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USACE / NAVFAC / AFCESA / NASA UFGS-03 37 13 (April 2006)
--------------------------
Preparing Activity:
USACE (CW) Replacing without change
UFGS-03371 (January 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated 1 April 2006
Latest change indicated by CHG tags
Section Table of Contents
SECTION 03 37 13
SHOTCRETE
04/06
PART 1 GENERAL
1.1 REFERENCES
1.2 SUBMITTALS
1.3 UNIT PRICES
1.3.1 Shotcrete
1.3.1.1 Payment
1.3.1.2 Measurement
1.3.1.3 Unit of Measure
1.4 QUALITY ASSURANCE
1.5 MIXTURE PROPORTIONS
1.6 EVALUATION AND ACCEPTANCE
1.6.1 Strength
1.6.2 [Compressive Strength
1.6.3 [Flexural Strength
1.6.4 [Toughness Index
1.7 QUALIFICATIONS
1.8 PRECONSTRUCTION TEST PANELS
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Cementitious Materials
2.1.1.1 Portland Cement
2.1.1.2 Blended Hydraulic Cement
2.1.1.3 Pozzolan Other Than Silica Fume
2.1.1.4 [Ground Granulated Blast-Furnace Slag
2.1.1.5 [Silica Fume
2.1.2 Aggregates
2.1.3 Water
2.1.4 Admixtures
2.1.5 Curing Materials
2.1.5.1 Impervious Sheet Materials
2.1.5.2 Membrane-Forming Curing Compound
2.1.6 Reinforcement
2.1.6.1 Steel Fiber Reinforcement
2.1.6.2 Other Types of Reinforcement
PART 3 EXECUTION
3.1 PRODUCTION OF SHOTCRETE
3.1.1 Dry Mix Process
3.1.1.1 Batching and Mixing
3.1.1.2 Delivery Equipment
3.1.2 Wet Mix Process
3.1.2.1 Batching and Mixing
3.1.2.2 Delivery Equipment
3.1.2.3 Air Content
3.1.3 Air Supply
3.2 PREPARATION OF SURFACES
3.2.1 Earth
3.2.2 Existing Concrete
3.2.3 Rock
3.2.4 Shotcrete
3.2.5 Construction Joints
3.3 PLACEMENT OF SHOTCRETE
3.3.1 General
3.3.2 Placement Techniques
3.3.2.1 Placement Control
3.3.2.2 Corners
3.3.3 Placement Around Reinforcement
3.3.4 Cover of Reinforcement
3.3.5 Placement Precautions
3.4 REPAIR OF DEFECTS
3.4.1 Defects
3.4.1.1 Repairs
3.4.1.2 Minor Patching
3.4.2 Core Holes
3.5 FINISHING
3.5.1 Natural Gun Finish
3.5.2 Cutting Screed
3.5.3 Flash Coat
3.5.4 Float and Trowel Finish
3.5.5 Fiber-Reinforced Shotcrete
3.6 CURING AND PROTECTION
3.6.1 Initial Curing
3.6.2 Final Curing
3.6.3 Formed Surface
3.6.4 Duration of Curing
3.6.5 Temperature Considerations
3.7 TESTS
3.7.1 Strength Testing
3.7.1.1 Test Panel
3.7.1.2 [Test Cores
3.7.1.3 [Compressive Strength
3.7.1.4 [Flexural Strength
3.7.1.5 [Toughness Index
3.7.2 Aggregate Moisture
3.7.3 Grading
3.7.4 Thickness
3.7.5 Mixture Proportions
3.7.6 Preparations
3.7.7 [Air Content
SECTION 03 37 13
SHOTCRETE
NOTE: This guide specification covers the requirements for materials, proportioning,
application, and curing of shotcrete.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of
technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a
Criteria Change Request
(CCR).
Use of electronic communication is encouraged.
Brackets are used in the text to indicate designer choices or locations where
text must be supplied by the designer.
PART 1 GENERAL
NOTE: The content of this specification is such that guidance given in EM 1110-2-2005,
STANDARD PRACTICE FOR SHOTCRETE, is applicable.
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
ACI INTERNATIONAL (ACI) |
|
ACI 506.3R | | (1991) Guide to Certification of Shotcrete Nozzlemen |
ASTM INTERNATIONAL (ASTM) |
|
ASTM A 820 | | (2004) Steel Fibers for Fiber-Reinforced Concrete |
|
ASTM C 1018 | | (1997) Flexural Toughness and First-Crack Strength
of Fiber-Reinforced Concrete (Using Beam with
Third-Point Loading) |
|
ASTM C 1077 | | (2005a) Laboratories Testing Concrete and Concrete
Aggregates for Use in Construction and Criteria
for Laboratory Evaluation |
|
ASTM C 1140 | | (2003a) Preparing and Testing Specimens from
Shotcrete Test Panels |
|
ASTM C 1141 | | (2001) Admixtures for Shotcrete |
|
ASTM C 1240 | | (2005) Silica Fume Used in Cementitious Mixtures |
|
ASTM C 1260 | | (2005) Potential Alkali Reactivity of Aggregates
(Mortar-Bar Method) |
|
ASTM C 136 | | (2005) Sieve Analysis of Fine and Coarse Aggregates |
|
ASTM C 150 | | (2005) Portland Cement |
|
ASTM C 1567 | | (2004) Potential Alkali-Silica Reactivity of
Combinations of Cementitious Materials and Aggregate
(Accelerated Mortar-Bar Method) |
|
ASTM C 171 | | (2003) Sheet Materials for Curing Concrete |
|
ASTM C 231 | | (2004) Air Content of Freshly Mixed Concrete
by the Pressure Method |
|
ASTM C 266 | | (2004) Time of Setting of Hydraulic-Cement Paste
by Gillmore Needles |
|
ASTM C 309 | | (2003) Liquid Membrane-Forming Compounds for
Curing Concrete |
|
ASTM C 33 | | (2003) Concrete Aggregates |
|
ASTM C 42/C 42M | | (2004) Obtaining and Testing Drilled Cores and
Sawed Beams of Concrete |
|
ASTM C 566 | | (1997; R 2004) Total Evaporable Moisture Content
of Aggregate by Drying |
|
ASTM C 595 | | (2005) Blended Hydraulic Cements |
|
ASTM C 618 | | (2005) Coal Fly Ash and Raw or Calcined Natural
Pozzolan for Use as a Mineral Admixture in Concrete |
|
ASTM C 685/C 685M | | (2001) Concrete Made by Volumetric Batching
and Continuous Mixing |
|
ASTM C 881/C 881M | | (2002) Epoxy-Resin-Base Bonding Systems for
Concrete |
|
ASTM C 94/C 94M | | (2004a) Ready-Mixed Concrete |
|
ASTM C 989 | | (2005) Ground Granulated Blast-Furnace Slag
for Use in Concrete and Mortars |
U.S. ARMY CORPS OF ENGINEERS (USACE) |
|
COE CRD-C 400 | | (1963) Requirements for Water for Use in Mixing
or Curing Concrete |
1.2 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.][information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] The following shall be
submitted in accordance with Section
01 33 00
01 33 00
01 33 00 SUBMITTAL PROCEDURES:
SD-06 Test Reports
Mixture Proportions[; G][; G, [_____]]
The recommended mixture proportions, sources of materials, and all test results shall be submitted
for approval.
Aggregates
Supplier's test reports for aggregates showing the materials meet the requirements of this
specification.
Accelerator Compatibility[; G][; G, [_____]]
The Contractor shall establish the compatibility of the job cement and the proposed accelerators.
Preconstruction Test Panels
Cores and sawed concrete beams shall be taken from test panels and tested.
SD-07 Certificates
Portland Cement
Portland cement shall be certified for compliance with all specification requirements.
Pozzolans
Fly ash and other pozzolans shall be certified for compliance with all specification requirements.
Silica Fume
Silica fume shall be certified for compliance with all specification requirements.
Accelerating Admixtures
Accelerating admixtures shall be certified for compliance with all specification requirements.
Curing Materials
Curing materials shall be certified for compliance with all specification requirements.
Steel Fiber Reinforcement
Fiber reinforcement shall be certified for compliance with all specification requirements.
Qualifications[; G][; G, [_____]]
Qualifications of each nozzleman shall be certified.
1.3 UNIT PRICES
NOTE: If Section 01 22 00.00 10 MEASUREMENT AND PAYMENT is included in the
project specifications, this paragraph title (UNIT PRICES) should be deleted
from this section and the remaining appropriately edited subparagraphs below
should be inserted into Section 01 22 00.00 10.
1.3.1 Shotcrete
1.3.1.1 Payment
Payment will be made for all costs associated with furnishing, delivering, and placing shotcrete.
1.3.1.2 Measurement
Shotcrete will be measured for payment based upon [the quantity in cubic meters yards of solid material gunned
through the nozzles.] [the quantity per cubic meter yard, based on [a unit length] [the area] shotcreted to the
thickness shown on the contract drawings.]
1.3.1.3 Unit of Measure
Unit of measure: cubic meter yard.
1.4 QUALITY ASSURANCE
The Contractor shall provide facilities and labor as may be necessary for obtaining and testing representative
test samples. Shotcrete shall be sampled and tested by the method given in paragraph STRENGTH TESTING.
1.5 MIXTURE PROPORTIONS
NOTE: Consult the appropriate DM to fill in the blanks.
Mixture proportions and test data from prior experience within [_____] years, if available, may be submitted
for approval. If test data from experience are not available or accepted, specimens shall be made and tested
from mixtures having three or more different proportions. The recommended mixture proportions, sources of materials,
and all test results shall be submitted for acceptance. [Mixture proportions for nonfiber-reinforced shotcrete
shall be selected on the basis of compressive strength tests of cores obtained from test panels fabricated in
accordance with ASTM C 1140 and having minimum dimensions of 750 by 750 by 100 mm 30 by 30 by 4 inches. Cores
shall be continuously moist cured until testing at [_____] days age. For mixture acceptance purposes, the average
compressive strength of at least three cores shall be at least equal to 1.2 times the required compressive strength
specified in paragraph COMPRESSIVE STRENGTH.] [Mixture proportions for fiber-reinforced shotcrete shall be selected
on the basis of flexural strength [and toughness index] of 100 by 100 by 350 mm 4 by 4 by 14 inch beams sawed
from test panels which are fabricated in accordance with ASTM C 1140 and having minimum dimensions of 750 by
750 by 100 mm 30 by 30 by 4 inches. Beams shall be continuously moist cured until testing at [_____] days age.
For mixture acceptance purposes, the average flexural strength [and toughness index] of at least three beams
shall be not less than the flexural strength [and toughness index] specified in paragraph FLEXURAL STRENGTH [and
TOUGHNESS INDEX].]
1.6 EVALUATION AND ACCEPTANCE
1.6.1 Strength
NOTE: Compressive strength should be specified for nonfiber-reinforced shotcrete
and flexural strength should be specified for fiber-reinforced shotcrete. Consult
EM 1110-2-2005 and the appropriate DM to fill in blanks.
If a flexural toughness index requirement is deemed necessary for fiber-reinforced
shotcrete, the minimum toughness index necessary for anticipated service conditions
should be specified. See EM 1110-2-2005 and ASTM C 1116 for guidance.
Final acceptance of the shotcrete will be based on [compressive] [flexural] strength results obtained from [cores]
[beams].
1.6.2 [Compressive Strength
The required compressive strength of cores shall not be less than [_____] MPa psi at [_____] days age when tested
in accordance with ASTM C 42/C 42M. The average compressive strength of cores taken from the [structure] [test
panel], representing a shift or not more than 40 cubic meters 50 cubic yards of shotcrete tested at [_____] days
of age, shall equal or exceed the required compressive strength specified with no individual core less than 85
percent of the required compressive strength. When the length of a core is less than 1.94 times the diameter,
the correction factors given in ASTM C 42/C 42M will be applied to obtain the compressive strength of individual
cores.]
1.6.3 [Flexural Strength
Fiber-reinforced shotcrete beams shall be obtained and tested in accordance with ASTM C 1140 and shall have a
flexural strength of not less than [_____] MPa psi at [_____] days age.]
1.6.4 [Toughness Index
The toughness index, [I10] [I20], of fiber-reinforced shotcrete beams shall be [_____] at [_____] days age when
tested in accordance with ASTM C 1018.]
1.7 QUALIFICATIONS
The Contractor shall submit a resume for each nozzleman certifying that each has not less than 1 year's experience
for the particular type of shotcrete to be applied. The resume shall include company name, address, and telephone
number, name of supervisor, and detailed description of work performed. All nozzlemen shall be certified in
accordance with ACI 506.3R. Qualifications of additional nozzlemen throughout the job shall be similarly submitted
for approval.
1.8 PRECONSTRUCTION TEST PANELS
Specimens of the preconstruction test panels shall be made by each application crew using the equipment, materials,
mixture proportions, and procedures for each mixture being considered, and for each shooting position to be encountered
in the job. [The same reinforcement as in the structure shall be provided in at least one-half of the panel
to test for proper embedment of reinforcing steel.] The test panels shall be fabricated to the same thickness
as the structure, but not less than 100 mm 4 inches. [At least five 75 mm 3-inch diameter cores from each panel
shall be taken for testing for compressive strength in accordance with ASTM C 1140 when nonfiber-reinforced shotcrete
is used. The compressive strength of the cores shall meet the requirements specified in paragraph COMPRESSIVE
STRENGTH.] [Three 100 by 100 by 350 mm 4 by 4 by 14 inch beams shall be obtained in accordance with ASTM C 1140
from the test panels when fiber-reinforced shotcrete is used. The flexural strength [and toughness index] of
the fiber-reinforced shotcrete beams shall meet the requirements specified in paragraph FLEXURAL STRENGTH [and
TOUGHNESS INDEX].]
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Cementitious Materials
NOTE: See the appropriate DM to select the proper requirements for the Cementitious
Materials Options. Other cementitious materials may be added if specifically
recommended and approved in the concrete materials DM.
Cementitious materials shall be portland cement, blended hydraulic cement, portland cement in combination with
pozzolan or ground granulated blast-furnace slag (GGBFS) [or [_____]], or [or portland cement in combination
with silica fume] and shall conform to appropriate specifications listed below.
2.1.1.1 Portland Cement
Portland cement shall meet the requirements of ASTM C 150 Type [I], [II], [III], [V] [low alkali] [with tricalcium
aluminate limited to [5] [8] percent if Type III is used].
2.1.1.2 Blended Hydraulic Cement
ASTM C 595 Type IS, IP[(MS)].
2.1.1.3 Pozzolan Other Than Silica Fume
Pozzolans shall conform to ASTM C 618, Class [C], [F], with the optional requirements for [available alkalies
from Table 1A] multiple factor, drying shrinkage, and uniformity of Table 2A.
2.1.1.4 [Ground Granulated Blast-Furnace Slag
Ground granulated blast-furnace slag shall conform to ASTM C 989, Grade [_____].]
2.1.1.5 [Silica Fume
Silica may be furnished as a dry, densified material or as a slurry. Silica fume, unprocessed, or before processing
into a slurry or a densified material, shall conform to ASTM C 1240.]
2.1.2 Aggregates
NOTE: This note may be disregarded for regions where Alkali-Silica Reactivity
(ASR) is not a concern. Some aggregate sources may exhibit an ASR potential.
ASR is a potentially deleterious reaction between alkalis present in concrete
and some siliceous aggregates, reference EM 1110-2-2000 paragraph 2-3b(6) and
appendix D. Where ASR is known or suspected to pose a concern for concrete
durability, it is recommended that aggregates proposed for use in concrete be
evaluated to determine ASR potential and an effective mitigation. EM 1110-2-2000,
provides recommendations for evaluating and mitigating ASR in concrete mixtures.
Aggregate evaluations may not be practical for projects requiring small quantities
of concrete (less than 250 cubic yards).
UFGS Section 32 13 11 CONCRETE PAVEMENT FOR AIRFIELDS AND OTHER HEAVY-DUTY PAVEMENTS
MORE THAN 10,000 CUBIC YARDS, paragraph 2.2.1.2 Alkali-Silica Reactivity, provides
a specification method for the Contractor to evaluate and mitigate ASR in concrete
mixtures. The expansion limits specified in Section 32 13 11 are requirements
for pavements and exterior slab construction. For structural concrete applications
the measured expansion shall be less than 0.10 percent. It may not be economical
or practical to specify different test limit requirements for use on the same
project. In which case the lower limit required by the application should be used.
The designer may use the specification method in UFGS Section 32 13 11 by incorporating
the relevant paragraphs into this specification, or may use the following requirements
(retain either the 0.10 or the 0.08 percent expansion limits as appropriate)
included in the set of brackets highlighted thus "[.]".
Aggregates shall conform to ASTM C 33 with the combined grading of coarse and fine aggregates conforming to the
grading shown below.
PERCENT BY MASS PASSING INDIVIDUAL SIEVES
SIEVE SIZE GRADING NO. 1 GRADING NO. 2 GRADING NO. 3*
19.0 mm (3/4 in.) -- -- 100
12.5 mm (1/2 in.) -- 100 80-95
9.5 mm (3/8 in.) 100 90-100 70-90
4.75 mm (No. 4) 95-100 75-85 50-70
2.36 mm (No. 8) 80-100 50-70 35-55
1.18 mm (No. 16) 50-85 35-55 20-40
600 µm (No. 30) 25-60 20-35 10-30
300 µm (No. 50) 10-30 8-20 5-17
150 µm (No. 100) 2-10 2-10 2-10
* Fine and coarse aggregates shall be [batched separately to avoid segregation.] "[tested and evaluated for alkali-aggregate
reactivity in accordance with ASTM C 1260. The fine and coarse aggregates shall be evaluated separately and
in combination, which matches the Contractor's proposed mix design proportioning. All results of the separate
and combination testing shall have a measured expansion less than 0.10 (0.08) percent at 16 days after casting.
Should the test data indicate an expansion of 0.10 (0.08) percent or greater, the aggregate(s) shall be rejected
or additional testing using ASTM C 1260 and ASTM C 1567 shall be performed. The additional testing using ASTM C 1260
and ASTM C 1567 shall be performed using the low alkali portland cement in combination with ground granulated
blast furnace (GGBF) slag, or Class F fly ash. GGBF slag shall be used in the range of 40 to 50 percent of the
total cementitious material by mass. Class F fly ash shall be used in the range of 25 to 40 percent of the total
cementitious material by mass.]"
2.1.3 Water
Fresh, clean, potable mixing water or nonpotable water which meets the requirements of COE CRD-C 400 shall be
used.
2.1.4 Admixtures
a. Admixtures to be used, when required or approved, shall comply with the appropriate sections of ASTM C 1141
. Except as otherwise accepted, soluble admixtures shall be dissolved in water before introduction into
the shotcrete mixture.
b. When accelerating admixtures complying with ASTM C 1141, Type II, Grade 1, are to be used, the Contractor
shall establish the accelerator compatibilityof the job cement and the proposed accelerators using ASTM C 266
, except as modified herein. The powdered accelerator shall be blended with 50 grams of cement until
uniform and 15 milliliters of water shall then be added. The liquid accelerator shall first be mixed
with 15 milliliters of water and then added to 50 grams of cement. Three percent of the proposed accelerator
by mass of cement shall be used as a starting point. Mixing shall be accomplished within 15 seconds.
The specimen shall be molded within 1 minute of adding the mixing water. If initial set is 2 minutes
or less and a final set is 10 minutes or less, the accelerator is considered compatible. If these values
are not achieved in the first test, additional tests shall be run using 2 percent and 4 percent of accelerator.
2.1.5 Curing Materials
Curing materials shall meet the following requirements.
2.1.5.1 Impervious Sheet Materials
ASTM C 171, type optional except polyethylene film, if used, shall be white opaque.
2.1.5.2 Membrane-Forming Curing Compound
ASTM C 309, Type 1-D or Type 2.
2.1.6 Reinforcement
2.1.6.1 Steel Fiber Reinforcement
Steel fiber reinforcement shall meet the requirements of ASTM A 820.
2.1.6.2 Other Types of Reinforcement
PART 3 EXECUTION
3.1 PRODUCTION OF SHOTCRETE
The shotcrete shall be produced by [wet-mix process] [dry-mix process].
3.1.1 Dry Mix Process
NOTE: Delete these three paragraphs if wet-mix process is specified.
3.1.1.1 Batching and Mixing
Aggregate and cementitious materials may be batched by mass or by volume. Equipment for batching by mass shall
be capable of the accuracy specified in ASTM C 94/C 94M. Volumetric equipment shall be capable of batching with
the accuracy specified in ASTM C 685/C 685M. The mixing equipment shall be capable of thoroughly mixing the
materials in sufficient quantity to maintain placing continuity and be capable of discharging all mixed material
without any carryover from one batch to the next.
3.1.1.2 Delivery Equipment
The equipment shall be capable of discharging the aggregate-cement mixture into the delivery hose and delivering
a continuous smooth stream of uniformly mixed material to the discharge nozzle. The discharge nozzle shall be
equipped with a manually operated water injection system (water ring) for directing an even distribution of water
through the aggregate-cement mixture. The water valve shall be capable of ready adjustment to vary the quantity
of water and shall be convenient to the nozzleman. The water pressure at the discharge nozzle shall be sufficiently
greater than the operating air pressure to ensure that the water is completely mixed with the other materials.
If the line water pressure is inadequate, a water pump shall be introduced into the line. The water pressure
shall be steady (nonpulsating). The delivery equipment shall be thoroughly cleaned at the end of each shift.
Equipment parts, especially the nozzle liner and water ring, shall be regularly inspected and replaced as required.
3.1.2 Wet Mix Process
NOTE: Delete these four paragraphs if dry-mix process is specified. See the
appropriate DM to select the proper air content.
3.1.2.1 Batching and Mixing
Batching and mixing shall be accomplished in accordance with the applicable provisions of ASTM C 94/C 94M. If
volumetric batching and mixing are used, the materials shall be batched and mixed in accordance with the applicable
provisions of ASTM C 685/C 685M. The mixing equipment shall be capable of thoroughly mixing the specified materials
in sufficient quantity to maintain continuous placing. Ready-mix shotcrete complying with ASTM C 94/C 94M may
be used.
3.1.2.2 Delivery Equipment
The equipment shall be capable of delivering the premixed materials accurately, uniformly, and continuously through
the delivery hose. Recommendations of the equipment manufacturer shall be followed on the type and size of nozzle
to be used and on cleaning, inspection, and maintenance of the equipment.
3.1.2.3 Air Content
Air-entraining admixture shall be used in such proportion that the air content of the shotcrete prior to gunning
shall be [_____] plus or minus (±) 1.0 percent as determined by ASTM C 231.
3.1.3 Air Supply
The Contractor shall provide a supply of clean, dry air adequate for maintaining sufficient nozzle velocity for
all parts of the work and, if required, for simultaneous operation of a suitable blowpipe for clearing away rebound.
3.2 PREPARATION OF SURFACES
3.2.1 Earth
Earth shall be compacted and trimmed to line and graded before placement of shotcrete. Surfaces to receive shotcrete
shall be dampened.
3.2.2 Existing Concrete
All unsound and loose materials shall be removed by sandblasting, grinding, or high-pressure water jets before
applying shotcrete. Any area to be repaired shall be chipped off or scarified to remove offsets which would
cause an abrupt change in thickness without suitable reinforcement. Edges shall be tapered to leave no square
shoulders at the perimeter of a cavity. The surface shall be dampened but without visible free water.
3.2.3 Rock
Rock surfaces shall be cleaned to remove loose or drummy material, mud, running water, and other foreign matter
that will prevent bond of the shotcrete. The rock surface shall be dampened prior to placement of shotcrete.
3.2.4 Shotcrete
When a layer of shotcrete is to be covered by a succeeding layer at a later time, it shall first be allowed to
develop its initial set. Then all laitance, loose material, and rebound shall be removed by brooming or scraping.
Hardened laitance set shall be removed by sandblasting and the surface thoroughly cleaned.
3.2.5 Construction Joints
Unless otherwise specified, construction joints shall be tapered to a shallow edge form, about 25 mm 1 inch thick.
If nontapered joints are specified, special care shall be taken to avoid or remove trapped rebound at the joint.
The entire joint shall be thoroughly cleaned and wetted prior to the application of additional shotcrete.
3.3 PLACEMENT OF SHOTCRETE
3.3.1 General
Shotcrete shall be placed using suitable delivery equipment and procedures. The area to which shotcrete is to
be applied shall be clean and free of rebound or overspray.
3.3.2 Placement Techniques
3.3.2.1 Placement Control
Thickness, method of support, air pressure, and water content of shotcrete shall be controlled to preclude sagging
or sloughing off. Shotcreting shall be discontinued or suitable means shall be provided to screen the nozzle
stream if wind or air currents cause separation of the nozzle stream during placement.
3.3.2.2 Corners
Horizontal and vertical corners and any area where rebound cannot escape or be blown free shall be filled first.
3.3.3 Placement Around Reinforcement
The nozzle shall be held at such distance and angle to place material behind reinforcement before any material
is allowed to accumulate on the face of the reinforcement. In the dry-mix process, additional water may be added
to the mixture when encasing reinforcement to facilitate a smooth flow of material behind the bars. Shotcrete
shall not be placed through more than one layer of reinforcing steel rods or mesh in one application unless demonstrated
by preconstruction tests that steel is properly encased.
3.3.4 Cover of Reinforcement
NOTE: Use 19 mm (3/4 inch) if grading No. 1 in paragraph AGGREGATES is selected;
otherwise, use 40 mm (1-1/2 inches).
The following minimum cover shall be provided.
a. For shotcrete used as linings, coatings, slab, or wall:[ 19 mm 3/4 inch.][ 40 mm 1-1/2 inches].
b. For required structural reinforcement in beams, girders, and columns: 40 mm 1-1/2 inches.
3.3.5 Placement Precautions
The following precautions shall be taken during placement.
a. Placement shall be stopped if drying or stiffening of the mixture takes place at any time prior to
delivery to the nozzle.
b. Rebound or previously expended material shall not be used in the shotcrete mixture.
3.4 REPAIR OF DEFECTS
3.4.1 Defects
Defective areas larger than 31 000 square mm 48 square inches or 50 mm 2 inches deep shall be removed and replaced
with fresh shotcrete. These defects include honeycombing, lamination, dry patches, voids, or sand pockets.
Defective areas shall be removed in accordance with the procedures described in paragraph EXISTING CONCRETE and
replaced with fresh shotcrete.
3.4.1.1 Repairs
All repairs shall be made within 1 week of the time the deficiency is discovered. All unacceptable materials
shall be removed and repaired by the procedures described in the following two paragraphs. Voids and holes left
by the removal of tie rods in all permanently exposed surfaces not to be backfilled and in surfaces to be exposed
to water shall be reamed and completely filled with dry-patching mortar as specified below.
3.4.1.2 Minor Patching
Minor patching may be accomplished with a dry-pack mixture, or with materials as approved by the Contracting
Officer. Patches that exceed 0.003 cubic meters 0.1 cubic foot in volume shall receive a brush coat of approved
epoxy resin meeting ASTM C 881/C 881M, Type II, as a prime coat. Care shall be taken not to spill epoxy or overcoat
the repair surface so that the epoxy runs or is squeezed out onto the surface which will remain exposed to view.
Epoxy resin shall be used in strict conformance with manufacturer's recommendations with special attention paid
to pot life, safety, and thin film tack time.
3.4.2 Core Holes
Core holes shall not be repaired with shotcrete. Instead, they shall be filled solid with a dry-pack mixture
after being cleaned and thoroughly dampened.
3.5 FINISHING
NOTE: See the appropriate DM for type of finish required. The specified finishes
should also be shown on the contract drawings. Delete the finishes not required.
3.5.1 Natural Gun Finish
Unless otherwise specified, undisturbed final layer of shotcrete as applied from nozzle without hand finishing
shall be provided.
3.5.2 Cutting Screed
After the surface has taken its initial set (crumbling slightly when cut), excess material outside the forms
and ground wires shall be sliced off with a downward cutting motion using a sharp-edged cutting screed.
3.5.3 Flash Coat
A thin coat of shotcrete containing finer sand applied from a distance greater than normal shall be applied to
the surface as soon as possible after the screeding.
3.5.4 Float and Trowel Finish
Final surface finish shall be provided using [wood float] [rubber float] [steel trowel]. Troweling of thin sections
of shotcrete shall be avoided unless both troweling and commencement of moisture curing take place within a relatively
short period after placement of shotcrete.
3.5.5 Fiber-Reinforced Shotcrete
NOTE: Include this paragraph if the exposed steel fibers pose a safety hazard.
The Contractor shall finish the outer surface of the structure with a layer of nonfiber-reinforced shotcrete
and provide an appropriate finish as denoted.
3.6 CURING AND PROTECTION
NOTE: See appropriate DM for protection durations and EM 1110-2-2005 on the
proper use of accelerating admixture.
3.6.1 Initial Curing
Immediately after finishing, shotcrete shall be kept continuously moist for at least 3 days. One of the following
materials or methods shall be used:
a. Ponding or continuous sprinkling.
b. Absorptive mat or fabric, sand, or other covering kept continuously wet.
c. Curing Compounds. On natural gun or flash finishes, use the coverage application requirement of
2.5 square meters/L 100 square feet/gallon or twice the manufacturer's requirement, whichever is less.
Curing compounds shall not be used on any surfaces against which additional shotcrete or other cementitious
finishing materials are to be bonded unless positive measures, such as sandblasting, are taken to completely
remove curing compounds prior to the application of such additional materials.
3.6.2 Final Curing
Additional curing shall be provided immediately following the initial curing and before the shotcrete has dried.
One of the following materials or methods shall be used:
a. Continue the method used in initial curing.
b. Application of impervious sheet material conforming to ASTM C 171.
3.6.3 Formed Surface
If forms are to be removed during curing period, one of the curing materials or methods listed in paragraph INITIAL
CURING shall be used immediately. Such curing shall be continued for the remainder of the curing period.
3.6.4 Duration of Curing
Curing shall be continued for the first 7 days after shotcreting or until the specified [compressive] [flexural]
strength of the in-place shotcrete as determined by specimens obtained and tested in accordance with ASTM C 42/C 42M
is achieved.
3.6.5 Temperature Considerations
The air temperature in contact with the shotcrete shall be continuously maintained at a temperature above 5 degrees
C 40 degrees F for at least [3 days after placement.] [[_____] days after placement if an accelerator is used.]
No shotcrete shall be applied when the concrete surface or air in contact with the concrete surface is below
5 degrees C 40 degrees F.
3.7 TESTS
3.7.1 Strength Testing
NOTE: See the appropriate DM for locations of test specimens and ages of tests.
Air content tests should only be specified on shotcrete produced by the wet-mix
process.
Test specimens shall be initially cured onsite, then shall be transported in an approved manner to an approved
testing laboratory meeting the requirements of ASTM C 1077 within 48 hours of scheduled testing time.
3.7.1.1 Test Panel
One test panel shall be made for every 40 cubic meters 50 cubic yards of shotcrete placed but not less than one
per each shift during which any shotcrete is placed. Panels shall have minimum dimensions of 450 by 450 by 100
mm 18 by 18 by 4 inches and shall be gunned in the same positions as the work represented during the course of
the work by the Contractor's regular nozzleman. Panels shall be field cured in the same manner as in the job.
[Three [_____] mm inch diameter cores shall be drilled from each panel at least 40 hours prior to testing and
tested in accordance with ASTM C 1140.] [Two 100 by 100 by 350 mm 4 by 4 by 14 inch beams shall be saw cut from
the test panels when fiber-reinforced shotcrete is used. The fiber-reinforced shotcrete beams shall be tested
in accordance with ASTM C 1140 [ASTM C 1018.] If the quality of shotcrete is questionable, the Government may
saw or core the panel specimens to determine the shotcrete quality and if remedial action is necessary.]
3.7.1.2 [Test Cores
Test cores shall be drilled from the structure at least 40 hours prior to testing and tested in accordance with
ASTM C 1140. A set of three cores shall be taken not less than once each shift that shotcrete is placed nor
less than once for each 40 cubic meters 50 cubic yards of shotcrete placed through the nozzle. The diameter
of core specimens shall be determined in accordance with ASTM C 42/C 42M.]
3.7.1.3 [Compressive Strength
The compressive strength of the shotcrete shall be determined from the average of three cores obtained from [a
test panel] [the structure] representing a specific volume of shotcrete and tested on the [_____] day after [panel
fabrication] [placement in the structure.]]
3.7.1.4 [Flexural Strength
The flexural strength of the shotcrete shall be determined from the average of two test specimens obtained from
a test panel and tested on the [_____] day after panel fabrication.]
3.7.1.5 [Toughness Index
The toughness index of the shotcrete shall be determined from the average of two test specimens obtained from
a test panel and tested on the [_____] day after panel fabrication.]
3.7.2 Aggregate Moisture
Prior to batching the shotcrete and at least once during a shift in which shotcrete is being batched, the coarse
and fine aggregate moisture content shall be determined in accordance with ASTM C 566. The batch weights of
both the aggregates and mixing water shall be appropriately adjusted to account for the available free moisture
in the aggregates. The amount of free moisture in the aggregates, expressed as kg pounds of water per cubic
meter yard, shall be recorded on the batching ticket and delivered to the Contracting Officer prior to placement
during the shift. The Contracting Officer will have the option to request additional aggregate moisture content
tests for each of the required tests.
3.7.3 Grading
The grading of the coarse and fine aggregate shall be determined in accordance with ASTM C 136. The fine and
coarse aggregate grading shall be determined prior to batching the shotcrete and at least once during a shift
in which shotcrete is being batched. The Contracting Officer will have the option to require one additional
sieve analysis test for aggregate type.
3.7.4 Thickness
The minimum shotcrete thickness shall be as shown in the drawings. The unhardened shotcrete shall be checked
for thickness using a probe by the nozzleman or laborer at the time of placement. These thickness checks shall
be at 15-minute intervals and all low or thin areas shall be corrected by applying additional shotcrete.
3.7.5 Mixture Proportions
Record and check mixture proportions at least once per shift for weigh batching. Record and check mixture proportions
as recommended by ASTM C 685/C 685M at least once per shift for volumetric batching and continuous mixing plants.
3.7.6 Preparations
Prior to each placement of shotcrete, the Contractor's inspector shall certify in writing or by an approved checkout
form that cleanup and preparations are in accordance with the plans and specifications.
3.7.7 [Air Content
Air content tests shall be conducted on wet-mix shotcrete according to ASTM C 231 with a frequency of not less
than once each shift nor less than once for each 40 cubic meters 50 cubic yards of shotcrete placed through the
nozzle. Tests shall be conducted on samples taken as the wet shotcrete mixture is placed in the delivery equipment.]
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