Wet-mix process
This technique permits better control and more versatile mix designs than the dry-mix process. Any type of admixture such as an air-entraining, water-reducing and/or setcontrolling agent can be used. Thorough mixing of the ingredients is easier to achieve. More accurate control of the mix proportions is possible. The mix proportions for the wetmix process are about the same as for the dry-mix process. The entire mix is premixed to a slump suitable for the work. The slump is usually in the range from 0 to 4 inches. The proper mix is determined by trial when it is desirable to use coarse aggregate. Start with 20- to 40-percent coarse aggregate and adjust subsequent mixes on the basis of trials. Because there is good control of water content and mixing, dust and rebound are kept at a minimum. Thus, there is less wasted material and cleanup. On the other hand, this technique is not accompanied
Dry-mix process
In this method, there is a wide range of control over the amount of mixing water used to adjust mix consistency as the job progresses. It also allows transportation of the mix through a longer length of hose than is possible with wet-mix. The drymix process is better suited for concrete containing lightweight porous aggregates than it is for a mixture with normal weight aggregate. It also requires that the operator of the nozzle be exceptionally skilled in controlling water content and, therefore, consistency, strength and
by the ready control of concrete consistency that is provided by the dry-mix process. Materials should be measured by weight rather than by volume. If aggregates must be measured volum e t ri c a l l y, their weight should be ascertained regularly to maintain a reasonably uniform water content. The efficiency of the two basic types of wet-mix equipment (pneumatic feed and positive displacement ) will vary with the brand and its operating condition. Ge n e ra l l y speaking, it is possible to design mortar or concrete to a lower slump with the pneumatic-feed type. The proposed equipment should be tested before the start of a job to determine its ability to place the concrete acceptably; this is especially important for vertical or ove rh e a d applications.
CHART I
Inclination of Surface Floor or slabs Sloping and vertical walls O ve rhead work Percentage of Rebound 5 -15 percent 15 -30 percent 25-30 percent
Materials
Requirements for materials used for shotcrete are basically the same as those used in conventionally placed concrete. Because of the nature of shotcrete, in some cases it is necessary to exercise greater control over physical and chemical properties. Cements ordinarily used in conventional concrete are also used in shotcrete. Type I portland cement is most commonly employed, although Type II is sometimes used for specific exposure requirements. Type III is employed where high early strength is needed. A cement that exhibits a tendency toward flash setting or rapid hardening should be avoided. Premature stiffening of the concrete could entail great loss of time in freeing shotcrete equipment and lines of hardened grout, mortar or concrete. Occasionally it is possible to use aggregates that do not meet appropriate ASTM specifications, but it will usually be found that sand finer than that called for will result in increased drying shrinkage; coarser sand will result in increased rebound. Especially when using coarse aggregate, it is necessary to
eliminate ove r- s i ze particles from the aggregates; over-size aggregates increase the possibility of clogging the lines. The safe procedure is to thoroughly screen all aggregates used. Sand should be sound and hard; soft sand particles break down on discharge through the nozzle, undermining the bonding strength of the cement. This condition is agg ra vated by long hose lengths. Admixtures are especially helpful in shotcrete work. The four types most often used are set controllers, air-entraining agents, water reducers and mineral admixtures. Accelerators or retarders will often be helpful in controlling both the setting and strength-developing characteristics of shotcrete. Rate of set is especially important in this procedure. Air entrainment, which is possible only with the wet-mix process, will be of value both in promoting cohesiveness and in increasing durability. As a rule of thumb, about twice the air content desired should be produced in the mix, since the gunning operation will generally cut air content in half. Water-reducing admixtures are commonly used for the improvements in strength, cohesiveness and reduction in shrinkage that they afford. Fly ash has been occasionally employed in shotcrete to increase plasticity and reduce sagging. Soluble admixtures are introduced into the concrete or mortar in the usual way in the wetmix process. In the dry-mix process, soluble admixtures can be dissolved in the mix water, but this will result in variations in the admixture quantity as the nozzle man varies the content.