SECTION 03370

SHOTCRETE

THIS SPECIFICATION SECTION RELATES TO STRUCTURAL ELEMENTS AND SHALL BE EDITED

ONLY BY THE STRUCTURAL ENGINEER OF RECORD FOR THE SPECIFIC PROJECT.

(NTS: This section is written to accommodate the special tests and inspections. Confer
with Chief Structural Engineer and coordinate local building code requirements for the
particular project and its locale.
PART 1 - GENERAL

1.01 DESCRIPTION:

A. Provide, finish, protect, and cure Shotcrete as indicated and specified.

1.02 RELATED WORK:

(NTS: Select and list specification sections for inserting into this subsection based on
the following:
1. Specification sections that contain products and construction that the reader might
expect to find in this section BUT are specified elsewhere.
2. Specification sections referenced in the body of this section.)
A. Section 03100: Concrete Formwork.

B. Section 03200: Concrete Reinforcement.

C. Section 03250: Construction and Expansion Joints.

D. Section 07150: Waterproofing, Dampproofing and Sealing.

1.03 REFERENCES:

(NTS: Select the appropriate references to be included in the project. Add or edit
references as appropriate. Delete those references that are not applicable.)
A. American Concrete Institute (ACI):

1. ACI 211.1: Standard Practice for Selecting Proportions for Normal,

Heavyweight, and Mass Concrete.

2. ACI 301: Standard Specifications for Structural Concrete.

3. ACI 304: Guide for Measuring, Mixing, Transporting, and Placing Concrete.

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 4. ACI 305R: Hot Weather Concreting.

5. ACI 306R: Cold Weather Concreting.

6. ACI 308: Standard Specification for Concrete Curing.

7. ACI 506.2: Specification for Shotcrete.

8. ACI 506.3R: Guide to Certification of Shotcrete Nozzlemen.

B. American Society for Testing and Materials (ASTM) Publications:

1. A 185: Standard Specifications for Wire Fabric, Plain, Welded Steel for
Concrete Reinforcement.

2. A 615: Standard Specifications for Bars, Deformed and Plain, Billet-Steel, for
Concrete Reinforcement.

3. A 820: Standard Specifications for Steel Fivers for Fiver Reinforced Concrete.

4. C 31: Standard Practice for Making and Curing Concrete Test Specimens in
the Field.

5. C 33: Standard Specification for Concrete Aggregates.

6. C 42: Standard Test Method for Obtaining and Testing Drilled Cores and
Sawed Beams of Concrete.

7. C 94: Standard Specification for Ready-Mixed Concrete.

8. C 109: Standard Test Method for Compressive Strength of Hydraulic Cement

Mortars (Using 2-in or [50-mm] Cube Specimens).

9. C 150: Standard Specification for Portland Cement.

10. C 171: Standard Specification for Sheet Materials for Curing Concrete.

11. C 309: Standard Specification for Liquid Membrane-Forming Compounds for

Curing Concrete.

(NTS: Include the next reference when fly ash or pozzolans are specified.)
12. C 311: Standard Test Methods for Sampling and Testing Fly Ash or Natural
Pozzolans for Use as a Mineral Admixture in Portland Cement Concrete.

13. C 330: Standard Specification for Lightweight Aggregates for Structural

Concrete.

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 14. C 595: Standard Specification for Blended Hydraulic Cements.

(NTS: Include the next reference when fly ash or pozzolans are specified.)
15. C 618: Standard Specification for Coal Fly Ash and Raw or Calcined Natural
Pozzolan for Use as a Mineral Admixture in Portland Cement Concrete.

16. C 642: Standard Test Method for Specific Gravity, Absorption, and Voids in
Hardened Concrete.

17. C 685: Standard Specification for Concrete made by Volumetric Batching and
Continuous Mixing.

18. C 1116: Standard Specification for Fiber-Reinforced Concrete and Shotcrete.

19. C 1140: Standard Practice for Preparing and Testing Specimens from
Shotcrete Test Panels.

20. C 1141: Standard Specification for Admixtures for Shotcrete.

21. D 75: Standard Practice for Sampling Aggregates.

22. E 154: Test Methods for Water Vapor Retarders Used in Contact with Earth
Under Concrete Slabs, on Walls, or as Ground Cover.

23. E 329: Standard Specification for Agencies Engaged in the Testing and/or
Inspection of Materials used in Construction.

C. Society for Protective Coatings (SSPC) Publications:

1. SP6: Surface Preparation Specification No. 6, Commercial Blast Cleaning.

D. Equivalent British/European codes and standards may be used; however, the

equivalency shall be demonstrated and submitted by the Contractor and approved by
the CM/CS.

1.04 SUBMITTALS:

A. Shop Drawings: Submit the following in accordance with Section 01300:

1. Name and address of proposed Contractor's testing laboratory firm and a brief
description of prior work which is similar to that proposed for this project.
Provide prior work owner's full name, address and telephone number. ASTM
E 329 will also be used as one of the basis for evaluating the testing laboratory
firm.

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 2. Shotcrete design mixes and results of strength tests from trial shotcrete mixes
by the Contractor's testing laboratory firm.

3. Material test results by the Contractor's testing laboratory:

a. Fineness modulus of fine and coarse aggregate per ASTM C 136.

b. Quality of fine and coarse aggregates per ASTM C 33.

4. Mill test reports for each shipment of cement, regardless of quantity, prior to
incorporation into the work.

5. Manufacturer's specifications and instructions for all admixtures, curing

materials, adjustable inserts and non-shrink non-metallic grout.

(NTS: Include the next paragraph when fly ash or pozzolans are specified. Do not use
pozzolan for liquid retention structures, including exterior foundation walls below
groundwater.)
6. Manufacturer's fly ash or pozzolan chemical analysis and results of physical
test reports in conformance with ASTM C 311 and as specified herein for each
shipment of fly ash or pozzolan, prior to incorporation into the work.

1.05 QUALITY ASSURANCE:

A. Provide in accordance with Section 01400 and as specified herein.

B. Perform shotcrete work in conformance with ACI-506.2 unless otherwise indicated or

specified.

C. Do not use admixtures, including calcium chloride, which will cause accelerated
setting of cement in shotcrete.

D. Do not place shotcrete into the work until design mix, material tests and trial shotcrete
batch mix compression test results are approved by the CM/CS. Approvals are
required at least 30 days before placing any production shotcrete.

E. The Contractor shall employ an independent testing laboratory firm, acceptable to the
CM/CS, to test conformity of materials to specifications and to design shotcrete
mixes.

F. Furnish, pay for and deliver representative samples of sufficient quantity of cement,
aggregates and admixtures required for trial shotcrete batch mixes to the testing
laboratory. Obtain materials from the shotcrete batching plant that will be supplying
production shotcrete in conformance with ASTM D 75.

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 G. Testing laboratory firm shall furnish trial shotcrete design mixes having proportions,
admixtures and slump proposed for use, based upon ACI 211.1.

H. Preconstruction Testing:

1. Prepare preconstruction test panels for examination by CM/CS prior to job

shotcrete placement. Preparation and testing shall comply with ASTM C
1140.

2. Produce test panels for each proposed mix proportion, each anticipated
shooting orientation, and each proposed nozzleman. Mixes shall meet
requirements as specified herein. In half of the test panels provide
reinforcement of the same size and spacing required for the work.

3. Obtain six test specimens from each panel, three nonreinforced specimens and
three with reinforcing steel.

4. Test the nonreinforced specimens for compliance with the specified physical
properties in accordance with ASTM C 42.

5. Visually grade the reinforced specimens for compliance with specified core
grade in accordance with ACI 506.2. The core grade of each core shall not be
greater than grade 2 as defined in ACI 506.2.

6. Test admixtures for compatibility with cement in accordance with ASTM C

1141.

7. Only nozzlemen with a test panel mean core grade less than or equal to 2.5
shall be allowed to place job shotcrete. When the prequalification test panel is
rejected, a second panel may be shot. If the nozzlemans second mean core
grade is greater than 2.5, the nozzleman shall not be permitted to shoot on the
project.

1.06 DELIVERY, STORAGE AND HANDLING:

A. Provide in conformance with Section 01610 and as specified herein.

B. Deliver, store, and handle materials to prevent contamination, segregation, corrosion

or damage. Store liquid admixtures per manufacturers instructions.

1.07 JOBSITE CONDITIONS:

A. Do not place shotcrete until conditions and facilities for making and curing control
test specimens are in compliance with ASTM C 1140 and as specified herein.

PART 2 - PRODUCTS

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2.01 MATERIALS:

(NTS: Use the following paragraph on projects where structures are to contain potable
water.)
A. All materials used in shotcrete or the curing and repair of shotcrete, which can contact
potable water, shall be certified as meeting requirements of ANSI/NSF 61 for contact
with potable water when in the finished shotcrete.

B. Furnish Portland cement conforming to ASTM C 150. Use one approved brand from
one mill throughout the contract term unless otherwise approved by the CM/CS. Use
cement of uniform color.

1. Reject the entire shipment when cement is lumpy, wetted, partially or wholly
set.

(NTS: Next item shall be used or modified to suit the project when fly ash and
pozzolans are specified.)
2. For mix designs containing fly ash or pozzolans, use ASTM C 150 Type II
cement with fly ash or pozzolan as a cement replacement.

C. Water:

1. Use water for shotcrete that is potable and free from injurious amounts of oil,
acid, alkali, organic matter or other deleterious substances, and conforms to
the requirements for water in ASTM C 94, and as specified herein.

2. The maximum water-soluble chloride ion in the water shall not exceed 0.060
percent by weight of cement.

3. Heat or cool water to obtain shotcrete temperatures indicated or specified, and

in conformance with ACI 305R and ACI 306R.

D. Aggregates:

1. Use fine aggregates for normal weight shotcrete consisting of well graded
natural sand conforming to ASTM C 33 and to the following requirements:

a. Fineness modulus: 2.50 to 3.10.

b. Soundness: Maximum of 10 percent weighted average loss after 5

cycles of magnesium sulfate soundness test as determined by ASTM C
88.

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 2. Use coarse aggregates for normal weight shotcrete consisting of washed, well
graded gravel or crushed stone conforming to ASTM C 33 and to the
following requirements:

a. Soundness: Maximum of 14 percent weighted average loss after 5

cycles of magnesium sulfate soundness test as determined by ASTM C
88.

3. Test aggregates for chert in conformance with ASTM C 33 as determined by

ASTM C 123.

(NTS: Delete following unless lightweight aggregates are to be used.)

4. Lightweight aggregates shall comply with ASTM C 330.

E. Admixtures:

1. General Requirements:

a. Include all admixtures in solution form in the water-cement ratio

calculations.

b. Do not use calcium chloride, admixtures containing chloride ions or

other admixtures causing accelerated setting of cement. Do not use
combinations of admixtures and cements producing erratic or
otherwise undesirable results with aggregates.

c. Reject admixtures that have been in storage for longer than

manufacturers recommendations or which have been subjected to
freezing.

d. Do not use admixtures in greater dosages than recommended by

manufacturer.

e. The strength of shotcrete with proposed admixtures after 48 hours shall

not be less than the strength of similar shotcrete without admixture.

f. All admixtures shall be obtained from one manufacturer. The

manufacturer shall be capable of providing qualified field service
representation.

g. Admixtures shall be used in compliance with the manufacturers

printed instructions. The manufacturer shall certify the compatibility
of multiple admixtures used in the same mix.

2. Air-Entrainment:

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 a. Air entrain all shotcrete. Use admixtures conforming to ASTM C
1141.

b. Total air content by volume in field mixtures of normal weight

shotcrete, with a tolerance of 1 percent:

(1) 7 percent for shotcrete using 3/8 inch [9.5 mm] or less
nominal maximum aggregate size.

(2) 6 percent for shotcrete using greater than 3/8 inch [9.5 mm]
nominal maximum aggregate size.

c. Measure air content in accordance with ASTM C 231.

(NTS: Include the next item when fly ash and pozzolans are specified.)
d. Adjust the admixture content to accommodate the fly ash or pozzolan
requirements, and other admixtures when used, in order to obtain the
specified air content.

3. Mid-Range Water Reducer: Use admixture conforming to ASTM C 1141.

(NTS: Delete, use or modify the next item to suit the project.)
4. High Range Water Reducer (Super Plasticizer): Use admixture conforming to
ASTM C 1194.

F. Curing Compound: Liquid form, which will form impervious membrane over,
exposed surface of shotcrete when applied to fresh shotcrete by means of spray gun.
Apply twice the coverage (double the application rate) recommended by
manufacturer. Compound not to prevent future bond of shotcrete layers, coverings, or
surface treatment. Use Type I-D compound with red fugitive dye, Class B, having 18
percent minimum solids conforming to ASTM C 309.

G. Curing Sheet materials: Curing sheet materials that cause stains on surface shall not
be used. Use materials conforming to ASTM C 171.

(NTS: Include the next paragraph when fly ash is specified.)

H. Fly Ash: Provide fly ash conforming to the following requirements:

1. Class F fly ash conforming to ASTM C 618 for chemical and physical
properties.

2. Supplemental requirements in percent:

a. Maximum carbon content 3%.

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 b. Maximum sulfur trioxide (SO3) content 4%.

c. Maximum loss on ignition 3%.

d. Maximum water requirement 100%.

(as a percent of control)

e. Fineness, maximum retained on 25%.

No. 325 sieve

2.02 MIXES:

A. Use 4000 psi [28 MPa] shotcrete for all shotcrete, unless otherwise indicated or
specified.

B. Secure, for every part of work, shotcrete of homogeneous structure having required
strength, water tightness, and durability. Give careful attention to selection of
materials, mixtures, transporting to discharge locations, shooting, and curing.

C. Consistency: Mix shotcrete to produce homogeneous consistency, capable of being

worked into constricted areas of forms, corners and around embedded items, without
segregation or bleeding of free water. Wet-mix shotcrete shall have a minimum
slump of 1 [25 mm].

(NTS: Include the next paragraph when fly ash or pozzolans are specified.)
D. Fly ash or pozzolan not to exceed 15 percent of the combined weight of fly ash or
pozzolan and cement.

2.03 SHOTCRETE TOLERANCES:

A. Conform to the requirements specified in Section 03100 for finish tolerances for
formed surfaces.

B. Maximum deviation in shotcrete structures not to exceed 1/4 inch [6 mm] in 10 feet [3
meters] as determined by a 10 foot [3 meter] straight edge placed anywhere on the
surface in any direction.

PART 3 - EXECUTION

3.01 BATCHING AND MIXING:

A. Weight batching shall comply with the accuracy specified in ASTM C 94.

B. Volume batching shall comply with the accuracy specified in ASTM C 685.

C. Volume batching shall be verified once a week by a weight batching check.

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3.02 EXAMINATION OF SURFACES TO RECEIVE SHOTCRETE:

A. Verify that surfaces are acceptable and are ready to receive shotcrete.

B. Verify that forms are to line and grade, braced against vibration, and constructed to
permit escape of air and rebound.

C. Verify that placement and clearance around reinforcement permits complete

encasement.

D. Verify that surfaces to receive shotcrete have been properly prepared.

3.03 SURFACE PREPARATION:

A. Earth: prepare surfaces to line and grade. Do not apply shotcrete to frozen surface.
Dampen surface immediately prior to shooting.

B. Concrete, Masonry, and Shotcrete: When bonding is required, remove all deteriorated,
loose unsound material or contaminants that may inhibit bonding. Chip areas to be
repaired to remove offsets causing abrupt changes in thickness. Taper edges to
eliminate square shoulders at the perimeter of a cavity. Surface shall be saturated
surface dry immediately prior to shooting.

C. Structural Reinforcement: The surface shall be free of deleterious materials that

inhibit bonding. For new construction, reinforcement laps shall be separated with a
clearance of at least three times the diameter of largest aggregate. Reinforcement
shall be secured to prevent movement.

D. Rock: Remove loose material, mud or other foreign material that will prevent
bonding. Clean surface and pre-wet surface immediately prior to shooting.

3.04 SEASONAL CONDITIONS:

A. Conform to ACI 305R and as specified herein for hot weather concreting. Do not
place shotcrete when material temperature is above 90 degrees Fahrenheit [32 deg. C]
for wet-mix; 100 degrees Fahrenheit [38 deg. C] for dry-mix. Lower temperature of
reinforcement and receiving surfaces below 100 degrees Fahrenheit [38 deg. C]
immediately prior to shooting. Do not add retarder admixture to any shotcrete.

B. Conform to ACI 306R and as specified herein for cold weather concreting. Do not
shoot when ambient temperature is 40 degrees Fahrenheit [4 deg. C] and falling
unless measures are taken to protect shotcrete. Shotcrete material temperature when
shot shall not be less than 50 degrees Fahrenheit [10 deg. C]or more than 90 degrees

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 Fahrenheit [32 deg. C]. Shotcrete shall not be placed against frozen surfaces. Do not
add accelerator admixture to any shotcrete.

C. Do not place shotcrete containing pozzolan during cold weather concreting, as defined
in ACI 306R.

3.05 JOINTS:

A. Provide joints as specified and as indicated.

B. Taper construction joints at a 1 to 1 slope where joint is not subject to compression

loads. Surface Preparation of joints shall comply with section 03361-3.01-B.
Reinforcement shall be continuous through the construction joint.

C. Place control joints as shown on drawings. Discontinue reinforcement at control

joints.

3.06 EMBEDDED ITEMS:

A. Clean embedded items of oil and all foreign matter.

B. Install inserts, anchors, sleeves and other items indicated or specified under other
sections of these specifications in formwork. Close ends of conduits, piping and
sleeves embedded in shotcrete with caps or plugs.

C. Complete required tests on embedded piping before starting shotcrete placement.

D. Check location and support of piping, electrical conduits and other embedded items
before depositing shotcrete. Correct locations as required and secure supports.
Maintain three-diameter minimum clear spacing between parallel runs of piping and
conduit. Do not install runs of piping and conduit between formwork and
reinforcement.

3.07 TRANSPORTING AND MIXING:

A. General: Conform to concreting procedures set forth in ACI 304R and as specified
herein.

1. Transport shotcrete to discharge locations without altering the specified

properties of water-cement ratio, slump, air entrainment, temperature and
homogeneity.

2. Shoot dry-mix shotcrete material within 45 minutes after batching or

predamping.

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 3. Shoot wet-mix shotcrete material within 90 minutes after batching.

4. During hot weather, or under conditions contributing to rapid setting of

shotcrete, a shorter mixing time is necessary, in conformance with the
following:

a. Reduce maximum mixing and placement time from 90 to 45 minutes

maximum when shotcrete temperature at time of placement is between
85 and 90 degrees Fahrenheit [30 and 32 deg. F].

b. Reject shotcrete with a temperature in excess of 90 degrees Fahrenheit

[32 deg. C] unless a lower placing temperature is specified as the limit
for rejection.

3.08 SHOTCRETE ACCEPTANCE:

A. The Contractor shall reject shotcrete exceeding time or temperature limitations

specified.

B. The Contractor shall reject shotcrete not conforming to specification before

discharging into the forms.

C. Remove and replace shotcrete that is delaminated, exhibits laminations, voids, or sand
pockets exceeding the limits for the specified grade.

D. Remove and replace shotcrete that does not comply with the specified material
properties.

E. Repair core holes in accordance with ACI 301. Do not fill core holes by shooting.

F. Shotcrete work that has previously failed to meet one or more requirements, but
which has been repaired to bring it into compliance to the satisfaction of the CM/CS,
will be accepted.

3.09 PLACING:

A. Install taut ground wires or other means to establish thickness and plane of required
surface. Install taut ground wires or other means at corners or offsets not established
by forms.

B. Provide a platform that permits nozzleman unobstructed access to the receiving

surface. Place shotcrete first in corners, recesses, and other areas where rebound or
overspray cannot escape easily. Remove rebound and overspray from previously
prepared surfaces prior to shotcrete placement.

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 C. Place shotcrete with nozzle held approximately perpendicular to the receiving surface.
In corners, direct nozzle at approximately 45 degree angle or bisect the corner angle.

D. Apply shotcrete so sags or sloughing do not occur. Discontinue shooting or shield the
nozzle stream if wind causes separation of ingredients during shooting.

E. Do not reuse rebound or overspray. Remove laitance from shotcrete surfaces to

receive additional shotcrete layers.

F. Do not apply shotcrete on surfaces with standing water or running water.

G. Remove hardened overspray and rebound from adjacent surfaces, including exposed
reinforcement.

H. Place shotcrete to completely encase reinforcing steel. Encase reinforcement by

shooting with sufficient velocity and plasticity so material flows around and behind
the reinforcement. Front face of reinforcement shall remain clean during encasement.
Place shotcrete to provide the cover over reinforcement required by ACI 301.

I. Protect surfaces not intended for shotcrete placement against deposit of rebound and
overspray or impact from nozzle stream. Remove rebound and hardened overspray
from final shotcrete surfaces and from areas not intended for shotcrete placement.

3.10 TESTING:

A. Testing During Construction:

1. Produce a material test panel for each mix and each work day or every 50
cubic yards [40 cubic meters] placed, whichever is less. Test panel shall be
kept moist and at 70 F 10 degrees Fahrenheit [21 C + 5 deg. C] until moved
to test laboratory. Obtain test specimens either from job site material test
panel or from in-place shotcrete. Test specimens from test panels in
compliance with ASTM C 1140.

2. Test specimens from in-place shotcrete in compliance with ASTM C 42.

3. Grade cores that include reinforcement in accordance with ACI 506.2.

4. The mean compressive strength of a set of three cores shall equal or exceed
0.85 times the specified compressive strength with no individual core less than
0.75 times the specified compressive strength. The mean of a set of three
cubes shall equal or exceed the specified compressive strength with no
individual cube less than 0.88 times the specified compressive strength.

3.11 CURING AND PROTECTION:

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 A. General:

1. Protect shotcrete from premature drying, hot or cold temperatures, and

mechanical injury, beginning immediately after placement and maintain
shotcrete with minimal moisture loss at relatively constant temperature.

2. Comply with curing procedures set forth in ACI 301, applicable portions of
ACI 308 and as specified herein.

3. Perform hot weather concreting in conformance with ACI 305R and as

specified herein when the ambient atmospheric temperature is 80 degrees
Fahrenheit [27 deg C] or above.

4. Perform cold weather concreting in conformance with ACI 306R and as

specified herein when the ambient atmospheric temperature is 40 degrees
Fahrenheit [5 deg. C] or below.

B. Duration:

1. Immediately after finishing, cure shotcrete continuously by maintaining in a

moist condition for seven days or until specified strength is attained or until
succeeding shotcrete layers are placed.

2. Avoid rapid drying at the end of the final curing period.

C. Curing Requirements:

1. Unformed Surfaces: Cover and cure entire surface of newly placed shotcrete
immediately after completing finishing operations and water film has
evaporated from surface or as soon as marring of shotcrete will not occur.
Protect finished slabs from direct rays of the sun to prevent checking, crazing
and plastic shrinkage.

2. Water retaining and below Grade Structures: Moist cure by the addition of
water to maintain the surface in a continually wet condition. Use water that is
free of impurities that could etch or discolor exposed shotcrete surfaces. Other
shotcrete shall be cured by moist curing, by moisture-retaining cover curing,
or by the use of curing compound. Use curing compound at water retaining
and below grade structures only in cold weather after the initial curing period
and only when approved by the CM/CS, in writing.

D. Curing Methods.

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 1. Water Curing: Use warm water curing for unformed surfaces. Continuously
water cure all exposed shotcrete for the entire curing period. Provide moisture
curing by any of the following methods:

a. Keeping the surface of the shotcrete continuously wet by ponding or

immersion.

b. Continuous water-fog spray or sprinkling.

c. Covering the shotcrete surface with curing mats, thoroughly saturating

the mats with water, and keeping the mats continuously wet with
sprinklers or porous hoses. Place curing mats so as to provide coverage
of the shotcrete surfaces and edges, with a 4-inch [100 mm] lap over
adjacent mats. Weight down the curing cover to maintain contact with
the shotcrete surface, as necessary.

2. Sealing Materials:

a. Use common sealing materials such as plastic film or waterproofing

paper when approved by the CM/CS.

b. Lap adjacent sheets a minimum of 12 inches [300 mm]. Seal edges with
waterproof tape or adhesive. Use sheets of sufficient length to cover
sides of shotcrete member.

c. Place sheet materials only on moist shotcrete surfaces. Wet shotcrete

surface with fine warm water spray if the surface appears dry.

d. The presence of moisture on shotcrete surfaces at all times during

prescribed curing period is proof of acceptable curing using sheet
material.

3. Membrane Curing Compound:

a. Apply membrane-curing compound uniformly over shotcrete surface by

means of roller or mechanical spray machine at a rate recommended by
the curing compound manufacturer, but not less than 1 gallon per 150
sq. ft. [1 liter per 4 sq. meters] of surface area. Agitate curing material
in supply container immediately before transfer to distributor and
thoroughly agitate it during application for uniform consistency and
dispersion of pigment.

b. Do not use curing compounds on construction and expansion joints or on

surfaces to receive liquid hardener, dustproofer/sealer, concrete paint,

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 tile, concrete fills and toppings or other applications requiring positive
bond.

c. Reapply membrane-curing compound to shotcrete surfaces that have

been subjected to rainfall within 3 hours after curing compound has been
applied by method for initial application.

d. Maintain the continuity of the coating and repair damage to the coating
during the entire curing period.

(NTS: Use the following paragraph on projects where structures are to contain potable
water.)
e. Provide a copy of manufacturers certification that the curing compound
meets the requirements of ANSI/NSF 61 for shotcrete surfaces that will
be in contact with potable water,

f. When curing compound is authorized for application to water retaining

or below grade members, it shall be applied at the manufacturers
recommended coverage rate and then applied again at the same rate to
provide twice the recommended coverage.

4. Natural Curing:

a. Natural curing is permitted if ambient relative humidity is maintained

above 95 percent.

E. Protection from environmental conditions: Maintain the shotcrete temperature

between 50 degrees Fahrenheit and 70 degrees Fahrenheit [10 deg. C and 21 deg. C]
continuously throughout the curing period. Make arrangements before shotcrete
placing for heating, covering, insulation or housing as required to maintain the
specified temperature and moisture conditions continuously for the curing period.

1. When the atmospheric temperature is 80 degrees Fahrenheit [27 deg. C] and

above, or during other climatic conditions which will cause too rapid drying of
the shotcrete, make arrangements before the start of shotcrete placing for the
installation of wind breaks or shading, and for fog spraying, wet sprinkling, or
moisture-retaining covering.

2. Protect the shotcrete continuously for the entire curing period.

3. Maintain shotcrete temperature as uniformly as possible, and protect from rapid

atmospheric temperature changes.

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 4. Avoid temperature changes in shotcrete that exceed 5 degrees Fahrenheit [3
degrees Celsius] in any one hour and 50 degrees Fahrenheit [10 degrees
Celsius] in any 24-hour period.

F. Protection from physical injury: Protect shotcrete from physical disturbances such as
shock and vibration during curing period. Protect finished shotcrete surfaces from
damage by construction equipment, materials, application of curing procedures and
rain or running water. Do not load shotcrete in such a manner as to overstress
shotcrete.

3.12 REPAIR:

A. General: Remove and replace shotcrete that is delaminated, exhibits laminations,

voids, or sand pockets exceeding the limits for the specified grade or shotcrete.
Remove and replace shotcrete that does not comply with the specified material
properties determined by the CM/CS. Make repairs in shotcrete surfaces to produce a
uniform color and texture and free of all irregularities.

B. Surface defects in all shotcrete surfaces that adversely affect the durability of the
shotcrete shall be repaired per the requirements of this section. Such surface defects
that require repair include all visible cracks in tank floors and walls and the exterior
envelope of structures below grade, regardless of width. Cracks in all other areas in
excess of 0.02-inch [0.5 mm] wide, honeycomb, rock pockets, and spalls.

C. Repair of Cracks:

1. Cracks, which have resulted from overstress conditions and are structural in
nature, shall be pressure grouted using an injectable epoxy.

2. Cracks in water retaining or below grade members, which have resulted from
shrinkage stresses and show any sign of leakage, or are positioned such that
leakage cannot be observed, shall be pressure grouted using hydrophilic resin.

3. Cracks in other members, which have resulted from shrinkage stresses and
exceed 0.020 inch [0.05 mm] in width shall be pressure grouted using
hydrophilic resin.

4. Apply crack repair materials in accordance with the manufacturers directions

and recommendations.

D. Repair of Defective Areas:

1. Remove rock pockets honeycombed and other defective shotcrete down to

sound shotcrete. Chisel edges a minimum of 1 inch [25 mm] deep
perpendicular to surface or slightly undercut. No featheredges permitted.

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 2. Dampen the area to be patched and area at least 6 inches [150 mm] wide
surrounding it for at least 24 hours to prevent absorption of water from
patching mortar.

3. Shotcrete repair material shall be a prepackaged polymer-modified

cementitious repair mortar with the following minimum properties:

a. Compressive strength at one day: 2000 psi [14 MPa] (ASTM C 109).

b. Compressive strength at 28 days: 6000 psi [42 MPa] (ASTM C 109).

c. Bond strength at 28 days: 1800 psi [12.5 MPa] (ASTM C 882

modified).

(NTS: Use the following paragraph on projects where structures are to contain potable
water.)
d. NSF Standard 61 potable water approved when used in water treatment
and related facilities.

4. Use no more mixing water than necessary for handling and placing. Mix
patching mortar and allow to stand with frequent manipulation with a trowel,
without addition of water, until it has reached stiffest consistency that will
permit placing.

5. Brush bond coat of neat cement well into surface after surface water has
evaporated from area to be patched. Consolidate mortar into place and strike
off so as to leave patch slightly higher than surrounding surface to permit
initial shrinkage. Leave patch undisturbed for at least 1 hour before final
finish. Keep patched area damp for a minimum of 7 days.

E. Final determination as to acceptability of shotcrete finishes and repair of surface

defects will be made by CM/CS.

3.13 FINISHES:

A. General: Gun finish or as specified.

B. Broom or roughen the surface of freshly placed shotcrete after shotcrete has reached
initial set when subsequent layers are to be applied.

C. Descriptions of finish:

1. Steel-Trowel Finish: Remove excess laitance from surfaces by tamping,

screeding and magnesium or bull floating. Compact surface with motor-

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 driven floats when slab has hardened so that water and fine material will not
work to top and trowel smooth. Leave surfaces with smooth hard finish free
of blemishes.

2. Broom Finish: Steel-trowel surface then broom to produce roughened surface

of uniform appearance.

3. Smooth Form Finish: Remove fins, finish flush with parent shotcrete and
make necessary repairs. Wet and rub finned and repaired areas with
carborundum stone or other abrasive until uniform color and texture are
produced. Complete rubbing not later than 24 hours after the curing period.

3.14 METALWORK IN SHOTCRETE:

A. Secure castings, inserts, conduits and other metalwork encased in shotcrete to prevent
metalwork from being displaced or deformed during shotcrete work.

B. Set anchor bolts by means of templates.

C. Build dovetail anchor slots into new shotcrete against which facing brick, shotcrete
masonry units, tile, stone or any type ashlar is to be installed. Provide vertically at
24-in. [600 mm] centers where facing brick, etc., passes by shotcrete. Provide one
continuous anchor slot where facing brick, etc., abuts the shotcrete work.

D. Aluminum embedded in shotcrete shall be coated in accordance with Section 05500.

3.15 CONTRACT CLOSEOUT:

A. Provide in accordance with Section 01700.

END OF SECTION

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