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Design &
Modeling
Plan
Design of a wet-mix shotcrete mixture
Strength and durability
Pumping:
Basic rules for shotcrete pumping
State-of-the-art approach
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Strength & Durability
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Strength &
Durability
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Strength & Durability
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Concrete Mix Design
The challenge is the same everywhere around the
globe:
Produce the cheapest ($) concrete while reaching the
specifications of the engineer
It is a simple calculation:
1 ton of cement: 180 $-220 $
1 ton of aggregate: 10-50 $
1 litre of water: ??? $
Admixtures: 5 - 60 $ (& ++)
For a concrete (m3) : 130-200 $/m3 (& ++)
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Concrete Mix Design
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Concrete Mix Design
A good mix design is therefore a
compromise where we look for:
Maximum amount of aggregate
A low w/cm for durable and strong paste
while maintaining adequate workability for
placement and consolidation (minimum amount
of paste in the system + admixtures)
and preventing instability (segregation or
bleeding)
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How to Mix design ACI 211
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PUMPING CONCRETE
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Concrete Pumping Why ?
Concrete pumping is widely used for:
Hard to reach places
Multi story buildings
Floors
Slabs on grade
Wet-mix shotcrete
Blockage
Stops productivity
$$$
Demoralizes the troops
Excessive wear on equipment
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How to Mix design for the PUMP
ACI 304.2R
Select a w/c based on exposure conditions AND
compressive strength (< value)
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Sand gradation -(304.2R)
Sieve
No.50: 15%-30%
Target FM: 2.68 No.100: 5%-10%
max variation: 0.2
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ACI 304.2R
Combined aggregates
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Aggregates
Gradation
Interesting Quotes (304R-00)
For gradation purposes, the fine and coarse
aggregate should be considered as one
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Literature review
Other publications (on concrete) all agree on
the importance of:
Coarse aggregate/Total aggregate content (<50%)
Fineness modulus of sand (2.5 2.9)
Amount of fines in the mix (all sources)
Gradation of the entire aggregate portion
Slump (5-15 cm 2-6)
Air content (3% -5%; up to 12% for shotcrete)
Admixture
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IF WE GO A LITTLE FURTHER
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Pumping Concrete
Pumpability (definition)
The ability of confined concrete to flow
under pressure while maintaining its
initial properties
which led to types of studies:
Stability under pressure
Mobility under pressure
Bingham rheological
model
= 0 +
Yield stress (0)
Plastic viscosity ()
Friction in the pipe ?
Tribology
Study of the interaction of surfaces in relative motion
Chapdelaine, 2006
Behavior
(Kaplan, 2000; Chapdelaine, 2006)
Bilinear model
Low speed tribology
Interface prop.
Higher speeds
rheology and tribology
Interface & flow prop.
Key pumping parameters
PIZZA EFFECT!
Pipe : 15 cm (6)
Pipe : 5 cm (2)
Lubricating layer: 2 mm
Lubricating layer: 2 mm
Paste in layer: 2.6% Paste in layer: 7.8%
Chapdelaine, 2006
Reducers
The MIX must therefore allow for a
rapid reorganization of the aggregates
to allow the migration of paste to the
exterior wall, while accelerating, and
while maintaining stability (not
segregation) !
= 15 cm (6)
Vout = 9
= 5 cm (2)
Vin = 1
SHOTCRETE
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Wet-mix Process
The concrete is pumped through a hose
and air is added at the nozzle to accelerate
the mixture to a high velocity
Wet-mix Process
Wet-mix Shotcrete
2 in. hose High Output
Wet-mix Shotcrete
1.5 in. hose Low Output
What is different with shotcrete?
Two supplemental requirements:
We have to pump in smaller hose diameter:
Pumping concrete in general: = 10-15cm (4-6)
Shotcrete: = 3.7-6 cm (1.5-2.5)
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Literature review
ACI 506R-05 Guide to shotcrete suggests:
the use of its Gradation #2 with 10 mm nominal
max. aggregates
Max. aggregate size = 1/3 of hose diameter
the use of 390-450 kg/m3 of cement (and adds)
a W/CM between 0.4 and 0.5
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ACI 506R-05 Guide to shotcrete
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Challenges in wet-mix shotcrete
Limit hose blockages
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How ?
Limit hose blockages
Increase workability while maintaining stability
(improve mix design (!), use of AEA and SP)
Target: slump of 5 - 12.5 cm (2-5)
Challenges & Dangers:
Difficulties in controlling quality and uniformity of mix
components (usually aggregate gradation)
Overuse of SP, creating stability problems: if it does not
pump at 15 cm slump, there is a problem!!
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How ?
Eliminate fall-outs from shotcreted
surface
Use set-accelerator at the nozzle
Dangers:
If the previous slide is not working and the mix pumped
is unstable or just too workable (slump > 15 cm), then
one needs more set-accelerator to prevent fall-outs
which may (will) result in reduced strength and
durability
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Examples of mix design
#1 -Mortar #2 - Concrete #3 SF Concrete
Cement (kg/m3) 540 450 395
Silica fume (kg/m3) - - 32
Sand (0-5 mm) 1600 1630 1090
(kg/m3)
Coarse agg. (2.5-12 - 235 600
mm) (kg/m3)
Water 230 170 210
(kg/m3) (w/b = 0.42) (w/b = 0.38) (w/b = 0.49)
AEA (ml/kg binder) 12.5 - -
SP (ml/kg binder) 1.3 - -
Air content (%) 10.3 5.0 4.6
Slump (cm) 12 4.5 5
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Summary
We have identified:
the aggregate gradations (sand & combined),
FM, (Coarse Agg./Total Agg)
the water/cement ratio
for strength and durability
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LETS GO EVEN FURTHER
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Research Project
Objective
Improve and understand wet-mix shotcrete
7%
Inital Concrete
Atmospheric
Solid Volume
93%
Pressure (250 psi) Pressure
Air = 100%
Remaining
100 Concrete
Under Solid areVolume
%pressure, air bubbles dissolved
= 93%of the mix
The solid phase now occupies 100%
volume
Air content
0% 0% Air
Active Paste Content
Example (7% air) Volume Volume
39.6% 32.6% = 35.1 = =
100% 93%
93% 100
Proportions Proportions
DF-10SF-7mod (atmosphere) (under pressure)
Concrete under
pressure
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Background
Study of particles transport
Zone of
interest!
Mix
Design
In-Place
Transport
(Equipment)
Background
A wide range of particle velocities are reported in literature
-Stewart (1933)
220-330 MPH (Gunite)
Nozzle
Nozzl
e
Y (m)
Y (m)
Y (m)
nozzl
e
Impact point
Armelin, 1997
Impact model
Particles
trajectory Verify and enhance
Particle tracking during the impact rebound model
accuracy
Discussion
Perspective of this study
Effect of equipment on material exit velocities,
velocity profiles and energy profiles
Understanding and describing the flow of material