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®

Sika Shotcrete Systems


Technology and Concepts for Shotcrete

Tunneling & Mining


Concrete System Documentation

®
Sika Shotcrete Systems
Your local Sika Company
Technology and
Sika Services AG
Corporate Construction
Concepts for Shotcrete
CH-8048 Zürich
Switzerland
Phone +41 44 436 40 40
Fax +41 44 436 46 86
www.sika.com
S&W 04.05 / 05SIC 21.17 / © Sika Services AG

Our most current General Sales Conditions shall apply. Please


consult the Product Data Sheet prior to any use and processing.

a nagemen
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since 1986 since 1997
Sika Shotcrete Technology
Sika – The Leader by permanent Innovation
The high reputation enjoyed by Sika in tunnelling is so wi- always clearly marked by the development of shotcrete

dely known because the Company’s activities always loo- technology. To cite just one example from this success

ked towards the future of tunnelling from its beginnings in story, the decision was made to use Sika products

1910. The first patent for a spraying machine was for the waterproofing to all the structures for the electrifi-

registered in the year that Sika was founded, a symbolic cation of the railway line through the 1st Gotthard Alpine

coincidence because the history of tunnelling at Sika was tunnel.

Machines Accelerators Flow Control Agents

Introduction 1920
In 1933 the Sigunite® Brand was born
For reasons of flexibility, speed and economy, In powder form,
shotcrete has grown continuously in importance added by hand
over recent decades, especially for heading sup- Quantity added 3 – 7 %
port in tunnelling. The main basis for this was
new developments or improvements in shotcrete
and process technology.
1940 Spribag BS-12/MS-12 Naphthalene Sulphonate
New developments in concrete additives and First dry-mix machines Melamine Sulphonate
fillers, cements and methods of application are (compressed air process) Sikament®, still a reliable flow control agent in tunnelling
leading to innovative new applications and with a spraying capacity Working time up to 2 hours
enabling shotcrete to be produced by the wet of up to 3 m3/hr.
spraying process which can meet the highest
strength and durability requirements. This poten-
tial has yet to be utilized to the full worldwide, as
shotcrete is often used as temporary support 1960 Alkaline Aluminates Cement particle
concrete that only has to meet quite low quality The first liquid setting accelerators
requirements. More recently, however, the fullest for shotcrete, Sigunite®-L Liquid
possible know-how on wet-mix shotcrete has Quantity added 3 – 6 %
been developed in a wide variety of projects and
for many different applications.

Clients and project designers can rely on the


experience gained and can go ahead confidently 1980 Sika® Aliva®-200/285 Aluminium Sulphate Vinyl Copolymers
with creative, innovative ideas and solutions. Rotor spraying machines and Sigunite®-49 AF Powder, SikaTard® shotcrete flow control agent
systems for dry and wet mixes the first alkali-free setting accelerator State of the art for decades
Cement particle
Quantity added 4 – 7 % Working time up to 4 hours

2000 Sika®-PM500
Highly-mechanized
shotcretingsystems for dry or
wet mix shotcrete
Aluminium Hydroxide Modified
Aluminium Sulphate Polycarboxylates
Sigunite® AF Liquid EQ Sika® ViscoCrete®, the latest
E
Conforms to the EFCA envi-
ronmental quality standard
Konform mit den Umwelt-
richtlinien der EFCA
Cement particle
of

s
nc uro p

setting accelerator innovation for shotcreting

Co

on
r e t e a n F e d e r a t i o n c i a ti
eA
d m ixture s A sso
Conforme aux directives
écologiques de l’EFCA

Quantity added 4 – 7 % Working time over 6 hours


2|3
Shotcrete Requirements: Shotcrete Requirements:
Ecology and Economy Quality and Performance
performance
Sika is committed to the global chemical Parameters influencing the rebound Clients, project designers, building Early Strength 1 Frost
industry environmental management quantity contractors and health and safety This is the prerequisite for overhead Unlike normally placed concrete, frost
system «Responsible Care» which defines Layer thickness authorities all set different specific spraying, particularly for high outputs, resistance is obtained in shotcrete
the principles for safety, health and envi- Grading curve standards for the shotcrete. when applying thick layers or when by a dense microstructure rather than by
ronmental protection. Substrate condition To the project designer, the most spraying onto water penetration points. introducing macropores. Fillers such
Jet trajectory important factor is meeting the specifi- The curve of strength development as silicafume cause a higher level of hy-
Many serious accidents in the past have Air volume and pressure cations, while the contractor places in the first few minutes has a strong dration, giving lower porosity and water
shown that working conditions on building Adhesion properties the emphasis mainly on the most eco- influence on dust generation and rebound. absorbency.
sites require special attention. Early strength nomic production and installation The strength development is normally
Dust generation must be reduced and the Fiber type method that guarantees the required plotted for the period between 6 and 60
hazards created by corrosive and toxic Fiber content minimum quality at minimum cost. minutes. The strength is also measured Shotcrete strength development 1
chemicals must be minimized. The market Spraying process Health and safety authorities demand at hourly intervals. specifications
launch of alkali-free setting accelerators maximum hygiene and safety on site Compressive strength N/mm2
such as Sigunite® AF is a milestone during the spraying operations Final Strength 2
in tunnelling. Our commitment to safety, (maximum early strength of the shot- The less water in the concrete mix, 20
health and environment crete applied for heading support, low the lower the porosity of the hardened 10
5
C
As far as dust pollution is concerned, the wet dust pollution and minimum hazards cement. This has an advantageous 2
pH value Conventional pH 3 – 8 1 Class J3 B
spraying process creates much less dust accelerator pH >13 Safe range for from toxic or alkaline substances). effect on most of the concrete properties, 0.5 Class J2 A
than dry-mix spraying. The amount of dust Basic human tissue especially compressive strength. The 0.2
and vascular 0.1 Class J1
14
can also be reduced by the best possible system amount of water necessary for cement hy-
nozzle technology. Non-toxic, alkali-free dration equates to a W/C ratio of about
6 10 30 1 2 3 6 9 12 24
accelerators with a pH value of around 3 8 0.40. Excess water evaporates after appli- Minutes Hours
reduce the human and environmental cation and leaves voids in the hardened
Effect of W/C ratio on 2
hazards during handling, storage and use. 3 cement.
Acid
compressive strength
The spray contains no corrosive aerosols,
so that damage to the skin, mucous mem- W/C ratio for wet shotcrete for low Compressive strength N/mm2

branes and eyes can be avoided. Sigunite AF Liquid specifications: < 0.55 70
60
W/C ratio for wet shotcrete for average
50
The spraying capacity is the main factor specifications: < 0.50 40
Pump pressure during concrete delivery
influencing the economics of the wet W/C ratio for wet shotcrete for high 30
spraying process. Depending on the appli- bar specifications: < 0.46 20
160 10
cation, up to 30 m3/hour can be achieved.
120 0
To obtain a high output, it is important Durability,
to find the best shotcrete formulation, layer 80 Watertightness 3 3 days 7 days 28 days
thickness and type and quantity of accel- 40 Durability means high watertightness. W/C ratio 0.40 W/C ratio 0.46 W/C ratio 0.50

erator. A high output cannot be obtained 0 Low capillary porosity is essential for 3
Without SikaPump: jerky feed pressure Effect of W/C ratio on depth
unless the concrete is easily pumpable. high watertightness and is obtained by of water penetration
If the concrete mixes are unsuitable, spe- bar correctly applied shotcrete with a low
cial additives help to prevent separation 160 W/C ratio and correct curing. 140

and reduce the pump pressure. 120 120


100
80 Sulphates 4
80
The amount of rebound loss is a crucial 40
Water-soluble sulphates react with
60
cost factor. the C3 A in the cement to form ettringite.
0 40
In addition to loading, transporting and dis- With SikaPump: steady feed pressure The ettringite crystals first propagate 20
posing of the rebound material, rebound into the pores. When the pores are filled,
costs also involve the extra shotcrete that ettringite develops explosive pressure Depth of water penetration in mm
W/C ratio 0.50 W/C ratio 0.40 1% Sika ViscoCrete
has to be produced and applied. that can destroy the concrete structure.
If sulphate-resistant shotcrete is required, Sulphate resistance of concrete cores 4
sulphate-resistant cement grades must Difference in mean linear deformation between
be used, e.g. composite cements with samples stored in sulphate and in water

slag, pozzolana or cement with a low C3 A 0.6


content and added silicafume. 0.5
0.4
0.3
0.2
0.1
0
–0.1
Days 7 14 28 90 180 360 540 720
CEM I CEM II CEM III
4|5
Shotcrete Formulations Quality Control

Formulations for shotcrete must always Examples of Concrete Formulations During the prequalification procedure
be adapted to the specifications of the client or project designer normally
the aggregate components and cement Dry-mix shotcrete 0 – 8 mm requires suitability tests to be car-
available so that the required early ried out to verify that the quality speci-
strength and workability can be obtained. Cement 280 kg fications are met. These tests have
Preliminary tests in the concrete laboratory ®
SikaFume - HR/-TU 20 kg to be done at the start of construction
make the site operations easier. ® and the locally available raw materials
Retarder SikaTard - 930 0.3 %
0 – 4 mm with 4% inherent moisture 55 % ca. 680 kg (cement and aggregate) and the plant Flow-table spread testing of fresh concrete 1
The cement grade has a strong influence and equipment planned for the works
4 – 8 mm with 2% inherent moisture 45 % ca. 560 kg
on both strength development in the must be used.
3
early stages and the final strength and Dry mix moist m * ca. 1540 kg
properties of the hardened concrete. *Must be checked by a yield test During construction the quality of the
SikaFume® is used for much higher Cement content shotcrete must be controlled in accord-
watertightness (durability) and reduced For 1000 litres dry mix, 280 kg cement is added to 800 litres aggregate ance with current standards or the
rebound. SikaTard ® (retarder) is For 1250 litres dry mix, 350 kg cement is added to 1000 litres aggregate tender documents.
used for long-time retarded shotcrete Shotcrete from 1 m3 dry mix gives on the wall
and SikaTard ® or ViscoCrete® Accelerated with Sigunite® AF Powder (rebound 16 – 20 %) 0.58 – 0.61 m3
(flow control agents) for better Accelerated with Sigunite® AF Liquid (rebound 20 – 25 %) 0.55 – 0.58 m3 Concrete spraying, spraying shadow/rebound 2
Cement content in the shotcrete ca. 450 – 460 kg/m3
workability at a reduced water content.
Steel fiber increase the load-bearing
capacity and ductile bearing properties of Wet-mix shotcrete 0 – 8 mm
the shotcrete. Polypropylene fiber is
Concrete
used for improved early shrinkage proper- Cement 425 kg 135 l formulation
ties and higher fire resistance of the SikaFume®- HR/TU 20 kg 9l
shotcrete. The air void content of the fresh ®
Flow control SikaTard /
shotcrete is increased, which improves
Sika® ViscoCrete® 1.2 % Concrete
the workability and spraying result. 1
Retarder SikaTard - 930 ®
0.3 % production
Early strength of 0 – 1 N/mm2 3
Penetrometer method
The maximum aggregate particle size Aggregate:
depends on the layer thickness and the 0 – 4 mm with 4% inherent moisture 60 % 967 kg 358 l
surface finish required for the shotcrete 4 – 8 mm with 2% inherent moisture 40 % 791 kg 293 l Concrete
Added water (W/C = 0.47) 155 kg 155 l delivery
layer. Approximately 95% of the aggre- Air voids (4.5 %) 45 l
gate surface is supplied by the 0 – 4 mm Steel fiber 40 kg 5l
sand fraction and variations in the sand
Shotcrete 1000 l
component have a massive effect on the Density per m3 2398 kg Concrete
fresh concrete properties, the W/C ratio 3
pumping
and therefore the properties of the 1 m of applied shotcrete gives set on the wall
Accelerated with Sigunite® AF Liquid (rebound 6 – 10 %) 0.90 – 0.94 m3
hardened concrete. The sand fraction Cement content in shotcrete 450 – 470 kg/m3 Early strength of 1 – 15 N/mm2 4
Stud-shooting method
must be analyzed with extreme care Steel fiber content in shotcrete 30 – 36 kg/m3
during the quality control process. We Spraying 2
distinguish between round and broken Sufficient fines ≤ 0.125 mm are important
aggregate. The best particle form is for pumpability. Recommended fines content
cubic/spherical: it is very important for (total aggregate + cement + additional fine
workability. The aggregate must be hard, aggregates): Shotcrete
clean and not weathered.
Aggregate 0 – 8 mm 0 – 16 mm
3
Round 500 kg/m 450 kg/m3
Early strength
3 4
Compressive strength of core sample 5
Broken 525 kg/m3 475 kg/m3 testing Compression press

Hardened concrete
5 6
testing

Curing
Water impermeability 6
Testing with water under pressure 6|7
Shotcrete Application

Use Typical requirement Wet Spraying Process Dry Spraying Process


Dense flow process Fine flow process Fine flow process
Heading Stabilization High early strength Sika®Aliva®- 278/Sigunite® AF Liquid Sika®Aliva®- 263/Sigunite® AF Liquid Sika®Aliva®- 263/Sigunite® AF Powder
in tunnelling Low final strength
High spraying capacity The shotcrete (wet mix) is loaded into The shotcrete (wet mix) is loaded into The shotcrete (dry mix) is loaded
the piston pump funnel tube the rotor machine funnel tube into the rotor machine funnel tube
Delivery to the nozzle is by Delivery to the nozzle is by Delivery to the nozzle is by
the dense flow process the fine flow process the fine flow process
Tunnel lining High early strength Just before the nozzle (distance depending Just before the nozzle (distance depending Just before the nozzle (distance depending on whether
with shotcrete High final strength
High watertightness on whether the accelerator is alkali-free or on whether the accelerator is alkali-free or alkaline) the accelerator is alkali-free or alkaline) the Sigunite®
High durability alkaline) the dense flow is broken up in the Sigunite® accelerator is added to accelerator is added to the shotcrete with water
the current transformer by high air pressure the shotcrete with air
The Sigunite® accelerator is added to the
Mining High early strength shotcrete with the air at the current transformer
Sealing of excavation faces
Low to medium final strength

Advantages Advantages Advantages


Low wear costs Easy to handle Easy to handle
High or increased Protective layer (no load-bearing function)
The machine can also be used The concrete does not have to be pumpable Does not need pumpable concrete
fire resistance High adhesion
Resistant to temperatures of for pumping/backfilling Start-up and pause without prelubrication Maximum early strength
over 1200°C Shotcrete with steel fiber or cleaning Delivery of gravel and sand
High output up to 30 m3/h Dry-mix spraying without change of machine
Low compressed air consumption Spraying with steel fiber
Slope stabilization Rapid strength development
Excavation Flexible use
stabilization Flexibility of use for spraying
small concrete volumes Disadvantages Disadvantages Disadvantages
Complex start-up and cleaning process Problems with fine aggregate (caking) Very high dust generation
Wear costs
Tunnel repair Long-term resistance
Higher rebound
Good adhesion
Chemical resistance
Suitable elastic modulus
Compressed air

Compressed air
Compressed air
Wet mix Wet mix Dry mix
Repair of High durability in thin layers
concrete dams Low elastic modulus

Pneumatic feed
Hydraulic feed
Low rebound

(dense flow)

(fine flow)
Pneumatic feed Pneumatic feed
(fine flow) (fine flow)
Repair of High mechanical resistance Concrete pump Concrete spraying machine Concrete spraying machine
harbour walls High resistance to chemical effects

Air
100 cm – 150 cm
Current transformer

alkali-free

100 cm – 150 cm
Sigunite,

Low elastic modulus


Sigunite,

80 cm – 120 cm
alkaline
Air

alkali-free
alkali-free

Sigunite,
Sigunite,

Sigunite,
Sigunite,

alkaline
alkaline
Air for current transformer Water
Bridge New concrete not susceptible
reconstruction to vibration from traffic
Frost and freeze/thaw resistance Accelerator Accelerator Accelerator + water

Liquid setting accelerator Liquid setting accelerator Liquid setting accelerator

8|9
Shotcrete Additives Shotcrete Accelerators

Workability Time of wet Shotcrete Mixes Table of the various Accelerator Types Elutability of the Calcium Hydroxide Ca(OH)2
and their main Properties
Property Accelerator type Calcium hydroxide content
in mmol / L  m2
60 cm
Alkaline Alkaline Alkali-free
Aluminate-based Silicate-based
50 cm 30
Dosing range 3–6% 12 – 15 % 4–7%
Long-time retarded 25
wet-mix shotcrete with pH value 13 – 14 11 – 13 3
40 cm SikaTard-930 and 20
Sika ViscoCrete Na2O equivalent 20 % 12 % <1 %
Wet-mix shotcrete with 15
basic retarding of 3 hours with
30 cm
SikaTard-203
Very early strength ++++ ++++ +++ 10
at same dosage
5
Consistency, flow

20 cm Final strength + -- +++


0
Watertightness ++ -- +++ 2h 4h 5h 1d 3d
Shotcrete with Sigunite AF (alkali-free)
Leaching behaviour --- -- - Shotcrete without setting accelerator
Shotcrete with conventional alkaline setting accelerator
Workability time 2h 4h 6h 8h Occupational health - + +++
Occupational and --- + +++
transport safety
Table of Additives and Fillers for Shotcrete

Type Product Use/effect Remarks

Flow control SikaTard® High water reduction Optimum effect when added
agent (FM) Sika® ViscoCrete® Better workability after the mix water
High-performance Time controlled workability Optimum dosage depends
flow agent Rapid increase in strength on cement type
Better shrinkage and creep properties For specific properties, Liquid, alkali-free Sigunite® AF Heading stabilization in tunnelling For the dry or wet spraying process
Higher watertightness preliminary tests with the setting accelerator Liquid Rock and slope stabilization Non-corrosive
cement and aggregates to High-quality lining shotcrete Low final strength reduction compared
be used are essential Very high early strength with the non-accelerated original
Increased watertightness concrete
Retarder (VZ) SikaTard®- 930 Adjustable workability Reduced eluate quantity Not compatible with alkaline
No cleaning of pumps and hoses Better health and safety accelerators
necessary during the retarding phase Metal parts in contact with this
accelerator must be of stainless steel
Silicafume slurries Sikacrete®- L Improved fresh concrete homogeneity Added at the batching plant
Silicafume powder SikaFume® Much higher watertightness Optimum curing is necessary
Improved adhesion between aggregate because silicafume concrete Powder, alkali-free Sigunite® AF
and hardened cement dries out very quickly on setting accelerator Powder
High frost and freeze/thaw resistance the surface
Lower rebound Liquid, alkaline Sigunite® Heading stabilization in tunnelling For the dry or wet spraying process
setting accelerator Liquid Rock and slope stabilization Corrosive
Polymer-modified Sikacrete®- PP1 As for SikaFume,® plus: As for SikaFume® Very high early strength Final strength reduction compared with
silicafume powder Significant water reduction Lower rebound the non-accelerated
For very high quality specifications Can be sprayed on a original concrete
wet substrate
Pumping agents SikaPump® Improvement in homogeneity and internal Addition increases the power
and stabilizers Sika® Stabilizer cohesion for unsuitable concrete mixes input of the mixer and the concrete
Increase in spraying output with lower consistency – do not adjust by Powder, alkaline Sigunite®
energy consumption, even for mixes with adding water setting accelerator Powder
broken aggregate

10 | 11
Dry and Wet Mix Spray Mortars Machines for Shotcreting

SikaShot® Concrete Spraying Systems Sika®-PM500


Stabilization and For significant water presence Highly mechanized concrete spraying
sealing gunite Maximum early strength systems for large and small tunnels
High watertightness High flexibility due to modular design
Good adhesion to substrate Ideal for high slopes
Dry spraying process
Usable with
rotor machines
1-component ready-mix gunite,
highly accelerated

SikaCrete®- Gunite®
Sealing gunite High durability Concrete Spraying Machines Aliva®- 246/Aliva®- 252/Aliva®- 263/
Silicafume-modified High frost and Aliva®- 285
freeze/thaw resistance Concrete spraying machines for
Sulphate-resistant dry and wet spraying
Good adhesion to substrate Low to medium outputs
Dry spraying process Mobile and multi-purpose
For spray mortar and shotcrete
SikaCem®- Gunite®
Sealing gunite Can be applied in thin layers
Polymer-modified High frost and
freeze/thaw resistance
Sulphate-resistant
Good adhesion to substrate Spraying Robots for TBM Aliva®- TBM Spraying Robots
Dry spraying process Heading Shotcreting robot for immediate
stabilization and lining by shotcreting
Sika® MonoTop® Medium to high outputs
Repair mortar Repair of concrete structures
Silicafume and High frost and
polymer-modified freeze/thaw resistance
Good adhesion to substrate
Ideal surface workability
Wet spraying process
1-component ready-mix mortar

Spray Arms/Metering Units Telescopic spraying arm


Sika®- PM Spraying Booms
Wide radius of operation
Maximum mobility

Liquid metering unit


Aliva®- 403.5
High efficiency
Synchronized metering control

Concrete Spraying Pump Sika®- PM702


Compact easy-to-operate concrete spraying pump
Synchronized accelerator dosage
Powered by electric or diesel engine

12 | 13
Uses of Shotcrete

Shotcrete Stabilization in conventional Heading Excavation Slope Stabilization with Wet or Dry Mix Shotcrete

Sika Solution Sika Solution


Flow control agent SikaTard®/Sika® ViscoCrete® Flow control agent SikaTard®
Retarder SikaTard®- 930 Setting accelerator Sigunite® AF Liquid, first generation
Setting accelerator Sigunite® AF Liquid, second generation Concrete spraying machines Aliva®-263/Aliva®-285
Shotcreting systems Sika®- PM500/Aliva®-503

Sika-PM500 shotcreting system for large sections Aliva-503 shotcreting system for small sections Slope stabilization Excavation stabilization

Shotcrete Stabilization in TBM Heading Concrete Repair with Dry Mix Spray Mortars

Sika Solution Sika Solution Sika Solution


Flow control agent SikaTard®/Sika® ViscoCrete® Bonding coat Sika® MonoTop® Seal SikaShot®
Retarder SikaTard®- 930 Patching mortar Sika® MonoTop® Patching mortar SikaCem®-Gunite®
Setting accelerator Sigunite® AF Liquid, second generation Concrete spraying machine Aliva®-246 Concrete spraying machine Aliva®-252
Robot sprayer Aliva®-303 L1/Aliva®-303 L2

Shotcrete stabilization in TBM heading Bridge repair Tunnel repair

14 | 15
®
Sika Shotcrete Systems
Technology and Concepts for Shotcrete

Tunneling & Mining


Concrete System Documentation

®
Sika Shotcrete Systems
Your local Sika Company
Technology and
Sika Services AG
Corporate Construction
Concepts for Shotcrete
CH-8048 Zürich
Switzerland
Phone +41 44 436 40 40
Fax +41 44 436 46 86
www.sika.com
S&W 04.05 / 05SIC 21.17 / © Sika Services AG

Our most current General Sales Conditions shall apply. Please


consult the Product Data Sheet prior to any use and processing.

a nagemen
d Qu lity Sy Ma
fie d t
st
rti

Sy
ie
em
Ce

Certif

stem
1
IS

00

IS
O

90
01 / E N 2
9 O 14 0 0 1
since 1986 since 1997

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