What is Shotcrete?

Shotcrete is a method when we spray concrete or mortar with a high velocity (130–170
m/sec) on a vertical surface. In the shotcrete method, a nozzleman sprays concrete or
mortar on a vertical surface to compact it with concrete.

A single shotcrete layer is 10–15 mm thick and has high mechanical strength (40–70
meganewtons per sq m), density, water tightness, and cold resistance.

The hardened property of shotcrete is the same as conventional concrete but the process
through which we apply it helps it in making an excellent bond with the substrates. This
method is applied specifically in new construction & repairs suitable for curved and thin
elements. Shotcrete is also known as sprayed concrete.

For example, the construction of tunnel linings and domes has become much easier after
the introduction of the shotcrete method. The care of concrete, in this case, should be
taken as any other concrete. Shotcrete also required adequate curing for better efficiency
and prevention of cracks.

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It must be cured with water for 14 days from the time the concrete was sufficiently set.
Adequately cured concrete can attain strengths around 450-550 kg/cm2 in 28 days.

Applications of Shotcrete

The shotcrete method is used in the construction of the thin overhead vertical and
horizontal surfaces.
It’s especially used in curved and folded surfaces such as tunnel lining, domes,
canals, or reservoirs.
Other structures for which it’s used are water-retaining structures, swimming pools,
and pre-stressed tanks.
It’s applied for the stabilization of rock slopes and temporary protection of freshly
excavated rock surfaces.
It’s utilized for protection against long-term corrosion of piling, coal bunker, oil tanks,
steel-frame structures, and other structures. Moreover, it’s also used for encasing
structural steel for fireproofing.

What Material is Used in Shotcrete?

The following materials can be used in shotcrete

Cement
Sand
Coarse Aggregates
Water
Chemical additives
Compressed Air

Materials, Proportioning of Shotcrete

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The material composition of shotcrete is an important part, the following proportion can be
used while making shotcrete:

Chemical admixtures are added for the acceleration of setting and hardening.
Sodium Carbonate = ½ Kg per 50 Kg bag of cement
Sodium Aluminate = ½ Kg per 50 Kg bag of cement
Calcium Carbonate = 1 Kg per 50 Kg bag of cement

Alternatively, the following additives can also be used:

Superplasticizer @ 1 % by weight of cement

Accelerator (say sodium Silicate) @ 5 % by weight of cement

Materials Quantity

Cement 450 kg/m³

Sand 1100 kg/m³ (0.70 m³)

Coarse aggregate (5 mm – 10 mm size) 500 Kg/M³ (0.30 M³)

Proportion by weight 1:2.44:1.11

Shotcrete Mix Design

The following grades of concrete and ratios of concrete mix design used in shotcrete:

Grades of Concrete Ratios of Concrete mix design

(Cement: Sand: Aggregate)

M5 1:5:10

M7.5 1:4:8

M10 1:3:6

M15 1:2:4

M20 1:1.5:3

M25 1:1:2

M30 1:0.75:1.5

M35 1:0.5:1

M40 1:0.25:0.5

Properties of Shotcrete

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 1. In this method, cement content is high and a small maximum size aggregate is
used.
2. It increases durability in most cases.
3. The conventional concrete is compacted by vibration. While the shotcrete is
compacted by high-velocity jet impinging on the surface.
4. This process increases the cement content and also brings about the different air-
void systems that will affect the durability of the concrete.
5. There is a greater effect on the properties of in-place concrete by the application
procedures than the mix proportions.
6. Shotcrete specimen is sewed from test panels of about one meter square and
75mm thick made by gunning out the plywood form, which is known as shotcrete.

Advantages of Shotcrete
Shotcrete has a rapid capability to get hardened.
This method usually works better on complex forms.
It requires less formwork than the conventional method of concreting.
It’s economical than the conventional method.
Doesn’t require much space and resources for batching and mixing.
Good adhesion, compact shotcrete.
less rebound
less dust.

Disadvantages of Shotcrete
To execute the shotcrete, you need a skilled nozzleman who can control the amount
of water mixed through nozzle tuning.

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 The spraying procedure is very tough. It requires immense attention and skills.
You have to face the problem of high dust release.
The water-cement ratio is based on the nozzleman.
You might have to face the difficulty in addition to additives.

Method of Shotcrete
There are basically two methods of applying the shotcrete:

1. Wet-Mix method
2. Dry-Mix method

What is the Wet-Mix Method?

The water is mixed with the ingredients before it enters into the delivery hose.
In the Wet-Mix method, the wet concrete is transferred from the Ready-mix truck to the
concrete pump, which is then sent to the nozzle under the effect of compressed air.

The rate and amount of mix are controlled manually since this method requires much
transportation, it’s applied at the larger construction sites.

Types of Equipment Used in Wet-Mix Shotcrete

The following are the main types of dry-mix shotcrete equipment:

1. Wet Concrete
2. Shotcrete Pump
3. hoses

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 4. nozzle
5. Air Compressor

Advantages of Wet Mix Method

• The water content is controlled more accurately.

• Not much labor is required in this method
• Due to lesser requirements of labor and maintenance, the cost goes lower in this
method.
• Spraying is easy in the Wet-Mix method.
• The consumption of air is lesser as compared to other methods.
• Additives can be added as per the requirement.

Disadvantages of Wet Mix Method

• A lot of wastage is produced in this method.

• The transportation of mix will require high control.

What is the Dry Mix Method?

The water is added to the ingredients at the nozzle. In this method, the mixed ingredients
are first placed at the hopper. Next, the ingredients are sent from hopper to nozzle
through the delivery hosepipe of the apparatus.

The water in the mix is controlled by the nozzleman using a valve and the Dry-Mix
method is applied where we have limited access areas.

Types of Equipment Used in Dry-Mix Shotcrete

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The following are the main types of dry-mix shotcrete equipment:

1. Pressure vessels;
2. Dry-mix shotcrete guns;
3. Batch plants; and
4. Predampeners.
5. Gunite Machine
6. hoses
7. nozzle
8. Air compressor

Advantages of Dry Mix Method

It offers better bonding ability and strength.

Water content can be controlled at the end of the nozzle.
The Dry Mix process generates lesser wastage.
The investment required for this process is lesser.

Disadvantages of Dry Mix Method

It requires a skilled nozzleman to control the water content. Otherwise, it would be

difficult to have the efficient mix.
The spraying procedure is tough in this method.
High dust is released in the process.
The water-cement ratio is based on the nozzleman.
It would be totally dependent on the manual process to make the mix efficient.
You may face difficulty in the addition of additives.

IS Code for Shotcrete

IS I9011 – 1978 code can we used for shotcrete, this Indian Standard was adopted by the
Indian Standards Institution on 30 November 1978, after the draft finalized by the Cement
and Concrete Sectional Committee had been approved by the Civil Engineering Division
Council.

Download IS Code for Shotcrete – IS:9012 – 1978

Download Link

What is Rebound in Shotcrete?

During the shotcrete process, rebound aggregate and cement paste ricochet off the
surface due to collisions with the hard surface, reinforcement, or aggregate particles
themselves.

The amount of rebound varies with the position of the working angle of the nozzle, air
pressure, cement content, water content, size and grading of aggregate, amount of
reinforcement, and thickness of the layer. Depending on the position of the work, the

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variation in the amount of rebound maybe
as below:

Surface Percentage of Rebound

Floor or slabs 5-15%

Sloping and vertical walls 15-30%

Overhead work 25-30%

Precautions to be Taken in Shotcrete

1. After completion, the finished shotcrete layer must be kept wet for at least a week.
2. During the operations, there will be rebounds that will not be used for shotcrete.
3. The time difference between the first and second layers should be as short as
possible for example less than 8 hours.
4. After the shotcrete is finished and the mix is set, the surface should be thoroughly
sounded with a hammer to look for drumming areas caused by rebound pockets,
lack of bond, and other issues that should be cut out and replaced with new or fresh
shotcrete.
5. Where the dry process is adopted the jetting of water should be synchronized with
that of the concrete mix for homogeneous shotcrete.

6. Where wet mix is adopted the specified water-cement ratio is to be strictly enforced.

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