EUROPEAN SPECIFICATION

for
SPRAYED CONCRETE

Association House, 99 West Street, Farnham, Surrey, GU9 7EN, UK

tel: +44(0)1252 739147 fax: +44(0)1252 739140
www.efnarc.org
EFNARC was founded in March 1989 by five national trade associations representing
producers and applicators of specialist building products. Membership has since been
widened to include major European companies who have no national body or institution
to represent their interests. EFNARC provides a common voice for the industry to make
known its comments and views to the European Commission, CEN Technical
Committees and other groups dealing with European Harmonisation of Specifications
and Standards in sprayed concrete, flooring and protection and repair of concrete
structures. EFNARC has specialist Technical Committees dealing with sprayed
concrete and flooring.
The Sprayed Concrete Technical Committee was formed in early 1991 and
subsequently produced a Final Draft of this document in 1993. Over 1,000 copies have
been circulated and it has been widely used as a reference document by specifiers,
contractors and material suppliers in many European countries and beyond such as
USA, Australia, the Far East, the Middle East and South Africa. It was also adopted by
the European Working Group CEN/TC104/WG10 as one of its main documents to
produce European Standard on Sprayed Concrete in 1994; and CEN/TC104/SC3 used
Appendix 1 on Admixtures as the basis for the production of the European Standard for
Sprayed Concrete Admixtures. This new edition takes account of comments made by
users of the document during this time.
Bayhass El-Jazairi
President

Acknowledgements
EFNARC wishes to gratefully acknowledge all the contributions and comments made
by the users to the 1993 Final draft and to the extensive work undertaken by the
members of its Technical Committee. EFNARC wishes to acknowledge with thanks
the work undertaken by Simon Austin, Loughborough University in the preparation of
this Edition of the Specification.

Although care has been taken to ensure, to the best of our knowledge that all data and information
contained herein is accurate to the extent that it relates to either matters of fact or accepted practice or
matters of opinion at the time of publication, EFNARC assumes no responsibility for any errors in or
misrepresentation of such data and/or information or any loss or damage arising from or related to its
use.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or
transmitted, in any form or by any means, electronic, mechanical, recording or otherwise, without prior
permission of EFNARC.

ISBN 0 9522483 1 X  1996 EFNARC

 CONTENTS
1. SCOPE .............................................................................................................. 1
2. REFERENCED STANDARDS............................................................................... 1
3. DEFINITIONS ...................................................................................................... 1
4. CONSTITUENT MATERIALS ................................................................................ 2
4.1 Cements............................................................................................... 2
4.2 Aggregates ........................................................................................... 2
4.3 Mixing water ......................................................................................... 2
4.4 Steel reinforcement................................................................................ 2
4.5 Fibres................................................................................................... 2
4.6 Admixtures ........................................................................................... 2
4.7 Additions .............................................................................................. 3
4.8 Curing agents........................................................................................ 3
5. REQUIREMENTS FOR CONCRETE COMPOSITION.............................................. 3
5.1 General ................................................................................................ 3
5.2 Cement ................................................................................................ 3
5.3 Additions .............................................................................................. 3
5.4 Aggregates ........................................................................................... 4
5.5 Admixtures ........................................................................................... 4
5.6 Fibres................................................................................................... 4
5.7 Consistence.......................................................................................... 5
5.8 Working temperature ............................................................................. 5
6. REQUIREMENTS FOR DURABILITY..................................................................... 5
6.1 General ................................................................................................ 5
6.2 Chloride content .................................................................................... 5
6.3 Alkali content ........................................................................................ 5
6.4 Requirements related to environment conditions ....................................... 5
7. MIX COMPOSITION............................................................................................. 5
7.1 General ................................................................................................ 5
7.2 Designed mixes .................................................................................... 5
7.3 Prescribed mixes .................................................................................. 6
7.4 Combined mix design ............................................................................ 6
8. EXECUTION OF SPRAYING ................................................................................ 6
8.1 Preparatory work ................................................................................... 6
8.2 Execution of spraying ............................................................................ 6
8.3 Curing .................................................................................................. 7
8.4 Protection against frost .......................................................................... 7
9. REQUIREMENTS FOR FINAL PRODUCT.............................................................. 7
9.1 Compressive strength ............................................................................ 7
9.2 Flexural strength ................................................................................... 8
9.3 Toughness properties............................................................................. 8
9.4 Modulus of elasticity.............................................................................. 10
9.5 Bond strength ....................................................................................... 10
9.6 Fibre content......................................................................................... 10
9.7 Permeability.......................................................................................... 10
9.8 Frost resistance.................................................................................... 10

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 10. TEST METHODS................................................................................................. 11
10.1 Test panels........................................................................................... 11
10.2 Compressive strength and density........................................................... 11
10.3 Flexural strength and residual strength.................................................... 12
10.4 Energy absorption class (plate test)........................................................ 14
10.5 Modulus of elasticity.............................................................................. 15
10.6 Bond strength ....................................................................................... 16
10.7 Permeability.......................................................................................... 16
10.8 Frost resistance.................................................................................... 16
10.9 Determination of fibre content ................................................................. 16
11. QUALITY CONTROL............................................................................................ 17
11.1 General ................................................................................................ 17
11.2 Preconstruction tests............................................................................. 18
11.3 Quality control....................................................................................... 18
12. HEALTH AND SAFETY........................................................................................ 20

APPENDIX 1 - Admixtures for Sprayed Concrete: Definitions, Specifications, Requirements,

Reference Concrete Mixes and Test Methods....................................................................... 21
CONTENTS ........................................................................................................ 22
1. SCOPE .............................................................................................................. 23
2. REFERENCES ................................................................................................... 23
3. DEFINITIONS ...................................................................................................... 24
4. REQUIREMENTS ................................................................................................ 24
5. REFERENCE SPRAYED CONCRETE .................................................................. 26
6. TESTING PROCEDURE....................................................................................... 28
7. DECLARATION OF CONFORMITY ....................................................................... 30
8. MARKING AND LABELLING ................................................................................ 30

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1. SCOPE
This specification deals with concrete or mortar which is pneumatically placed onto a surface. The term
sprayed concrete covers both wet and dry processes.
Sprayed concrete can be categorised according to application as follows:
a. Structural
b. Supporting rock and excavation
c. Short-term support
d. Surface improvement
e. Repair

2. REFERENCED STANDARDS
The following standards are referred to in the specification. However, any subsequently published or
revised European standard (EN) should always take preference over standards referred to herein. The
hierarchy of authority is EN standard, ISO standard, National standard.
EN 197 Cement; Composition, specifications and conformity criteria
EN 206 Concrete - Performance, production, placing and compliance criteria
EN 450 Fly ash for concrete - Definitions, requirements and quality control
EN 934-2 Admixtures for concrete, mortars and grouts - Part 2: Concrete admixtures -
definition, specification and conformity criteria
EN 934-5 Admixtures for concrete, mortars and grouts - Part 5: Sprayed concrete admixtures -
definition, specification and conformity criteria
EN 934-6 Admixtures for concrete, mortars and grouts - Part 6: Sampling, quality control,
evaluation of conformity and marking and labelling
EN 1008 Mixing water for concrete
EN 1504 Products and systems for the protection and repair of concrete structures
EN 1542 Products and systems for the protection and repair of concrete structures - Test
methods - Measurement of bond strength by pull-off
EN 4012 Testing concrete - Determination of compressive strength of test specimens
EN 6275 Testing concrete - Determination of density of hardened concrete
EN 6784 Testing concrete - Determination of static modulus of elasticity in compression
EN 7031 Testing concrete - Determination of the depth of penetration of water under pressure
EN 7034 Testing concrete - Cored specimens - Taking, examining and testing in compression
EN 10080 Steels for Reinforcement of Concrete. Weldable, ribbed reinforcing steel B 500.
Technically delivery conditions for bars, coils and welded fabric
EN 10138 Pre-Stressing steel, Part 1 - Part 5
ASTM C 666 Test Method for Resistance of Concrete to Rapid Freezing and Thawing
ASTM C 672 Scaling Resistance of Concrete Surfaces Exposed to Deicing Chemicals
ASTM A 820 Specification for Steel Fibres for Fibres-Reinforced Concrete
SS 137244 Betongprovning - Hårdnad betong - Frostresistens
Note: Some of these EN standards are in preparation.

3. DEFINITIONS
Sprayed concrete is a mixture of cement, aggregate and water projected pneumatically from a nozzle
into place to produce a dense homogeneous mass. Sprayed concrete normally incorporates admixtures
and may also include additions or fibres or a combination of these.
Wet process is a technique in which cement, aggregate and water are batched and mixed together prior
to being fed into a purpose-made machine and conveyed through a pipeline to a nozzle where the
mixture is pneumatically and continuously projected into place. The mixture normally incorporates
admixtures and may also include additions or fibres or a combination of these.
Dry process is a technique in which cement and aggregate are batched, mixed and fed into a purpose-
made machine wherein the mixture is pressurised, metered into a compressed air stream and conveyed

1
through hoses or pipes to a nozzle where water is introduced as a spray to wet the mixture which is then
projected continuously into place. The mixture may also incorporate admixtures or additions or fibres or
a combination of these.
Layer is a term used for a discrete thickness of sprayed concrete, built up from a number of passes of
the nozzle and allowed to set
Rebound losses are part of the overall production losses and consist of material which, having been
sprayed through the nozzle and struck the surface, does not adhere.
Nozzle is the equipment through which the mix is discharged; it consists of a pipe with a mixing unit
into which constituents are injected. With the dry process, water and any liquid admixtures are added;
with the wet process, liquid admixtures and pressurised air are added.
Binder is the total amount of cement and cementitious addition in the sprayed concrete.
Fibre reinforced sprayed concrete is primarily made of cements, aggregates and discrete reinforcing
fibres. Fibres suitable for reinforcing concrete and mortar have been produced from steel and organic
polymers. Glass and carbon fibres have also been used in mortar matrices.

4. CONSTITUENT MATERIALS
Materials shall fulfil the general requirements given below. Specific requirements for materials for
sprayed concrete are given in Section 5.

4.1 Cements
Cements shall comply with the requirements of EN197or alternatively with the national standards
or regulations valid in the place of use of the sprayed concrete. Only cement with established
suitability for sprayed concrete applications shall be used.

4.2 Aggregates
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.

4.3 Mixing water

Water for mixing shall comply with the requirements of EN 1008 or the national standards and
regulations.

4.4 Steel reinforcement

Reinforcement shall comply with the requirements of EN 10080 for reinforcing steel and EN 10138
for prestressing steel or with the national standards or regulations valid in the place of use.

4.5 Fibres

4.5.1 Steel fibres

Steel fibres shall comply with the requirements given in ASTM A 820 or similar national
regulations.

4.5.2 Synthetic fibres

Synthetic fibres shall be in accordance with national standards or regulations valid in the
place of use of the sprayed concrete.

4.6 Admixtures
Admixtures for concrete and sprayed concrete shall comply with the requirements of EN 934-2
and EN 934-5 respectively, and sprayed concrete admixtures with Appendix 1, or with the national
standards or regulations valid in the place of use. For their sampling, evaluation of conformity,
marking and labelling they shall comply with EN 934-6.

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 4.7 Additions

4.7.1 General
The most commonly used additions in sprayed concrete are fly ash, ground granulated
blastfurnace slag and silica fume. These additions shall comply with the relevant European
standards or national standards or regulations valid in the place of use of the sprayed
concrete.

4.7.2 Fly Ash (Pulverised fuel ash)

Fly ash is a finely divided inorganic Pozzolanic material which can be added to concrete to
improve or achieve certain properties in the plastic and/or hardened state.
Fly ash used in sprayed concrete shall comply with EN 450 or with the national standards
or regulations valid in the place of use.

4.7.3 Ground Granulated Blastfurnace Slag (GGBS)

GGBS is a fine granular latent hydraulic binding material which can be added to concrete in
order to improve or achieve certain properties in the plastic and/or hardened state.
GGBS used in sprayed concrete shall comply with national standards and regulations valid
in the place of use of the sprayed concrete.

4.7.4 Silica Fume

Silica fume is a finely divided, highly active inorganic pozzolanic material which can be
added to concrete to improve or achieve certain properties.
Silica fume used in sprayed concrete shall comply with the European standards or national
standards or regulations valid in the place of use of the sprayed concrete. Where such
standards and/or regulations do not exist the use of silica fume shall comply with the
recommendations of the suppliers.

4.7.5 Pigments
The inclusion of pigment shall comply with European standards or national standards or
regulations valid in the place of use of the sprayed concrete.

4.8 Curing agents

The curing agents shall be in accordance with the European standards or national standards or
regulations valid in the place of use of the sprayed concrete.

5. REQUIREMENTS FOR CONCRETE COMPOSITION

5.1 General
The concrete mix including cement, aggregates, water and any admixtures, additions or fibres
shall be selected to satisfy all the performance criteria for the fresh and hardened concrete.

5.2 Cement
The minimum cement content for a particular environmental condition shall be as required by
Section 6.4 and EN 206.

5.3 Additions
The contractor is allowed to add an approved cementitious material as described in Section 4.7
within the limits given in Table 5.3.1 unless otherwise directed by the client or the client's
representative. Addition of pigment should comply with the requirements of EN 206.
Cement additions may also be specified as a cement replacement, but must not exceed the
relative proportions given by Table 5.3.1.

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 Table 5.3.1: 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

5.4 Aggregates
The gradation curve should normally be in the shaded area given in Figure 5.4.1, the finer region
being more suitable for dry mixes (although a high proportion of particles ,< 0.25 mm can lead to
dust problems without adequate pre-dampening). It is the responsibility of the contractor to
choose the most suitable grading for the process and materials available.
For dry mixes the natural moisture content in the aggregate must be as constant as possible and
should not be more than 6%.

Figure 5.4.1: Recommended aggregate gradation zone

material passing (% by weight)

5.5 Admixtures
Admixtures for shall comply with EN 934-5 or Appendix 1 of this specification (for sprayed
concrete) or EN 934-2 (for concrete). Other admixtures shall be permitted provided that they
comply with the general requirements stated in Table 1 of these standards and Table 1 of
Appendix 1. Full account should be taken of their effect on the finished sprayed concrete and
there should be sufficient data about their suitability, including previous experience with such
materials. Records concerning details of the performance of such admixtures shall be maintained.

5.6 Fibres
Fibre reinforcement shall be specified preferably by the fibre reinforced sprayed concrete’s
performance requirements (or alternatively by the type and amount in the sprayed concrete).
Different fibre types may require different amounts to reach the same performance levels.

4
 The length of the steel fibres shall not exceed 0.7 of the internal diameter of the pipes or hoses
used unless a test has proven that longer fibres can be sprayed without blockage.
Fibres shall be stored in accordance with the suppliers recommendations.

5.7 Consistence
The concrete consistence required for wet spraying depends on the type of conveyance and the
application procedure. For a given cement content and w/c ratio the consistence can be adjusted
by admixtures added at the mixing plant or on site.

5.8 Working temperature

The temperature of the mix before placing shall not be below 5°C and shall not exceed 35°C
unless special provisions are made. Spraying shall not be undertaken when ambient temperature
is below 5°C.

6. REQUIREMENTS FOR DURABILITY

6.1 General
To produce a durable concrete, which protects the reinforcing steel against corrosion and
withstands satisfactorily the environmental and working conditions to which it is exposed during its
lifetime, the following factors shall be taken into consideration:
a) choice of suitable constituents, containing no harmful components, or those which may
interact unfavourably;
b) choice a concrete composition that satisfies all specified performance criteria.

6.2 Chloride content

The chloride content of the in situ sprayed concrete shall not exceed the values that are specified
in ENV 206 Section 5.5.

6.3 Alkali content

The alkali content of the aggregate shall comply with the requirements of current National
Standards to prevent alkali-silica reaction.

6.4 Requirements related to environmental conditions

The sprayed concrete shall be specified to meet the appropriate environmental exposure classes
given in Section 5 of EN 206 and related prescriptive requirements, with the following exceptions:
(i) the maximum water/cementitious ratio shall not exceed 0.55;
(ii) the minimum cement content shall be 300 kg/m³
(iii) frost resistance shall be determined by freeze-thaw testing (see section 9.8) not by
minimum air content; and
(iv) the minimum cover requirements relate to bar and mesh reinforcement but not steel fibres.

7. MIX COMPOSITION

7.1 General
The Designed Mix approach is the preferred method of mix specification for dry process sprayed
concrete because it produces a better defined and more consistent end product than the
Prescribed Mix approach.

7.2 Designed mixes

The mix shall be designed by the contractor to achieve the specified compressive strength and/or
other specified properties (see Section 9), using materials which comply with Section 4.
The concrete specification may also contain additional requirements such as:
• minimum cement content
• maximum water/cement ratio
• flexural strength

5
 • toughness
• early strength
• maximum strength
• permeability
• water absorption
• bond to substrate

7.3 Prescribed mixes

The contractor shall provide, or propose for the approval of the client, a prescribed mix which
experience has shown to be suitable for the intended purpose.
The prescribed mix shall be specified by the following data:
• cement type and content
• water/cement ratio and/or consistence
• aggregate/cement ratio
• fibre type and content (in situ)
• type and quantity of aggregate
• type and quantity of admixtures
• type and quantity of additions
It is difficult to prescribe the water content with the dry process but in situ water/cement ratios will
typically be in the range 0.35 to 0.50.

7.4 Combined mix design

Where neither the Designed Mix nor Prescribed Mix approach is appropriate, the contractor may
be required to produce a mix to a hybrid specification, combining elements of Sections 7.2 and
7.3.

8. EXECUTION OF SPRAYING

8.1 Preparatory work

Before spraying of the concrete can start the following preparatory work shall be done.
For rock support:
• poor and loose rock shall be removed from the surface;
• the rock shall be mapped so the total need for support can be clarified; and
• water leakages shall be drained out, either by drainage channels or shall be blocked by the
use of an accelerated cement paste - mortar or by grouting.
For repair of concrete:
• the condition of the structure shall be assessed;
• the causes of deterioration shall be identified and eliminated wherever possible:
• defective and loose substrate (concrete, brick, etc.) shall be removed and the remaining
material must provide a sound substrate;
• if concrete substrate is carbonated or penetrated by chlorides, the concrete shall be
realkalised or the chlorides removed. If this is not possible the contaminated concrete shall
be removed, subject to maintaining structural integrity.

8.2 Execution of spraying

For spraying the following shall be undertaken:
• Pre-wetting shall be carried out unless otherwise specified.
• Big cavities shall be carefully built up before the main application.
• Spraying shall start from the bottom and continue upwards. This is to avoid spraying in
rebound losses.
• The nozzle direction shall generally be maintained at 90° to the surface.

6
 • The velocity and spraying distance shall be the optimum for maximum concrete adherence
and compaction.

8.3 Curing
Sprayed concrete shall be cured in accordance with the recommendations set out in EN 206 or
any other method which has been shown to allow continuous hydration of the cement over the
curing period.
Curing agents which impair bond shall not be used where a further layer of sprayed concrete is to
be applied. Field tests of the bond between layers shall be carried out prior to commencement of
work if any other type of curing agent is used.
If necessary, the curing agent shall be removed by water jetting, grit blasting or a similar process,
before application of the next layer.

8.4 Protection against frost

Protection against frost is needed until the sprayed concrete has developed a compressive
strength of at least 5 MPa.

9. REQUIREMENTS FOR FINAL PRODUCT

9.1 Compressive strength

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 9.1.1).

Table 9.1.1: Compressive strength classes for sprayed concrete (EN 206)

Characteristic strength (MPa)

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

To determine that the concrete meets the requirements to compressive strength, the in situ
strength requirements given in Table 9.1.2 shall be met, which are based on a 50 mm diameter by
100 mm long core and include a 0.85 reduction factor to allow for effects of insitu coring.

Table 9.1.2: In-situ strength requirements

Minimum compressive strength (MPa)

STRENGTH C24/30 C28/35 C32/40 C36/45 C40/50 C44/55 C48/60
CLASS
Core 20.5 24 27 30.5 34 37.5 41

The values in Table 9.1.2 are average values from 3 samples at 28 days. No single value shall be
below 75% of the required strength.
If applicable, the compressive strength development shall be specified by compressive strength
tests at agreed concrete ages. If the influence of the site conditions on the strength development
has to be taken into account, special curing conditions for the specimens shall be agreed.
For test methods refer to Section 10: Test Methods.

9.2 Flexural strength

If requirements for flexural strength are specified, the values given in Table 9.2.1 may be used.
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 - see Section 10.3.2.

7
 Table 9.2.1: Flexural strength

Minimum flexural strength (MPa)

STRENGTH CLASS C24/30 C 36/45 C 44/55
Beam flexural strength 3.4 4.2 4.6

The average flexural strength of three beams shall be equal to, or above, the required class value
given in Table 9.2.1. No single beam shall be lower than 75% of the class value. For test method
refer to Section 10: Test Methods.

9.3 Toughness

9.3.1 General
The toughness of the material is either specified by residual strength class (from a beam
test) or energy absorption class (from a plate test). These will not give values that are
comparable.
For testing methods refer to Section 10: Test Methods.

9.3.2 Residual strength class

There are five residual strength classes for sprayed concrete which are defined in Figure
9.3.1 and Table 9.3.1 in terms of the shape of the beam stress/deflection curve. The table
defines precisely the four points that define the boundaries between each residual strength
class. At least two of the three beams shall maintain a flexural stress on, or above, the
required class boundary given in Figure 9.3.1 up to the deflection limit appropriate to the
deformation class; e.g. a beam specified for the Normal deformation class must maintain a
flexural stress on or above the specified residual strength class boundary between 0.5 and
2.0 mm central deflection. No beam shall have a stress/deflection curve which falls below
the next lower class (with the exception of beams specified for class 1).
The purpose of the deformation classes is to give designers flexibility in the choice of
deformation required of the sprayed concrete under service conditions. For the purpose of
design, the deflection limit for a deformation class can be considered in terms of the
equivalent angular rotation or nominal crack width for a beam cracked at midspan (e.g. 1
mm equals 0.25° and 0.67 mm respectively).

8
 Figure 9.3.1: Residual strength classes

Table 9.3.1: Residual strength class definition points

Deformation class Beam deflection (mm) Residual stress (MPa) for strength
class
1 2 3 4
0.5 1.5 2.5 3.5 4.5
Low 1 1.3 2.3 3.3 4.3
Normal 2 1.0 2.0 3.0 4.0
High 4 0.5 1.5 2.5 3.5

9.3.3 Energy absorption class

If the energy absorption capacity of the material is specified, the plate test can be performed
and the requirements given in Table 9.3.2 may be used.

Table 9.3.2: Energy absorption requirements

Toughness classification Energy absorption in joule for deflection

up to 25mm
a 500
b 700
c 1000

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 9.4 Modulus of elasticity
When the modulus (in compression, tension or bending) influences the designed capacity or
required behaviour of the structure, the in-situ modulus used for the structural design shall be
verified. If there are any requirements for thermal expansion or shrinkage this should be specified
by the designer.
For test method refer to Section 10: Test Methods.

9.5 Bond strength

If requirements for bond strength are specified the values given in Table 9.5.1 for concrete and rock
surfaces may be used. Should the rock afford no bond, even after proper cleaning, no bond
strength shall be specified.
For test methods refer to Section 10: Test Methods.

Table 9.5.1: Bond strength: minimum requirements

Type of bond Minimum bond strength to Minimum bond strength to

concrete (MPa) rock (MPa)
NON STRUCTURAL 0.5 0.1
STRUCTURAL 1.0 0.5

The values given in Table 9.5.1 are average values from 3 samples at 28days. No single value shall
be lower than 75% of the required value.

9.6 Fibre content

The content of steel fibre in the sprayed concrete shall be expressed in kg/m3 after it has been
sprayed. The required in-situ fibre content to meet the flexural strength and/or toughness
requirements may be determined from testing. A minimum fibre content (either insitu or in test
panels) may be agreed for the purposes of quality control, in which case fibre content
determinations shall be made (each from the average of three fresh or hardened samples). The
average value shall exceed the agreed minimum value and no single value shall be lower then 75%
of the minimum value.
For test methods refer to Section 10: Test Methods.

9.7 Permeability
When water-tight sprayed concrete is required the maximum value of penetration in accordance
with EN 7031 shall be 50 mm, and the mean average value shall be less than 20 mm.
Alternatively, water-tightness can be determined by measuring water permeability. Sprayed
concrete is considered water-tight when the coefficient of water permeability is less than 10-12
m/s.
Sprayed concrete in environmental exposure class Highly aggressive is normally used when
water-tight concrete is specified.
When applicable, the requirement to gas permeability shall be specified by the client and
preconstruction tests shall be carried out.

9.8 Frost resistance

Sprayed concrete subjected to freezing and thawing in moderate water saturation without salt (EN
206 class) shall have no additional requirement for frost resistance testing. Sprayed concrete
exposed to more aggressive environments, as specified in EN 206, shall fulfil the requirements for
frost resistance as given in:
• SS 137244 or ASTM C 672 for scaling resistance, tested with or without salt water, according
to the exposure classification.
• ASTM C666 for freeze-thaw resistance to immersion in water.

10
10. TEST METHODS

10.1 Test panels and samples

Moulds of steel or other non-water-absorbing rigid material shall be used (a minimum of 4 mm
steel sheet or 18 mm plywood). The minimum plan dimensions shall be 600 x 600 mm for hand
spraying and 1000 x 1000 mm for robot spraying,. The thickness should be appropriate to the
size of test specimens to be cut from the panel, but shall not be less than 100 mm. Appropriate
measures shall be taken to avoid entrapment of rebound in the mould (such as using chamfered or
slotted sides).
The moulds shall be positioned vertically and sprayed with the same equipment, technique, layer
thickness per pass, spraying distance etc. as the actual work. The operator shall also be the
same.
The panel shall be protected immediately against moisture loss using the same method to be
used in construction. The samples shall be marked for later identification (Mix, location, date,
operator).
The panel shall not be moved within 18 hrs of being sprayed. Curing shall continue thereafter for 7
days or until samples are to be extracted.
The test samples shall be cored in accordance with EN 7034 or sawn from the panel, but shall not
include material within 125 mm of the edge (with the exception of the ends of beams for
flexural/toughness testing).
During transportation to the testing laboratory the panel or sawn samples shall be packed to
protect it against mechanical damage and moisture loss.

10.2 Compressive strength and density

Compressive strength tests shall be performed in accordance with EN 4012 on drilled cores taken
from the sprayed concrete structure or from sprayed test panels. Their minimum diameter shall
be 50mm and the height/diameter ratio shall be in the range 1.0 to 2.0. Test results from cores
with height/diameter ratio different from 2.0 shall be converted to equivalent cylinder strengths
using the values given in Table 10.2.1.

Table 10.2.1: Conversion factors to equivalent cube and cylinder strengths

Height/diameter ratio of Cube factor Cylinder factor

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

Alternatively the compressive strength can be determined from cubes cut from sprayed test
panels. The minimum dimensions shall be 60 x 60 x 60mm and the samples shall be tested in
accordance with EN 4012.
The density shall also be determined by weighing the sample in water and air in accordance with
EN 6275 (water displacement method).
Normal testing ages shall be 7 and 28 days.
The test report shall contain:
• test specimen identification
• moisture condition of the test specimen
• test specimen dimensions

11
 • curing conditions and age at test
• maximum load and compressive strength (to nearest 0.5MPa)
• test specimen density (to nearest 10kg/m³)
• appearance of the test specimen (if unusual)
• remarks (if any)

10.3 Flexural strength and residual strength

10.3.1 Testing arrangement

Testing of flexural strength and residual strength shall be carried out on beams with
dimensions of 75 x 125 x 600 mm cut from sprayed panels. The beams shall be tested
under third point loading on a 450 mm span. The prisms shall be stored in water for a
minimum of 3 days after sawing and immediately before testing. The sawn beams shall
normally be orientated as shown in Fig 10.3.1. The top of the beam may be orientated as
the tension face if required by the designer, although in this case the top surface should not
be sawn (to avoid cutting end anchorages of the steel fibres). Testing shall normally be
performed at 28 days.

Figure 10.3.1: Cutting and orientation of beams from the sprayed concrete

The arrangement for testing shall be as shown in Figure 10.3.2 and shall be so that it is
possible to measure bending deflections (i.e. net of support settlement) at the midspan of
the beam. The deformation rate of the midspan of the beam shall be 0.25 +/- 0.05 mm per
minute until a deflection of 0.5 mm. After this point the rate of deflection can be increased
to 1.0 mm/min. The load-deflection curve (deformation at midspan) shall be continuously
recorded.
The stiffness of the testing machine shall be such that the test shall be real deflection
controlled. The supports and loading points of the testing machine shall all be rounded with
a radius of 10 - 20mm. The test shall be finished when a midspan deformation of 4 mm is
obtained.

Figure 10.3.2: Flexural testing with third-point loading

12
10.3.2 Determination of flexural strength
The flexural strength shall be estimated from the load-deflection curve (Figure 10.3.3) as
follows. The initial straight line portion of the curve shall be determined, based on data up
to 50% of the peak load, and a line drawn parallel at a horizontal offset of 0.1 mm midspan
beam defection. The flexural strength shall be calculated from the first peak load (P 0.1 )
achieved up to and including the point at which the 0.1 mm offset line intercepts the
load/deflection curve (see Figure 10.3.3). The flexural strength shall be calculated as an
equivalent elastic tensile strength:
flexural strength (in MPa) = P0.1 x L / b x d²
where P0.1 is defined above (in N)
L is the span (450 mm)
b is the actual beam width (nominally 125 mm)
d is the actual beam depth (nominally 75 mm)

Figure 10.3.3: Determination of P0.1 load from load/deflection curve

The report shall contain:

• type of the testing machine
• specimen identification
• test specimen dimensions
• curing conditions and age at testing
• rate of deformation
• load-deformation curve including first peak load (P 0.1 )
• calculated flexural strength

10.3.3 Determination of residual strength class

The residual strength class shall be estimated from the load/deflection curve using flexural
stress values between 0.5 and 1, 2 or 4 mm depending on the specified deformation class,
see Figure 9.3.1 and Table 9.3.1.
It is recommended that each beam is classified by converting the flexural stresses defining
the classification boundaries (given in Table 9.3.1) into load values (using the beams actual
dimensions) and plotting these (joined by straight lines) on the beam load deflection curve.

13
 The report shall contain:
• type of the testing machine
• specimen identification
• test specimen dimensions
• curing conditions and age at testing
• rate of deformation
• load-deformation curve including flexural stress values for the specified deformation
class deflections
• deformation class and residual strength class

10.4 Energy absorption class (plate test)

A test plate of 600 x 600 x 100mm shall be supported on its 4 edges and a centre point load
applied through a contact surface of 100 x 100mm (Figure 10.4.1). The rough side shall be on the
bottom during the test, i.e. the load is applied opposite to the spraying direction.
The rate of deformation of the midpoint shall be 1.5mm per minute.

Figure 10.4.1: Set-Up for plate test

The plate shall be produced from a sprayed panel by levelling the panel at a thickness of 100mm -
0/+10mm, immediately after spraying. The sloped edges of the panel shall be sawn off when the
plate is prepared in the laboratory. The prepared plate shall be stored in water for a minimum of 3
days immediately before testing and kept moist during testing.
The load-deformation curve (Figure 10.4.2) shall be recorded and the test shall continue until a
deflection of 25mm is achieved at the centre point of the slab.
From the load-deformation curve a second curve shall be drawn giving the absorbed energy as a
function of the slab deformation (Figure 10.4.3).
The toughness requirements are given as a specified energy absorption at a certain deflection.

14
 Figure 10.4.2: Example of load-deformation curves

Figure 10.4.3: Example of energy-deformation curves

The report shall contain:

• type and stiffness of the testing machine
• specimen identification
• test specimen dimensions
• curing conditions and age at testing
• rate of deformation
• calculated energy-deformation curves
• first crack load and maximum load
• calculated energy-deformation curves
• energy absorption in Joule for a deflection until 25mm

10.5 Modulus of elasticity

The testing shall be done in accordance with EN 6784.
The report shall contain:
• specimen identification

15
 • test specimen dimensions
• curing conditions and age at testing
• rate of deformation
• load-deformation curve including maximum load
• estimated modulus of elasticity

10.6 Bond strength

The bond strength shall be determined by a partial core test (where appropriate in accordance with
EN 1542) or a tensile test, the testing arrangement being similar to those shown in Figure 10.6.1.
The rate of loading shall be within 1.0-3.0 MPa per minute. The core diameter shall be within the
range 50 to 60 mm. Precautions shall be taken to ensure that the tensile force is applied axially.
The report shall contain:
• specimen identification
• specimen dimension
• age at testing and curing conditions
• rate of loading
• max. load and calculated bond strength
• description of failure plane and mode

Fig. 10.6.1: Examples of core pull and direct tension testing arrangements for bond strength

10.7 Permeability
The testing shall be done in accordance with EN 7031.

10.8 Frost resistance

The testing shall be done in accordance with ASTM C672 or SS 137244 for scaling resistance and
ASTM C666 for freeze-thaw resistance.

10.9 Determination of the fibre content of sprayed concrete

The fibre content of sprayed concrete can be determined from either fresh or hardened (i.e. before
or after set) mortar/concrete samples. Both types of sample are applicable with steel fibres, but
only the method for a fresh sample is appropriate with synthetic fibres.
Fresh samples may be extracted from the basic mix, the insitu material or from a test panel.
Hardened samples may be cut from the insitu material or from a test panel. It should be
16
 appreciated that the fibre content at each of these locations may be different, due to the spraying
process. The most appropriate sample type and location should be used, which will depend on
the purpose of the quality control and on the compliance requirements of the specification.
For hardened samples the test may be conducted in as-received, saturated or oven-dried moisture
states.
The volume of the sample (before fibre extraction) can be determined by calculation (using actual
dimensions) or by water displacement (reference method). The mass of the fibre is then
determined by weighing, following extraction of the fibres from the fresh or hardened sample.

10.9.1 Hardened sample (Method A )

Three test cores shall be cut from the insitu material or a test panel. The core diameter
shall be 75-150 mm and the core length shall be 75-150 mm (unless the layer thickness is
less than 75 mm, in which case the core length should equal the layer thickness).
The volume (V c ) of the cores shall be determined according by calculation (using actual
dimensions) or weighing in air and water (method given in EN 6275).
The concrete cores shall be crushed in a compression testing machine, or other suitable
device, so that all the fibres in each core can be separated from the concrete. Magnetic
fibres can be easily removed by a magnet. The fibres from each core shall be cleaned and
then weighed (mf) to 0.1 g.

10.9.2 Fresh sample (Method B)

Three samples shall be cut from the insitu material or a test panel. The samples shall
weigh 1 - 2 kg and must be carefully extracted in one piece.
The volume (V c ) of the samples shall be determined by weighing in air and water (method
given in EN 6275).
Wash-out the fibre from each sprayed sample; the sprayed concrete shall be placed in a
filter equipment where the cement and other fine materials can be washed out such that the
fibre can be separated from the mass. With synthetic fibres the samples may be soaked
with alcohol and stirred until the fibres float on the surface. The fibres shall be cleaned ,
dried and then weighed (mf) to 0.1 g.

10.9.3 Calculation of fibre content

The fibre content of each sample shall be calculated from the determined fibre mass and
sample volume, using the formula:
Cf (kg/m³) = mf x 1000 / Vc
where Cf is the fibre content (in kg/m³)
mf is the mass of fibre extracted from the sample (in g)
Vc is the volume of the sample in (cm³)
The report shall contain:
• specimen identification (including location of sample and time of spraying)
• specimen type (hardened or fresh), sizes and volumes
• date and time of testing
• description of fibre type
• calculated fibre content of each sample and the mean value of the three samples

11. QUALITY CONTROL

11.1 General
The production of sprayed concrete shall be subject to quality control procedures. Quality control
is defined as a combination of actions and decisions taken in compliance with specifications and
checks to ensure that the specified requirements are satisfied.
There are 3 classes of control:
I Minor control

17
 II Normal control
III Extended control
The choice of control class shall be at the discussion of the designer, based on type of project
and consequence of failure.
There are no special requirements for the organisation of the work in control classes I and II. In
control class III there shall be a organigram for each project with a quality assurance engineer,
dedicated to quality control.

11.2 Preconstruction tests

Composition of the sprayed concrete is determined in the course of preconstruction tests in which
the required properties are checked. Examples of properties to be checked:
Fresh concrete:
• water demand, workability, pumpability,
• sprayability/rebound
• slump, density
• dosage of accelerator
Hardened concrete:
• compressive strength at 7 and 28 days
• flexural strength
• residual strength
• fibre content
• bond
The need for such tests is dependent on the type of project and the utilisation of the sprayed
concrete, but should always be done in control class III.

11.3 Quality control

11.3.1 Underground support

There are two types of control to be specified:
• Production control
• Conformity control
The production control shall be in accordance with EN 206. The conformity control includes
control of:
• compressive strength
• flexural strength
• residual strength value
• residual strength
• energy absorption
• bond
• fibre content
• thickness
All tests are to be done on samples taken either from in-situ material or test panels
according to Section 10.1.
The frequency of the tests shall be decided by the designer, bearing in mind the function of
the sprayed concrete (including structural integrity), its design life, the difficulty of
installation, the environmental classification and the consequences of a failure. The values
given in Table 11.3.1 may be used as a guide.

18
 Table 11.3.1: Frequency of control testing

TYPE OF CONTROL MINOR NORMAL EXTENDED

Compressive strength 500 250 100
Flexural strength 500 250
Residual strength value 1000 500
Energy absorption 1000 500
Bond 500 250
Fibre content 250 100
Thickness 50 25 10
m² between tests

11.3.2 Alignment control

Alignment control is necessary to establish line and grade in sprayed concrete construction
and to ensure that proper and uniform material thickness and cover are maintained.
Alignment control is accomplished by the use of guide wires, guide strips, depth gages,
depth probes, or conventional forms.
Guide wires - Guide wires consist of 1 or 0.8mm high strength steel wire combined with a
device, usually a turn-buckle or spring coil, that places the wire under suitable tension.
They are the most convenient means to establish line and grade where forms are used for
backup purposes. Wires may be used individually to establish corners while several parallel
wires in combination may be spaced 0,6 to 0,9m apart to provide screed guides for flat
areas.
Guide strips - Guide strips consist of wood lath usually no larger than 25x50mm connected
by crosspieces at 0.6 to 0.9m intervals. Guide strips serve as an excellent method of
alignment control in both repair and new sprayed concrete construction. Chamfered edges
are readily attained using a chamfer strip at the corner of the guide strips.
Depth gauges are small metal or plastic markers attached to or installed perpendicularly in
the substrate or backup material at convenient intervals and heights. They provide a preset
guide to the thickness of the sprayed concrete and are positioned just below the finish coat
of sprayed concrete. They are left in place provided they do not affect the integrity of the
application.
Depth probes - Depth probes are used in situations where there is greater latitude in the
finish tolerance requirements. They are usually made of steel, 0.67 to 0.78mm, and marked
with the specified sprayed concrete thickness. Probes are inserted into the sprayed
concrete until the substrate is reached indicating the depth of sprayed concrete. They
should only be used if puncture holes can be tolerated in the lining.
Formwork - The use of conventional forms in sprayed concrete work is the exception rather
than the rule; however, when they are used, they usually provide automatic alignment
control eliminating special devices for line and grade. Nozzle techniques must be carefully
controlled to avoid sand pockets and other defects.
Surface finishes - The specific finish requirement shall be detailed as follows:
"As Shot" The sprayed concrete shall be left as from the nozzle.
"Cut & Flash" The sprayed concrete shall be trimmed to true lines and after initial set
shall be sprayed with an overwetted flash coat to produce a textured finish.
Trowelled Finishes - Following the treatment detailed in the "Cut & Flash" the material
shall be trowelled smooth with one of the following:
• Steel float
• Wooden float
• Brush
• Sponge
Tolerances - The specifier shall detail:
19
 • Maximum +/- tolerance on thickness
• Maximum deviation in 2m straight edge

12. HEALTH AND SAFETY

Application of sprayed concrete should meet all the Health and Safety regulations valid in the
place of use.

20
 APPENDIX 1

APPENDIX 1

Admixtures for Sprayed Concrete; Definitions, Specifications, Requirements,

Reference Concrete Mixes and Test Methods.

21
 APPENDIX 1

CONTENTS
1. SCOPE .............................................................................................................. 23
2. REFERENCES ................................................................................................... 23
3. DEFINITIONS ...................................................................................................... 24
3.1 Wet concrete basic mix and dry concrete basic mix................................. 24
3.2 Sprayed concrete admixture................................................................... 24
3.3 Sprayed concrete accelerating admixture ................................................ 24
3.4 Thixotropic admixture............................................................................. 24
3.5 Hydration control admixture.................................................................... 24
3.6 Sprayed concrete bond improving admixture ............................................ 24
3.7 Identification.......................................................................................... 24
3.8 Performance ......................................................................................... 24
3.9 Compliance dosage ............................................................................... 24
3.10 Recommended range of dosage.............................................................. 24
4. REQUIREMENTS ................................................................................................ 24
4.1 General requirements............................................................................. 25
4.2 Performance requirements...................................................................... 25
5. REFERENCE SPRAYED CONCRETE .................................................................. 26
5.1 Constituent materials............................................................................. 26
5.1.1 Reference cement ................................................................... 26
5.1.2 Reference aggregate................................................................ 26
5.1.3 Mixing water ........................................................................... 27
5.2 Reference sprayed concrete mixes for conformity testing .......................... 27
5.3 Mix proportions ..................................................................................... 27
5.4 Production of reference mix for laboratory testing...................................... 28
5.5 Application procedure ............................................................................ 28
5.5.1 Equipment .............................................................................. 28
5.5.2 Spraying test panels................................................................ 28
5.5.2.1 Laboratory moulds................................................................... 28
5.5.2.2 Spraying process of control mix panel....................................... 28
5.5.2.3 Spraying process of test mix panel ........................................... 28
6. TESTING PROCEDURE....................................................................................... 28
6.1 General ................................................................................................ 28
6.2 Laboratory conditions............................................................................. 29
6.3 Determination of setting time .................................................................. 29
6.3.1 Non-accelerating admixtures .................................................... 29
6.3.2 Determination of setting time for sprayed concrete containing acceleration
admixture ............................................................................... 29
6.3.2.1 Constituent materials............................................................... 29
6.3.2.2 Preparation of reference cement paste ...................................... 29
6.3.2.3 Test procedure........................................................................ 29
6.3.2.4 Test report .............................................................................. 29
6.4 Determination of compressive strength .................................................... 29
6.5 Tensile bond strength between layers and at interface with substrate ......... 30
7. DECLARATION OF CONFORMITY ....................................................................... 30
7.1 General ................................................................................................ 30
7.2 Testing ................................................................................................. 30
7.3 Quality control....................................................................................... 30
7.4 Declaration of conformity by the manufacturer .......................................... 30
8. MARKING AND LABELLING ................................................................................ 30

22
 APPENDIX 1

1. SCOPE
This appendix defines and specifies requirements, reference mixes and test methods for sprayed
concrete admixtures.
Provisions governing the practical application of these types of admixtures in the production of sprayed
concrete, i.e. requirements concerning composition, mixing, spraying, curing etc. of sprayed concrete,
are not part of this specification. For such provisions reference should be made to EFNARC Specification
for Sprayed Concrete or any national standards or regulations valid in the place of use.

2. REFERENCES
This appendix incorporates dated or undated references and provisions from other publications. These
references, mostly normative, are cited at the appropriate places in the text and the publications are
listed hereafter. For dated references, subsequent approved amendments to, or revisions of, any of these
publications apply to this appendix. For undated references, the latest edition of the publication referred
to applies.
EN 196-3 Methods of testing cement - Part 3: Determination of setting time and soundness
EN 196-6 Methods of testing cement - Part 6: Determination of fineness
EN 197-1 Cement - Composition, specifications and conformity criteria - Part 1: Definitions and
compositions
EN 206 Concrete - Performance, production, placing and compliance criteria
EN 480-1 Admixtures for Concrete, Mortar and Grout; Test Methods - Part 1: Reference
concrete and reference mortar for testing
EN 480-2 Admixtures for Concrete, Mortar and Grout; Test Methods - Part 2: Determination of
the setting time
EN 480-6 Admixtures for Concrete, Mortar and Grout; Test Methods - Part 6: Infrared analysis
EN 480-8 Admixtures for Concrete, Mortar and Grout; Test Methods - Part 8: Determination of
the conventional dry material content
EN 480-10 Admixtures for Concrete, Mortar and Grout; Test Methods - Part 10: Determination of
water soluble chloride content
EN 934-2 Admixtures for Concrete, Mortar and Grout - Part 2: Concrete Admixtures -
Definitions, Specifications and Conformity Criteria
EN 934-6 Admixtures for Concrete, Mortar and Grout - Part: Sampling, quality control and
evaluation of conformity
EN 1008 Mixing Water for Concrete - Specification and Tests
EN 1542 Products and Systems for the Protection and Repair of Concrete Structures; Test
Methods - Pull off test
EN 4012 Testing concrete - Determination of compressive strength of test specimens
EN 4109 Testing concrete - Determination of consistency - Slump test
EN 7034 Testing concrete - Cored specimens - Taking, examining and testing in compression
EN 9812 Testing concrete - Determination of consistency - Flow test
EN 29000 Quality systems - Model for quality assurance in design, development, production,
installation and servicing
ISO 780-1979 Liquid chemical products for industrial use - Determination of density at 20oC
ISO 1158 : 1984 Plastics - Vinyl chloride homopolymers and copolymers - Determination of chlorine
ISO 4316 : 1977 Surface active agents - Determination of pH of aqueous solutions - Potentiometric
method
DIN 1048-2: 1991 Testing methods for concrete - Hardened concrete in structures and components
ZTV-SIB 90 “Regulation for bond testing of surfaces and layers” issued by the Federal Ministry of
Traffic, Germany (1990)
Note: Some of these EN standards are in preparation.

23
 APPENDIX 1

3. DEFINITIONS
For the purposes of this appendix, the following definitions apply:

3.1 Wet concrete basic mix and dry concrete basic mix:
• Wet concrete basic mix - wet concrete before the spraying process.
• Dry concrete basic mix - dry concrete mix prior to the addition of water and before the spraying
process.

3.2 Sprayed concrete admixture:

Material added to the concrete mix before or during the spraying process to modify the properties
of the mix in the fresh or/and hardened state.

3.3 Sprayed concrete accelerating admixture:

Admixture added to the mix before or during the process of spraying to develop very early
acceleration of the setting and/or very early hardening of the concrete beyond the limits of
conventional concrete accelerating admixtures as defined and specified in EN 934-2.

3.4 Thixotropic admixture:

Admixture added to the mix before or during spraying to develop thickening in the concrete to
prevent sagging before the setting of the sprayed concrete.

3.5 Hydration control admixture:

A two-component admixture system. One component is added to the wet concrete basic mix
before spraying to inhibit setting and retain consistence or added to a dry concrete basic mix,
containing wet aggregate, to inhibit setting. The second component is added at the nozzle to
reactivate the setting and hardening process.

3.6 Sprayed concrete bond improving admixture:

Admixture added to the basic mix of the sprayed concrete or at the nozzle to improve the bond
between the sprayed concrete layers and/or the tensile bond of the substrate surface of the
sprayed concrete.

3.7 Identification:
A procedure to characterise an admixture and to check its batch-to-batch uniformity by
measurement of its homogeneity, colour, relative density, dry material content and pH value and
recording its infrared adsorption spectrum.

3.8 Performance:
Ability of an admixture to be effective in its intended use without detrimental effects.

3.9 Compliance dosage:

Quantity of admixture, expressed in percentage by mass of hydraulic binder, stated by the
manufacturer to meet the requirements of this specification. The compliance dosage shall be
within the recommended dosage range.

3.10 Recommended range of dosage:

Dosages between limits, expressed in percentage by mass of hydraulic binder, which the
manufacturer recommends for the product, based on experience on site.
NOTE: The use of a recommended dosage does not imply that compliance with the specification
will be met over the whole range. Trial tests should be carried out with the materials to be used on
site.

4. REQUIREMENTS
All the admixtures defined in this specification shall conform to the general requirements given in Table 1
and the appropriate performance requirements given in Tables 2 to 5. Other types of admixtures meeting
the requirement of EN 934-2 shall also be deemed to meet the requirements of this specification.

24
 APPENDIX 1

4.1 General requirements

All the admixtures defined in this specification shall conform to the general requirements given in
Table 1 when tested in accordance with the methods given therein. Homogeneity, colour, effective
component, relative density, conventional dry material content and pH value constitute the
identification requirements as defined in sub-section 3.7.
Table 1: General requirements
Property Test method Requirements
(1)
Homogeneity Visual Homogeneous when used. Segregation shall not exceed
the limit stated by the manufacturer.
Colour (1) Visual Uniform and similar to the description provided by the
manufacturer.
Effective component (1) EN 480-6 (2)
Infrared spectra to show no change with respect to the
effective component when compared to reference
spectrum provided by the manufacturer.
(1)
Relative density ISO 758 D ± 0.03 if D > 1.10;
D ± 0.02 if D < 1.10;
where D is manufacturer's stated value of density
(3)
Conventional dry EN 480-8 0.95 T < X < 1.05 T
material content (1) for T > 20%
0.90 T < X < 1.10 T
for T < 20%
T is manufacturer's stated value % by mass;
X is test result % by mass on dry material content
(1) (4)
pH value ISO 4316 Manufacturer's stated value ± 1 or within manufacturer's
stated range.
Total chlorine (1) (5)
ISO 1158 Either < 0.10% by mass or not above the manufacturer's
stated value.
Water soluble chloride EN 480-10 Either < 0.10 % by mass or not above the manufacturer's
(1) stated value.

Alkali content EN 480-12 Not above the manufacturer's stated maximum.

(1)
(Na2O - equivalent)
(6) (7)
Corrosion behaviour No corrosion promoting effects on steel embedded in
concrete.
(1)
Manufacturer's stated value shall be provided in writing to the user on request.
(2)
In case of the Infrared method not being applicable, the manufacturer shall supply an alternative method.
(3)
If the method in EN 480-8 is not suitable, the manufacturer shall recommend an alternative test method.
(4)
It is recommended for safety reasons that sprayed concrete admixtures added at the nozzle should have a
pH in the range of 4 - 10.
(5)
If there is no significant difference between total chlorine content and water soluble chloride content, only
the water soluble chloride content shall be determined in subsequent tests on the admixture involved.
(6)
For testing cement CEM I with C 3A content less than 5% by mass shall be used.
(7)
CEN Standard for test method not yet available.

4.2 Performance requirements

The admixtures in this specification shall conform to the appropriate performance requirements
given in Tables 2 to 5.
The tests for performance shall be carried out on a reference sprayed concrete, prepared in
accordance with this specification, as required for the test method described in the appropriate
sections of this specification. The result of a test on the reference concrete containing the
admixture (the test mix) is compared with the result of the same test on a reference concrete or
reference mortar without the admixture (the control mix). The dosage of the admixture in the test
mix shall be that recommended by the manufacturer.

25
 APPENDIX 1

Table 2: Performance requirements for sprayed concrete accelerating admixture

Property Test method Performance required

Setting time EN 196-3 Initial setting time not more than 10 min., final setting
time not more than 60 min., in two out of every three
tests.
Compressive strength EN 7034 At 28 days: test mix ≥ 75% of control mix at 28 days
At 90 days: test mix ≥ test mix at 28 days

Table 3: Performance requirements for thixotropic admixture

Property Test method Performance required

Flow EN 9812 Flow reduction of test mix 50% compared to control mix.
Slump EN 4109 Slump reduction of test mix 50% compared to control
mix.
Compressive strength EN 7034 Compressive strength of test mix not less than control
mix at 28 days.

Table 4: Performance requirements for hydration control admixture

Property Test method Performance required

Consistence Flow: EN 9812 or Consistence retention of test mix > consistence
Slump: EN 4109 retention of control mix in accordance with the
specification of supplier.
Setting time EN 480-2 Immediately after preparation of test mix and after
consistence retention time, specified by the supplier.
Compressive strength EN 7034 Compressive strength of test mix not less than
control mix, both at 28 days.

Table 5: Performance requirements for sprayed concrete bond improving admixture

Property Test method Performance required

Tensile bond strength EN 1542 Test mix > 125% of control mix, measured on 100
between layers DIN 1048-2 mm diameter cores at 28 days
Tensile bond strength EN 1542 Test mix > 125% of control mix, measured on 50 mm
at surface DIN 1048-2 diameter cores at 28 days
Compressive strength EN 7034 Compressive strength of test mix not less than
control mix, both at 28 days.

5. REFERENCE SPRAYED CONCRETE

This section specifies the constituent materials, the composition and mixing/spraying procedure to
produce reference sprayed concrete for testing the efficacy of an admixture that conforms to this
specification.

5.1 Constituent materials

5.1.1 Reference cement

The reference sprayed concrete mixes and reference mortars for the performance tests
shall be made with CEM 1 cement of strength class 42.5 conforming to EN 197-1. The
cement used shall have a C3A content of 7 to 11% by mass and a specific surface area of
320-400m²/kg determined in accordance with EN 196-6.

26
 APPENDIX 1

5.1.2 Reference aggregate

A natural normal weight aggregate with low water absorption (less than 2% by mass) shall
be used. The grading of the aggregate used in the production of reference concrete shall
comply with Table 6.
Table 6: Grading of aggregate for reference sprayed concrete mix

SIEVE SIZE (mm) % PASSING(1)

4.00 100
2.00 75 - 100
1.00 50 - 75
0.50 25 - 50
0.25 7.5 - 20
0.125 <7.5
(1)
The variation in the quantity passing each sieve of the chosen grading for both mixes (control and test
mix) shall not exceed ± 2.0 %.
5.1.3 Mixing water
Water for mixing shall comply with the requirements of EN 1008. Distilled or deionised
water may be used.

5.2 Reference sprayed concrete mixes for conformity testing

The wet mix system is used for laboratory evaluation of a sprayed concrete admixture. The
performance of an admixture is assessed by carrying out tests on a reference sprayed concrete.
The result of a test on the reference sprayed concrete containing an admixture (the test mix) is
either given directly or is compared with the same test on a reference sprayed concrete without
any admixture (the control mix). The ratio of these two results is expressed as a percentage. The
test mix and the control mix shall have the same aggregate/cement ratio and constituent
materials shall be from the same delivery.
The composition of sprayed concrete with and without the sprayed concrete admixtures shall
correspond to that specified in section 5.1, the fresh concrete being properly sprayed.
The constituents of the mix for testing shall be conditioned to a temperature of 20o ± 2oC prior to
mixing or alternatively the temperature of the fresh concrete shall be 20o ± 2oC immediately after
mixing is completed.

5.3 Mix proportions

The mix proportions of the components shall be in accordance with Table 7.
Table 7: Mix proportions of reference sprayed concrete mix1 for testing sprayed concrete
admixtures

MATERIAL QUANTITY FOR 1m³

Cement 500kg ± 5kg

Water 225kg ± 5kg
Aggregate (to Table 6) to complete 1m³

The aggregate addition shall be calculated from the aggregate’s relative density. Aggregates shall
be used either in an over dry condition, to remove any moisture content variation, or their moisture
content shall be determined and the mix proportion corrected accordingly. In case of dispute, oven
dry aggregates shall be used.

1 Additionally a water-reducing plasticising admixture or a high range water-reducing superplasticising admixture may be
added to the mix to produce a pumpable consistency of no less than 100 mm slump in accordance to test method ISO
4109.

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 APPENDIX 1

The water content of liquid concrete admixtures shall be taken into account in the water/cement
ratio when determining batch weights.

5.4 Production of reference mix for laboratory testing

The sprayed concrete reference mix shall be produced according to Table 7. The mixing may be
performed with a pan mixer or in an integral mixer belonging to the spray equipment.

5.5 Application procedure

5.5.1 Equipment
The wet process machine2 shall have an output capacity of 0.5m3/h. The dispensing unit for
the admixture shall have an accuracy of ± 0.5% of the recommended dosage. The
admixture shall be incorporated as recommended by the manufacturer.

5.5.2 Spraying test panels

Before spraying the test panels the spraying process shall be optimised to ensure a
continuous output. The output capacity shall be determined. The reference concrete panel
and the panel of concrete with the admixture shall be sprayed using the same mix.

5.5.2.1 Laboratory moulds

Moulds shall have approximate dimension of 500x500x120mm deep and shall be
of rigid construction.

5.5.2.2 Spraying process of control mix panel

The mould shall be positioned horizontally on the ground. The mould to nozzle
distance shall be between 0.5 and 1m and perpendicular to the mould base. The
spraying time shall be recorded. The control mix may contain admixture, in which
case, the consumption of the admixture shall be determined by weighing to an
accuracy of ± 5%. The admixture dosage shall be calculated using the
determined output and shall not exceed the maximum recommended dosage.
After completion of spaying, the sprayed concrete panel shall be sprayed with a
curing membrane and covered with a plastic sheet to ensure proper curing.

5.5.2.3 Spraying process of test mix panel

The mould shall be positioned vertically. The mould nozzle distance shall be
between 0.5 and 1m and perpendicular to the mould base. The spraying time shall
be recorded and the consumption of the accelerator shall be determined by
weighing to an accuracy of ± 0.5%. The admixture dosage shall be calculated
using the determined output and shall not exceed the maximum recommended
dosage. After completion of spraying, the sprayed concrete panel shall be
sprayed with a curing membrane and covered with a plastic sheet to ensure
proper curing.

6. TESTING PROCEDURE

6.1 General
All tests shall be carried out on both the control mix (reference mix without admixture) and test
mix (reference mix with admixture).

6.2 Laboratory conditions

Unless otherwise stated the laboratory conditions for samples and testing shall be:
Temperature 20 ± 2°C
Relative humidity > 65 %

2 Pump type - mono/screw pump with stepless adjustable output.

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 APPENDIX 1

6.3 Determination of setting time

6.3.1 Non-accelerating admixtures

The setting time of all sprayed concrete containing admixtures, with the exception of
sprayed concrete containing accelerating admixtures, shall comply with EN 480-2 for the
test method using reference mortar. The constituent materials, mix proportions and mixing
procedure of the reference mortar shall comply with EN 480-1.

6.3.2 Determination of setting time for sprayed concrete containing accelerating

admixture
Reference cement pastes with admixture (test mix) and without admixture (control mix)
shall be used. The test (Vicat apparatus) for setting time shall comply with EN 196-3. The
test of setting time is not a comparative test between control mix and test mix. Information
of setting time for both control and test mix is essential.
Note: This specification describes the reference procedure; it allows the use of alternative
apparatus, provided that they do not affect the results. In the event of a dispute, only the
reference procedure described in this appendix shall be used.

6.3.2.1 Constituent materials

Constituent materials shall comply with sub-clauses 5.1.1 to 5.1.3 of this
specification.

6.3.2.2 Preparation of reference cement paste

Cement, water, admixture and apparatus used shall be stored under laboratory
conditions as specified in sub-clause 6.2 for at least 12 hours before the cement
paste is prepared.
Prepare the cement paste by mixing, in a suitable container, 300 ± 15 g of
reference cement with 105 ± 5 g of water to a homogeneous paste. Add to the
paste the quantity of the admixture specified by the supplier, mix quickly and
thoroughly and place in the mould of the Vicat apparatus. Mixing and filling of the
mould shall be within 15-30 seconds, without undue segregation or vibration.

6.3.2.3 Test procedure

The testing procedure and the determination of the initial and final setting time
shall comply with EN 196-3.

6.3.2.4 Test report

• Type of test equipment
• Constituent materials
• Temperature at which the test is carried out to the nearest 1oC
• Initial and final setting times for the control and test mix expressed in minutes

6.4 Determination of compressive strength

The compressive strength shall be determined according to EN 4012. Cores for compressive
strength measurement shall be taken from the control and the test concrete panels after 1, 7, 28
and 90 days. The cores shall be 100 mm in diameter and 100 mm in height respectively.
Core drilling shall be performed 2 hours before testing unless the time of the core drilling and
curing of core samples are otherwise specified. For each compressive strength measurement an
average of 5 test results shall be used.

6.5 Tensile bond strength between layers and at interface with substrate
The preparation and procedure for tensile bond strength shall comply with the relevant
specification of EN 1542 or ZTV-SIB 90. (The latter includes specification for the preparation of the
sprayed concrete for this test).

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 APPENDIX 1

7. DECLARATION OF CONFORMITY

7.1 General
This procedure is intended for the approval of a sprayed concrete admixture.

7.2 Testing
Testing has to be carried out by the manufacturer to prove the conformity of sprayed concrete
admixture requirements in order that it fulfils all the general requirements given in Table 1 and the
appropriate performance requirements given in Tables 2 to 5.

7.3 Quality Control

The manufacturer shall operate a quality control system in accordance with EN29000 at each
facility where admixtures are produced.
Compliance with this requirement shall be verified by an approved certification body which shall
issue a certificate to each production facility where procedures have been verified.
After initial certification, an audit of each production facility shall be carried out by the approved
certification body not less than once per year. If any non-compliance with the requirements of
EN29000 is found, the certification body shall either:
(i) require correction of non-compliance within a stated time which, if not carried out, shall
result in withdrawal of the certificate
or
(ii) immediately withdraw the certificate.

7.4 Declaration of Conformity by the Manufacturer

Provided the requirements of 7.2 and 7.3 have been fulfilled, a declaration of conformity with this
specification shall be issued by the manufacturer for each admixture which satisfies the
appropriate requirements in this specification.
A new declaration of conformity shall be issued following any change in formulation or in
constituent materials which results in a change of the characteristics of the product.
The time between conformity tests shall be not more than 5 years.

8. MARKING AND LABELLING

When admixtures are supplied in containers, they shall be clearly marked with the following information.
When the material is supplied in a bulk container at the point of delivery, the same information shall be
provided in writing at the time of delivery as follows:
a) the name, trade mark or other means of identification of the manufacturer
b) the trade designation of the product, i.e. brand name, reference number and/or letter and batch
number
c) type of admixture
d) the chloride ion content, expressed as a percentage by mass of total admixture
e) alkali content expressed as Na2O equivalent percent by mass of admixture
f) a summary of storage requirements including any special requirements on storage life shall be
clearly marked, e.g. This admixture shall not be taken to comply with this specification after “Best
Use Before (date)”
g) instructions for use and any necessary safety precautions
h) the manufacturer’s recommended range of dosage
i) the number, date and relevant section of this specification.

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