
10 11,0 12,0
8,0 8,0
4,0 3,0
0 1,0
0,063 0,125 0,25 0,5 1 2 4 8 16 24 32
Particle size (mm)

CEMENT
The minimum cement content for a particular environmental
condition shall be as required by:
• MSZ EN 206.
• MSZ EN 197 és MSZ EN 196
• ÖNORM B 3327-1
The cement content should normally be between 350 and 450 kg/m3 of concrete for the dry
process and between 400 and 500 kg/m3 for the wet spraying process.
The type and content of cement should be selected to meet the specified requirements for
concrete strength and durability. Any material proposed as a binder which is not included
in EN 197 must first be tested for suitability and should comply with the minimum
requirements for traditional cement.
Normally, the initial setting time will be between 1.5 and 3.5 hours for a cement grain
fineness higher than 350 m2/kg.
Maximum temperature of the cement in the mixing plant silos should be limited to 70°C
and it should not exceed 50°C at the time of mixing.
Water, steel and steel fibre
• MSZ EN 1008
• MSZ EN 10080 and MSZ EN 10138
Type of fibre Normal concrete Sprayed concrete
Steel fibre 25 – 50 30 – 60
PP fibre 0,9 – 1,5 0,9 – 2,5
AE* Glass fibre 0,9 –10 > 0,9
(AR)
* AR alkaliresistant
• MSZ EN 14488-7: „Testing sprayed concrete.

Fibre content of fibre reinforced concrete”
Admixtures
Admixtures for shall comply with EN 934-5 or Appendix 1 of this specification (for
sprayed concrete) or EN 934-2 (for concrete).
Accelerators
Generally, all accelerators should be used at the manufacturer's recommended
dosages.
When alkali-free accelerators are used the following requirements should be met:
 The maximum Na20 - equivalent of the accelerators is limited to 1.0% by
mass.
 The dosage (by mass of the binder) is preferably:
• powder accelerators: 4 - 8 %
• liquid accelerator: 4 - 10 %
 The pH value of liquid accelerators is preferably between 2,5 and 8.
Alkali-containing accelerators should comply with the following dosage limits:
– powder accelerators: 4 - 8 % (by mass of binder)
– liquid accelerators: 4 - 12 % (by mass of binder)
The decrease in compressive strength (at 7 days or 28 days) of the accelerated
sprayed concrete should not exceed 25% for both powder and liquid accelerators.
Performance requirements for sprayed
concrete accelerating admixture
Performance requirements for

thixotropic admixture
Performance requirements for hydration
control admixture
Performance requirements for sprayed

concrete bond improving admixture
Additions
Maximum level of additions (by weight)
Cementitious material Maximum addition
Silica Fume 15% of Portland cement

Fly Ash 30% of Portland cement
15% of Portland/Fly Ash cement
20% of Portland blastfurnace slag
cement
GGBS 30% of Portland cement
Concrete mix
dry-mix sprayed wet-mix sprayed concrete

concrete
Cement, SBM addition 310 – 360 kg/m3 380 – 420 kg/m3
30 – 50 kg/m3 0 – 70 kg/m3
Binder 340 – 380 kg/m3 400 – 450 kg/m3
water-cement ratio ≤ 0,50 J2 and/or J3
Consistency 550-700 mm
Aggregates dmax 8, dmax 11 dmax 8, dmax 11
Factors of influence on the quality
Water/Cement - Ratio
Influence of fines content on shotcrete
mix design (0 – 8 mm aggregates)
Early strength classes of young sprayed
concrete
Compressive strength fc [N/mm²]
Increase of rebound
Risk of falling down
Minutes Hours
Interacting of aluminate and
silicate reaction
pH range of shotcrete accelerators
Compressive strength classes for
sprayed concrete (EN 206)
C25/30 → 25×0,85 = 21 N/mm2
By EFNARC: European Federation of National Associations of Specialist

Contractors and Material Suppliers for the Construction Industry
The strength grade of sprayed concrete shall be specified in accordance with

concrete strength classes C24/30 to C48/60 as specified in EN 206 (see Table)
Characteristic strength
STRENGTH C24/30 C28/35 C32/40 C36/45 C40/50 C44/55 C48/60
CLASS
Cylinder 24 28 32 36 40 44 48
Cube 30 35 40 45 50 55 60
In-situ strength requirements
• 32 N/mm2 × 0,8 × 0,85 = 22 N/mm2

• where:
• 32 = Characteristic cast cube requirement
• 0,8 = conversion for cube/cylinder specimen
• 0,85 = conversion factor for in situ sampling
Flexural strength
F
F/2 F/2
75
Sprayed Concrete mm
450 mm 125 mm
600 mm
Flexural strength
Minimum flexural strength, N/mm2
Strength Class C24/30 C36/45 C44/55
Beam flexural 3,4 4,2 4,6
strength
The flexural strength is mainly dependent on the

concrete/mortar matrix (even with fibre reinforcement)
and is defined in this specification as the equivalent
maximum elastic tensile stress at the first peak load
Residual strength class definition
points
Deformation Beam Residual stress for strength
class, N/mm 2
class deflection,
mm 1 2 3 4
0,5 1,5 2,5 3,5 4,5
Low 1 1,3 2,3 3,3 4,3
normál 2 1 2 3 4
High 4 0,5 1,5 2,5 3,5
Residual strength classes
5
4,5 Class 4 1 2
4 3 4
Residual Stress, N/mm2
3,5 Class 3
2,5 Class 2
1,5 Class 1
1
0,5
Class 0
0
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5
Beam [75×125×600 (500) mm] deflection, mm
Flexural strength : P0.1 × l/(b ×d2)
Set-Up for plate test
600 mm
100 mm
100 mm
500 mm
Example of energy-deformation
curves
Energy absorption requirements
Toughness Energy absorption in joule

classification for deflection up to 25mm
a 500
b 700
c 1000
Load / Deflection curve of steel fiber
reinforced shotcrete, EN 14488-5
Bond strength: minimum
requirements
Type of bond Minimum bond strength Minimum bond
to concrete, strength to rock,
N/mm2 N/mm2
Non structural 0,5 0,1
Structural 1,0 0,5
The values given in Table are average values from 3 samples

at 28days. No single value shall be lower than 75% of the
required value.
Conversion factors to equivalent
cube and cylinder strengths
Height/diameter Cube factor Cylinder factor
ratio of core
2,00 1,15 1,00
1,75 1,12 0,97
1,50 1,10 0,95
1,25 1,07 0,93
1,10 1,03 0,89
1,00 1,00 0,87
0,75 0,88 0,76
w/c effect on the compressive strength
Minimum Dimensions of Panel
Forms (in mm)
Sprayed Concrete Testing
Methods for strength development
measurement
• A - Penetration needle φ 3 mm
• B - Stud driving method with Hilti DX 450-SCT and Green
cartridge (threaded studs with a diameter of 3,7 mm):
• Standard-method for the strength range from 2,0 und 16,0
N/mm²
• C1 - Concrete cores for strength > 10,0 N/mm²
• C2 - Stud driving method with Hilti DX 450-SCT und Yellow
cartridge (threaded studs with a diameter of 3,7 mm):
Special-method for the strength range from 17,0 to 56,0
N/mm²
Since 2009 the formerly used tool DX 450 L will be distributed
with the new designation DX 450-SCT.
SCT stands for Sprayed Concrete Testing.
Fire testing of fire resistant sprayed
concrete
Examples
Concrete mix, BASF
Concrete mix, example 2
(Sika)
Concrete mix, example 3 (Sika)
Example 4
Example 5
falling down, m%
falling down
relationship between angle and
falling down
Angle
Influences on rebound
HUNGARIAN STANDARDS
• MSZ EN 12350-1: 2000 „A friss beton vizsgálata. 1. rész: Mintavétel”
• MSZ EN 12390-1: 2000-2006 A megszilárdult beton vizsgálata. 1. rész: A
próbatestek és sablonok alak-, méret- és egyéb követelményei
• MSZ EN 12390-3:2002 „A megszilárdult beton vizsgálata. 3. rész: A próbatestek
nyomószilárdsága”
• MSZ EN 12390-4: 2000 A megszilárdult beton vizsgálata. 4. rész: Nyomószilárdság.
Előírások a vizsgálóberendezésekre
• MSZ EN 12504-1: 2000 „A beton vizsgálata szerkezetekben. 1. rész: Fúrt
próbatestek. Mintavétel , vizsgálat és nyomószilárdság meghatározás”
MSZ EN 14487-
Lőtt beton. 1. rész: Fogalommeghatározások, előírások és megfelelőség
1:2006
MSZ EN 14487-
Lőtt beton. 2. rész: Kivitelezés
2:2007
MSZ EN 14488-
Lőtt beton vizsgálata. Mintavétel friss és megszilárdult betonból
1:2005
MSZ EN 14488-
Lőtt beton vizsgálata. 2. rész: A fiatal lőtt beton nyomószilárdsága
2:2007
Lőtt beton vizsgálata. 3. rész: A szálerősítésű gerendapróbatestek
MSZ EN 14488-
hajlítószilárdságának (első repedési, legnagyobb és nagy lehajlásokhoz
3:2006
tartozó maradék szilárdságának) meghatározása
MSZ EN 14488- Lőtt beton vizsgálata. 4. rész: A fúrt mag tapadószilárdsága közvetlen
4:2005+A1:2008 húzással
MSZ EN 14488- Lőtt beton vizsgálata. 5. rész: A szálerősítésű lappróbatestek
5:2006 energiaelnyelő képességének meghatározása
MSZ EN 14488-
Lőtt beton vizsgálata. 6. rész: Az alapfelületre fellőtt beton vastagsága
6:2007
MSZ EN 14488-
Lőtt beton vizsgálata. 7. rész: A szálerősítésű beton száltartalma
7:2006
Adalékszerek betonhoz, habarcshoz és injektálóhabarcshoz. 5. rész:
MSZ EN 934-
Adalékszerek lőtt betonhoz. Fogalommeghatározások, követelmények,
5:2008
megfelelőség, jelölés és címkézés
thank you for your attention

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SPRAYED CONCRETE,

Dr. Salem Georges NEHME

• Aggregates shall comply with the requirements

Particle size (mm)

• MSZ EN 14488-7: „Testing sprayed concrete.

Performance requirements for

Performance requirements for sprayed

Cementitious material Maximum addition

Silica Fume 15% of Portland cement

dry-mix sprayed wet-mix sprayed concrete

Risk of falling down

By EFNARC: European Federation of National Associations of Specialist

The strength grade of sprayed concrete shall be specified in accordance with

• 32 N/mm2 × 0,8 × 0,85 = 22 N/mm2

The flexural strength is mainly dependent on the

Toughness Energy absorption in joule

The values given in Table are average values from 3 samples

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