UndergroundInternationalGeneralQ I am a TBM Tunnel Engineer from India, and I was looking for information on the applicable compressed air pressure range required for a wet-mix shotcrete application (small shotcrete pump-capacity 7 CU.M/Hr) hand spraying with a 30m hose for a better-compacted mix. I would kindly request you to please send me information on the pressure range to be expected for good quality shotcrete placement of the concrete mix on the rock substrate in NATM Tunneling.
Wet-mix shotcrete depends on air flow at the nozzle to accelerate the concrete to 60 to 80 mph (100 kph to 130 kph). Most air compressors produce their air flow capacity at 100 to 120 psi (7 to 8.4 kg/cm2) at the compressor. However, depending on the size length and couplings in the air hose, there may significant pressure drops when the air reaches the nozzle. Here’s what ACI 506R-16 Guide to Shotcrete Section 4.4.2 states for wet-mix:
“The recommended ft3/min (m3/min) needed for the wet-mix process is between 200 to 400 ft3/min (5.7 to 11.3 m3/min) air volume at 100 psi (7 bar). Higher air volume capacities are needed for higher volume and higher-velocity shotcrete applications. If a blowpipe is to be used during the shooting process, more air will be required to run both operations simultaneously. Conducting a test during the preconstruction testing phase using a blowpipe while gunning the wet-mix material will indicate if the air compressor has enough air volume capacity to perform both tasks at the same time. Long, small-diameter lines may not provide sufficient air volume capacity, even with a large air compressor. Test and consider increasing the size of the air line.”
Though there is no direct guidance for air pressure at the wet-mix nozzle you may consider the guidance for dry-mix air pressure in ACI 506R Section 4.4.1:
“The operating air volume (ft3/min [m3/min]) drives the material from the gun into the hose, and the air pressure is measured at the material outlet or air inlet on the gun. The operating pressure varies directly with the hose length, the density of the material mixture, the height of the nozzle above the gun, and the number of hose bends. Experience has shown that operating pressures should not be less than 60 psi (4 bar) when 100 ft (30 m) or less of material hose is used, and the pressure should be increased 5 psi (0.34 bar) for each additional 50 ft (15 m) of hose and 5 psi (0.34 bar) for each additional 25 ft (7.5 m) the nozzle is above the gun.”
The minimum 60 psi (4 bar) necessary for dry-mix could be applied to the wet-mix air supply as the velocity created by the air flow is similar.
