1 System Description

This method statement describes the procedure for application of shotcrete onto the
rock formation using wet concrete mix by the wet spraying technique. The system
Build up on the rock formation substrate may consist of water for wetting the substrate,
mesh for stabilization of the rock; and shotcrete.




















This document refers to the "Method Statement for Shotcrete Systems Using Ready
Mi x concr ete wet mi x.

1.1 References
This method statement has been written in accordance with the recommendations
contained in European Standards EN 1504: Products and systems for the protection
and repair of concrete structures, and the following relevant parts:
EN 1504 Part 1: Definitions, requirements, quality control and evaluation of
conformity

EN 1504 Part 3:

EN 1504 Part 7:

EN 1504 Part 10:

Structural and non-structural repair

Reinforcement corrosion protection

Site application of products and systems, and quality control of
works

1.2 Limitations

Always refer to the manufacturer's instructions before use the spraying machine.
Products shall only be applied in accordance with their intended use.
For specific construction I build information refer to the Architect's, Engineer's or
Specialist's details, drawings, specifications and risk assessments.
All work shall be carried out as directed by a supervising officer or a qualified
engineer.
This method statement is only to be used as a guide and shall be adapted
to suit local products, standards, legislation or other local requirements.







2. Products

Material to be used:
- D49 Mesh Reinforcement applied on the slopes to hold the rocks while application
of the shotcrete and to be anchored to the rocks at 1m centers by hilti bolts
- Wet mix Concrete as per attached mix design


2.1 Material Storage
Materials shall be stored properly in dry c o o l e d conditions.


3. Equipment

3.1 Hand Tools



Trowel Smoothing
float/trowel
Mixing Sponge
bowel
Basic tool set Measuring
cylinder
Levelling
profile


3.2 Mixing Tools




/ .



Drill and Mixing Paddle
Small quantities
Double Mixing Paddle
Medium quantities
Forced Action Pan
Mixer
Large quantities








3.3 Mechanical Tools




1 1 2

Water spray < > Spraying Equipment < > < >Air compressor

(1) Example of spray equipment for illustration purposes
(2) Only necessary if required for the spray machine.

3.4 Spraying Equipment
See attached Catalogue of REED Equipment




Wet Spraying
There are different types of wet spraying machines to select from. These include:

Rotor Machines
Screw Pumps
Piston Pumps
Double Piston Pumps
Squeeze Pumps

The following wet spraying machine(s) are recommended for use on this site to use
ready mix concrete products.

Compressed Air Equipment
Typically a hopper gun uses an air flow rate of approximately 0.15 - 0.30 m
3
/minute.
Wet spraying equipment which does not have a built in supply of compressed air
requires an air flow rate of approximately 8- 12 m
3
/minute. However, always read the
Requirements of the spraying equipment before starting.

4. Health and Safety

4.1 Risk Assessment
The risk to health and safety from falling objects or defects in the structure shall be
properly assessed. Always assess risks to minimise and eliminate dangerous
operations?

Platforms and temporary structures shall provide a stable and safe area to work and
comply with local regulations. Do not take any unnecessary risks!





4.2 Personal Protective Equipment
Work Safely!

Handling or processing cement products may generate dust which can cause mechanical
irritation to the eyes, skin, nose and throat.
Appropriate eye protection shall be worn at all times while handling and mixing
mortars.
Approved dust masks and face and neck protection shall be worn to shield the nose
and throat from dust and grain rebound.
Safety shoes, gloves and other appropriate skin protection shall be worn at all times.
Always wash hands with suitable soap after handling products and before food
consumption.

FOR DETAILED INFORMATION REFER TO THE MATERIAL SAFETY DATA SHEET


4.3 First Aid
Seek immediate medical attention in the event of excessive inhalation, ingestion or
eye contact causing irritation. Do not induce vomiting unless directed by medical
personnel.

Flush eyes with plenty of clean water occasionally lifting upper and lower eyelids.
Remove contact lenses immediately. Continue to rinse eye for 10 minutes and then
seek medical attention.

Rinse contaminated skin with plenty of water. Remove contaminated clothing and
continue to rinse for 10 minutes and seek medical attention.


5. Environment

5.1 Cleaning Tools I Equipment
Clean all tools and application equipment with water immediately after use. Hardened
material can only be removed mechanically.

Spray equipment shall be thoroughly cleaned at appropriate intervals during the
application process to prevent accumulation of residual deposits using
adequate pressure water.



5.2 Waste Disposal

Do not empty surplus material into drains; dispose responsibly through
licensed waste disposal contractor in accordance with legislation and local/

regional authority requirements. Avoid runoff onto soil or into waterways,
drains or sewers.








6. Preparation
The Contractor is responsible for preparation of the work to ensure the proper
functioning and quality of the spraying application.

Prior to the work starting the Contractor's representative shall have visited job site and
inspected all aspects of the application requirements. The Contractor shall provide a
method statement detailing the procedure for the spraying application for approval by
the Engineer.

The Contractor shall provide the necessary competence and support to ensure the
spraying application is carried out in a safe and efficient manner.

Nozzle operators shall be certified and proficient in the application of sprayed
concrete. All spraying operatives shall work under the direction of a suitably trained
supervisor/instructor.


6.1 Rock Substrate
Machine applied mortars shall not be applied to the substrate without the prior approval
of the Engineer. The Contractor shall communicate in writing to the Engineer an
agreed period of notice of his intention to spray.

The rock substrate shall be in a good sound condition and free from large loose
rocks, loose material, and materials which reduce bond.


6.2 Reinforcement
The steel mesh reinforcement shall be fixed to the sloped rock surface to hold loose
materials which reduces bond.











6.3 Pre-Wetting Substrate

Rock surface surfaces shall be saturated with water a minimum 2 hours before
application ensuring that all pores and pits are adequately wet and prevent suction.
The surface shall not be allowed to dry before the concrete application.


6.4 Formwork
Formwork can be used regulate the thickness of the application, or used to re-profile
the required shape of the rock surface. The formwork shall be capable of withstanding
the load imposed by the machine applied spray concrete.


7. Spraying Equipment

7.1 Pumping Equipment
The pump machine and ancillary equipment shall be of adequate capacity for the
volumes to be applied. The equipment shall have been tested prior to the main work
for compatibility with the relevant concrete mix.

The chosen equipment shall be capable of conveying readymix concrete at a regular rate
and ejecting it through a nozzle onto a prepared rock substrate. The velocity of the
ejected concrete shall promote adherence and compaction onto the surface, to
maximise concrete density with minimum rebound.

All moving parts, fittings and hopper shall be inspected for cleanliness and damage
before use. Any hardened material shall be removed. The equipment shall not leak.

Before starting work the applicator(s) shall be familiar with the use of the equipment.
Always read the instructions provided by the equipment manufacturer.

Power for the equipment shall be approved for use on job site. Always conform to local
laws and restrictions when using diesel powered equipment. When using an electric
motor check the voltage requirement is available on job site.

The Contractor shall keep full details and records of the type of machine and equipment
used for the project. This information shall be provided to the Engineer, when
requested.



7.2 Hose or Pipe
The diameter of the hose or pipe shall be uniform throughout and appropriate for
use with readymix concrete.

The hose or pipe shall not have any dents or kinks and be long enough to reach from
the pump location to the point of application. It is advisable to use the shortest hose
length available to reduce the risk of stoppages. Always consult with the
recommendations provided by the machine manufacturer.

7.3 Nozzle
The type and size of nozzle varies for different mortar applications and shall be
selected depending on the type of concrete to be sprayed. Refer to machine
manufacturer's recommendations.








Template for translation,only for internaluse



Nozzles shall be designed for:-
1. Maximum grain size of concrete
2. Admixtures e.g. liquid or fibres
3. Compressed air to maintain speed and high compaction



7.4 Air Compressor Equipment

Compressed air is used to project the concrete at high velocity onto the substrate. Refer
to the machine manufacturer's requirements.

Air from the equipment shall be clean, dry and free from oil or contamination.

The air shall remain continuous at not less than the operating pressure and volume rate
specified by the machine manufacturer.


8. Mixing
Pre-mixed concrete shall be used in wet formation, No pre-mixing is required for the dry
spray technique.

The concrete consistency shall be suitable for spray applications.

During the application there shall be no interruption in the concrete supply from the spray
machine. Use a suitable sized mixer according to demand and application rate of the
spray machi ne.

The pot life of the concrete shall not exceed the time required to apply the concrete on
the substrate. Pot life shall be determined by tests on job site according to the ambient
temperature and climate conditions.
























9. Application

9.1 General Information
Working space shall be sufficient in size, clean and tidy with no obstructions. Working
areas shall be well illuminated. Adjoining areas shall be adequately protected against
overspray.

When starting the work the nozzle shall be directed away from the application area until
the mix is correctly adjusted. Slurries or pre-wetting mixes for the hose or pipe shall not
be sprayed on the application area.

A test area shall be completed before starting the main application to verify embedding
of steel mesh and surface quality.

Layers of sprayed mortar shall be built up on the rock substrate making several
passes with the nozzle. Always use good working practices and nozzle manipulation to
apply each layer.

The sprayed mortar shall emerge from the nozzle in a steady un-
Interrupted flow. The nozzle shall be held at the correct distance and at
90 degrees to the surface. If the flow of the spray becomes intermittent,
the nozzle shall be directed away from the substrate until the spray
becomes constant again.

When spraying behind steel reinforcement mesh the nozzle shall be held closer to the
substrate surface at an angle to prevent rebound entrapment behind the mesh. The
applicator shall ensure the mesh is fully encapsulate with no voids left between the
mesh and substrate.

For vertical, or near vertical applications, spraying shall commence from the bottom up.
On curved overhead surfaces concrete shall be applied from the shoulder to the crown.

A free top edge on a thick layer application shall be finished at 45 degrees to the
surface.

Do not exceed the specified maximum layer thickness of the concrete. When the
concrete depth exceeds the maximum layer thickness of the material, then layers may
be built up on top of one another to increase the overall depth. The first layer shall be
hardened and be at the ambient temperature before applying the second layer. Do
not smooth the first layer before applying a second layer. The first layer shall be
cleaned before applying subsequent concrete layers to remove dirt and loose
material. Use adequate water pressure or compressed air. The first layer shall not be
damaged.





No concrete shall be applied onto surfaces containing rebound. All rebound
material shall be removed from the working area and not re-used.

Always maintain a non-interrupted flow of concrete through the pump machine, do
not stop-start.

Never switch on the spray machine when there is no material inside.

Pockets, sags or other defects in the sprayed concrete shall be cut out using
appropriate method, carefully removed and re-sprayed. It is recommended the area
of re-spray shall not be less than 300 x 300 mm.




9.2 Wet Spraying Process

Compressed
air


Hydraulic
conveyance
(dense stream)


Airstream

conuete
pump



Air for
stream converter



Stream
converter

#refer to machine manufacturer's recommendations

A pre-mixed quantity of concrete is fed into a hopper on the spraying machine. The
pump then conveys the concrete to the point of application. Air added at the nozzle
dissipates and propels the mortar onto the substrate.

The machine and equipment for the wet spraying process shall be assembled
according to the manufacturer's instructions.

Water can be used before spraying to check the machine is working with no leaks. Fill
the pump's hopper with water and turn on the machine. If any leaks are found turn off
the machine disassemble thefaulty part(s) and re-assemble correctly. If the water fails
to pump turn off the machine immediately and locate the problem.

The pump, hose and pipe shall be lubricated to prevent suction using a slurry mortar
mix. The slurry mix shall not contain too much water to cause sedimentation. Do
not spray the lubricating slurry on the application area.

The concrete mix shall be pre-mixed in accordance with the approved mix design. A
high viscous concrete mix can cause the application to slump on the surface. A dry
low viscous concrete may not be conveyed by the pump, and it can cause a stoppage.

The lubricating slurry shall not be pumped out of the hose until the mixed concrete is
ready. Add the concrete into the pump's hopper so that it follows on immediately
after the lubricating slurry. Continue to spray away from the application area until all
the lubricating slurry has been emptied from the hose or pipe. Allow some concrete
waste until it is certain all lubricating slurry has been used.

Once all the lubricating slurry has been used the main application can begin.








The application nozzle is hand held and directed at the substrate by the nozzle
operator. The nozzle operator adjusts the amount of high pressure air required to
produce a homogenous mass of mortar on the application substrate.


Refer to the machine manufacturer's recommendations for the nozzle application
distance from the substrate.

Too much high pressure air will result in an increase of rebound and wasted
concrete. Too little air will not provide sufficient compaction of the mortar on the
application surface.

Protect the hose or pipe from direct sunlight. If necessary lay a moist material over the
top of the hose as protection, and do not allow to dry.








9.3 Reducing the Risk of a Blockage

The table below illustrates possible causes and suggestions for minimizing the risks.


Item
Possible Cause of
Blockage
Minimizing Risk of Blockage
Pump Machine Maintenance Service regularly (refer to instructions)
Inspect all parts for wear and/or damage
Remove all hardened material
Assemble in accordance with instructions

Rust and corrosion
Un-clean
Incorrect assembly
Hose /Pipe and No compaction Correct nozzle selection
Keep two hoses/pipes and nozzles
Lay to straight or gentle curves
Thoroughly clean hose and nozzle
Protect from extreme high/low temperatures
Thoroughly pre-wet
Do not use fast accelerated mortars
Use a short length (where possible)
Uniformdiameter hose/pipe
Nozzle Damaged
Kinks and bends
Blocked
Extreme
temperatures
Suction
Pre-Wetting
Hose I Pipe
Grains stuck in
pump
Sedimentation in slurry
Worm too small for maximum grain size
Pre-Mixed
Mortar
Large grain size
Mortar too dry
Lumpy mortar
Sedimentation
Defective powder
Admixtures/fibres
Different
characteristics
Read spray equipment instructions
Read relevant product data sheet
Mix mortar 3 mins until homogeneous
Store materials correctly
Use Sika compatible admixtures
Use consistent mixing ratio
Climatic
Conditions
Extreme
temperatures
Hardening fast
Mortar is too
viscous
Read mixing instructions in PDS
Check mortar setting time
Protect from direct sunlight
Protect from rain
Packaging Contamination Take care when opening bags
Prevent packaging entering mortar
Application
Pauses and
Breaks
Hardened mortar Plan breaks before starting
Never leave mixed mortar un-attended
Discuss daily spray objectives
Keep a continuous flow of material when
spraying
No stop-starts on application area

J ob Site
Contamination
Foreign particles
Changing products
Different mortar
characteristics
Protect mixer & pump hopper
Clean thoroughly when swapping mortars
Do not oil parts in contact with mortar (refer
to manufacturer's instructions)
Table 7 - Examples of preventing blockages





9.4 Surface Finishing
Finish the surface in accordance with the Engineer's specification.

Concrete placed slightly thicker than required can be aligned using a steel or timber profile. Start from the top of application and work
downwards with the profile. Do not disturb the mortar bond on the concrete substrate.

Lightly finish the surface with a wooden or PVC float. Do not over work the finished surface as this will produce a cement rich surface texture,
which may cause the formation of random (crazing) cracking in the surface.

Care shall be taken when finishing the surface with a trowel on a thin application. Do not to disturb the concrete bond on the rock substrate. Do
not add additional water on the surface.

9.5 Curing
Cure with proper curing methods for minimum 3 days or spray with appropriate curing method or curing compound (once any
surface water has evaporated). Curing methods include jute/hessian and water, plastic sheets or other suitable membranes.
The method of curing shall be approved by the Engineer.

Curing shall take place within 60 minutes of application.

Do not apply a curing compound if a layer or overcoat is to be added on top.

The application shall be protected from wind, rain, frost and direct sunlight. The curing period is dependent on climate conditions. In warm
temperatures with low humidity the application shall be protected from premature drying.


9.6 Application Limits

Avoid application in direct sun and/or strong winds.

Always check the concrete setting time and adjust for climate
conditions.
Temperature of the concrete and substrate shall not differ significantly.