We are working on a repair/renovation project in Boston, MA. A long, concealed wall next to an adjacent property is now visible, as the adjacent property is being renovated. We have been told that our wall must now have a 2-hour fire rating. Our wall is comprised of concrete masonry units (CMUs) and exposed structural steel members. Applying shotcrete to the CMUs and steel is a good solution for several reasons. Can you provide or point me to a shotcrete specification that will have a 2-hour fire rating on CMUs and structural steel?

Shotcrete is a placement method for concrete. Thus, the fire resistance for shotcrete placement is the same as concrete. The primary reference for fire resistance of concrete is ACI 216.1-14(19), “Code Requirements for Determining Fire Resistance of Concrete and Masonry Construction Assemblies.”

I have a 24 in. (610 mm) thick shotcrete wall that needs to be scanned for voids. The project has been struggling to locate a local expert who has the capability to scan this thick of a wall. In addition, this new 24 in. thick shotcrete wall was dowelled and made an “as-one-unit” together with an existing 24 in. form-and-pour wall. Any thoughts and ideas would be greatly appreciated.

Shotcrete is a placement method for concrete. Thus, all nondestructive testing (NDT) applicable to concrete walls would be usable on your wall. However, it is difficult to get good results with a scanning system for heavily reinforced concrete walls of your thickness. Impact echo and impulse response are two one-sided techniques that can provide good results for a portion of the 24 in. thickness, although they would likely not be able to scan the entire depth. Ultrasonic pulse velocity is a potential if you can access both sides of the wall. For one-sided investigation at greater depth, you may be able to use a MIRA system. It is a sophisticated tomographic system that says it can test from 50 to 800 mm (32 in.) thickness. There are national consulting firms that provide these investigation systems. Each requires a highly trained, experienced operator—so be sure to verify the firm can document successful experience using the method.

A contractor has proposed using shotcrete to repair the concrete in the elbows of a draft tube. I have not heard of shotcrete being used in a draft tube. Velocities would range from 10.5 to 3.8 ft/s (3.2 to 1.2 m/s). I am concerned about whether the shotcrete would delaminate after time or be abraded away, as there is considerable abrasion present where the concrete cover has been abraded away on the floor of the elbow. Any guidance would be helpful.

Shotcrete has been used in many dam repairs, including large-diameter draft tubes. Shotcrete is high-velocity (60 to 80 mph [100 to 130 km/h]) placement of concrete. When shotcreting with proper concrete materials, equipment, placement, and curing techniques, along with complete surface preparation, you can expect a tensile bond strength of at least 150 psi (1 MPa) between the existing concrete and the newly shotcreted material. Original Portland Cement Association research by Felt from 1956 showed that 200 psi (1.4 MPa) bond shear strength is required for bonded overlays to act monolithically in flexure. Research by Silfwerbrand in 2003 showed that the ratio of bond shear strength to direct tensile bond strength ranges from 1.9 to 3.1. Thus, using the low value of the range with a 150 psi tensile bond strength yields a shear strength of at least 285 psi (2 MPa), well above the 200 psi needed. You may find more information on the bond between concrete and shotcrete layers in the article “Shotcrete Placed in Multiple Layers does NOT Create Cold Joints” that can be found in our article archive.

Regarding the abrasion, shotcrete displays good toughness in a wide variety of demanding applications. Quality shotcrete should have at least a 4000 psi 28-day compressive strength and, with attention to mixture design using silica fume and a low water-cementitious materials ratio (w/cm), can comfortably reach 6000 to 8000 psi (40 to 55 MPa) or more. Shotcrete also can easily use steel or synthetic fiber to significantly increase the toughness of the in-place concrete.

Finally, because shotcrete requires no formwork or bonding agent for a high-quality repair, you will find the shotcrete process provides an economical solution.

An article about a draft tube modification project can be found in our article archive.

We are constructing a new custom roundabout with water running through the bridges on the Coast of Zintan, Tripoli, Libya, using a three-dimensional (3-D) panel system. It’s basically a system with an expanded polystyrene (EPS) panel with a wire mesh and shotcrete on both sides. Because of the heat, sea salt, and high humidity of the region, we are looking for a mixture formula for a waterproof shotcrete for the exterior coating with the right aggregate size to help prevent moisture migration to the interior and prevent cracks. Do you have any recommendations for the shotcrete?

If looking for a low-permeability concrete mixture for shotcrete placement, you should consider using supplementary cementitious materials (SCMs) such as silica fume, fly ash, or slag to reduce the permeability. You should also be sure to require a minimum 4000 psi 28-day compressive strength to assure good paste content and the ability to fully encase your reinforcement. The addition of microfibers and early wetting of the finished shotcrete surface will help to reduce the potential for early-age plastic shrinkage cracking. Proper curing for at least 7 days is also important to help increase strength gain and reduce the potential for drying shrinkage cracking. You can consult our Buyer’s Guide to locate our corporate members, who may consult with you on the mixture design. However, please be aware that many of the panel systems with an EPS core don’t use high-velocity (60 to 80 mph) shotcrete for consolidation and compaction of the sprayed concrete, but use a low-velocity sprayed mortar (LVSM). Because LVSM doesn’t have the compaction of shotcrete impact, it depends on a more sophisticated and expensive cementitious mixture, often with a latex or other admixture to improve adhesion and reduce permeability. You’ll need to consult with the material supplier of the LVSM product to verify the permeability of their in-place product.

We’re building a pool 25 x 45 ft (7.6 x 14 m) and had a massive cave-in on our deep end. The builder wants to build temporary walls to shoot the shotcrete against, then remove the plywood walls and backfill with gravel. I’m wondering if this will work and if they will be able to remove the plywood without damaging the shotcrete walls. I know with typical forms you would prep the form with oil so the concrete doesn’t stick. Would that be necessary for shotcrete, too? Also, is there a recommended wait time for curing before we backfill?

Shooting shotcrete against a one-sided form (what you called a temporary wall) is a common way to build a shotcrete wall. Once the shotcrete sets and builds strength, the plywood form can easily be stripped off the back of the wall. Form release agents (not oil) can be applied to the plywood to make the stripping easier. Once the forms are removed and the concrete has gained adequate strength, the walls can be backfilled with compacted soil or gravel, depending on the drainage needs.

We recommend 7 days of curing. Continuous water curing is best, but if impractical, applying a curing compound on the exposed surface at twice the manufacturer’s recommended rate for a good seal is acceptable. If they remove the forms before 7 days, they should also water cure or apply curing compound to that newly exposed surface. The shotcrete needs to build up enough strength to resist the external force of the backfill, so check with the pool designer to see what they need for the required strength of the concrete before backfilling. With most good-quality shotcrete materials and placement techniques, you can expect about 4000 psi (28 MPa) compressive strength in 7 days.

I am working on a restoration of a small 1870s train station constructed of serpentine stone in the Philadelphia, PA, area. In many areas the stone has deteriorated, leaving deep “divets” in the exterior wall faces and, in some cases, there is no stone at all. Our intent is to build (infill) the walls back to a flush face for stucco treatment for the lower portions of the wall and to repair or replace stone above that point. Is there a minimum amount of treatment recommended for a shotcrete application? If it can be used for such an application, is reinforcement required? The stone is rather friable and I don’t want to attach too much to it for fear of further damaging the stone.

This is a great application for shotcrete placement of high-quality concrete without formwork. If you are merely adding shotcrete to fill out to a uniform surface profile without any structural requirements you may not need reinforcement. However, it may still be advisable to include fibers in the shotcrete mixture to help control plastic shrinkage cracking. Generally, you would want to keep a minimum thickness of 1 in. (25 mm) to provide enough thickness for finishing. If you need the shotcreted sections to be self-supporting and carry loads as structural concrete, you should consult with a structural engineer to determine the appropriate thickness and reinforcement for the expected loads. Shotcrete is a placement method for concrete, so standard reinforced concrete design is appropriate for shotcreted sections.

How much shotcrete coverage over No. 4 reinforcing bar is required?

Shotcrete is simply a placement method for concrete. The specified concrete cover over reinforcing bar is usually included in contract documents for construction and values vary depending on exposure conditions. ACI 318 provides cover requirements for structural concrete in buildings, and ACI 350 provides cover requirements for concrete liquid-containing structures. Local building codes and fire codes may also require specific cover in concrete construction. If your project doesn’t specify the cover requirements, we recommend you consult with a professional engineer experienced in the type of project you are working on to learn what the code requirements may be.

What is the best way to check the sand-to-cement ratio in gunite batch trucks? Is it normal (common) to get up to 10% air straight from the mixing auger? I had a gunite truck fill a 5 gal. (19 L) bucket with mixed material (sand and cement) then put it in my lab mixer and wetted it up to a 3 in. (75 mm) slump and ran a test for air, unit weight, and cast a set of cylinders. I am trying to figure out the sand-to-cement ratio, but I don’t have a cement diverter to run a real-time sand-to-cement ratio test, so I am testing dispensed material to see if it makes 70% strength in 7 days, which indicates a good mixture. Are there any other ways of checking sand-to-cement proportions? I tested the mixed material in a lab about 5 minutes after it was dispensed.

By “gunite batch truck” we assume you are referring to a volumetric mixer supplying material for a dry-mix shotcrete operation. Gunite is the original tradename for what we now call dry-mix shotcrete. Here’s the description from an ACI Materials Journal (January-February 1991 issue) article about the calibration of volumetric mixers:

“To insure production of quality concrete, each volumetric-measuring unit must be calibrated for each respective concrete ingredient, following the manufacturer’s recommendations and ASTM C 685. These ingredients must be the same as those to be used in actual concrete production. The measuring devices for aggregates, cement, and dry admixtures are calibrated by weighing the discharged ingredient. Devices for water, latex modifier (if required), and liquid admixtures such as air-entraining and water-reducing admixtures generally are calibrated by weighing or measuring the volume of the discharged ingredient. The objective of calibration is to coordinate the discharge of all concrete ingredients to produce the proper mixture.”

ASTM C685/C685M states, “The proportioning and indicating devices shall be individually checked by following the equipment manufacturer’s recommendations as related to each individual concrete batching and mixing unit. Adequate standard volume measures, scales, and weights shall be made available for the checking accuracy of the proportioning mechanism.” Thus, you need to check with your equipment supplier for their recommended procedures to verify batching. Because concrete mixtures always are based on weight of ingredients there you will need to weigh a given volume to confirm the batching is accurate.

The air content test is a measure of total air so includes both entrapped and entrained air. Ten percent is definitely high. The 10% air is likely not representative of the in-place shotcrete. It may have been an issue with the lab mixer introducing more entrapped air for some reason. Estimating the air content from the unit weight test requires a good value for the theoretical unit weight. I’m not sure if you have that with the volumetric batching. You should run the air meter test (ASTM C231/C231M) to measure the air content to get a more accurate assessment.

Regarding the verification of mixture proportions, this is from ASTM C685/C685M:

“7.5 Proportioning Check—Whenever the sources or characteristics of the ingredients are changed, or the characteristics of the mixture are noted to have changed, the purchaser is permitted to require a check of the fine aggregate content and the coarse aggregate content by use of the washout test. Essentially, in the washout test, 1 ft3 [0.03 m3] of concrete is washed through a No. 4 [4.75-mm] sieve and through a No. 100 [150-µm] sieve; that retained on the No. 4 sieve is normally considered coarse aggregate whereas that passing the No. 4 and retained on the No. 100 sieve is considered fine aggregate. Corrections to the quantity of aggregates (per cubic foot or cubic meter of concrete) shall be made if the original sieve analysis of each aggregate is available.”

Because you are only interested in the sand and cement, you can simply weigh the sample of concrete, then wash out all the cement, and then weigh the remaining sand. You would need to bring the sand to roughly the same moisture content as the sand in the truck, so you aren’t including in the weight of excess water in the sand. You should note that with shotcrete impact during placement we will generally lose 50% of the air content, so your final in-place air should be around 5%. That is a reasonable value for good freezing-and-thawing durability.

I would like to better understand the limitations related to the height of install when it comes to the gunite application. Because gunite is a dry concrete mixed with water at the nozzle of the applying apparatus, I have been told by others in the industry that the application is only intended for use of walls less than 4 or 5 ft tall. If that is the case, is it safe to assume that the gunite application strategy should not be used for below-grade vaults exceeding a height of 5 ft? I am looking for design literature specific to gunite.

Dry-mix shotcrete adds mixing water to the dry concrete materials as the concrete materials flow through and out the nozzle. Gunite is the original tradename for dry-mix shotcrete. Though you may not find design information using the old gunite name, you will find numerous current design references to dry-mix shotcrete. This includes ACI 506R-16, “Guide to Shotcrete”; ACI 506.2-13, “Specification for Shotcrete”; ACI 506.6T-17, “Visual Shotcrete Core Quality Evaluation Technote”; ACI 372, “Design and Construction of Circular Wrapped Prestressed Concrete Tanks”; ACI 350-06, “Code Requirements for Environmental Engineering Concrete Structures”; ACI 350.5, “Specifications for Environmental Concrete Structures”; and seven ASTMs that directly cover shotcrete. ACI 318-19, “Building Code Requirements for Structural Concrete,” has also added specific shotcrete provisions. Dry-mix shotcrete has been used for decades to build structural concrete walls over 50 ft high in circular prestressed concrete tanks that withstand a full head of water pressure. This is a substantially greater water pressure than your 5 ft vault wall would experience. There are no limitations in the dry-mix placement process that would preclude use in high walls. Both dry-mix and wet-mix shotcrete using quality materials, proper equipment, and experienced placement crews will produce in-place concrete of equal strength, durability, and low permeability. However, generally wet-mix shotcrete can offer placement rates up to four times higher than dry-mix. Thus, in thicker, longer walls, wet-mix shotcrete may be more cost-effective because it can be placed faster.