SD0207 1

GUNITING
SD0207
BHATT MEHUL P.
SD0207 2
HISTORY
In the early 1900s, Carl Akeley, a famous hunter,
naturalist and professor, devised a novel method of making
plaster models of large animals for taxidermy work. He
made a wire frame, and with a special gun he devised,
sprayed plaster onto the frame by means of compressed air.
The principle of Akeleys method was to hold a supply of
dry material in the gun, convey it to the nozzle with
compressed air, and wet it with the proper amount of water
as it was blown onto the frame. This resulted in strong,
thin coatings that would not slump off the frame and
eliminated the problem of the plaster setting up before it
was fully placed.


SD0207 3
The equipment then was used to patch deteriorated concrete with
a sand and cement mix. The results were excellent, and in 1911,
patents and trade names were issued for the "Cement Gun"
which is what the equipment was called, and "Gunite," the
material produced by the process.

Until the 1960s all Shotcrete work was dry-process, using
pressure-tank guns. During that decade, the rotary type of gun
was developed. Today variations of these two basic designs are
used for all dry-process applications.

The wet process also was developed in the 1950s, with pressure
tanks being used to force a stiff mortar through the hose.
Additional air was added at the nozzle and the process came to
be known as Shotcrete. The subsequent development of
dependable concrete pumps of various types hastened the
advancement of this technology, and today the wet process is
widely used and favored for certain applications.

SD0207 4
Shotcrete is today an all-inclusive term that describes spraying
concrete or mortar with either a dry or wet mix process. However, it
may also sometimes be used to distinguish from gunite as a wet-
mix. The term shotcrete was first defined by the American Railway
Engineers Association (AREA) in the early 1930s.By 1951,
shotcrete had become the official generic name of the sprayed
concrete process.
Gunite refers only to the dry-mix process, in which the dry
cementitious mixture is blown through a hose to the nozzle, where
the water is injected immediately prior to application. Gunite was
the original term coined by Akeley, and trademarked in 1909,
patented in North Carolina. The concrete is blasted by pneumatic
pressure from a gun, hence "gun"-ite.
SD0207 5
The term "Gunite" became the registered trade mark of
Allentown the oldest manufacturer of gunite equipment.
Other manufacturers were thus compelled to use other
terminology to describe the process such as shotcrete,
pneumatic concrete, guncrete, etc. Shotcrete emerged as
the most commonly used term after gunite and after the
later development of the wet process came to be used for
both methods.

SD0207 6
Dry-mix process
The dry mix method involves placing the dry ingredients into a
hopper and then conveying them pneumatically through a hose to
the nozzle.
The nozzleman who holds the nozzle then controls the addition of
water at the nozzle. The water and the dry mixture is not completely
mixed, but is completed as the mixture impinges on the receiving
surface. This requires a highly skilled nozzleman, especially in the
case of thick or heavily reinforced sections.
Advantages of the dry mix process are that the water content can be
controlled and adjusted instantaneously by the nozzleman which
allows the material to placed more effectively in overhead and
vertical applications without the use of accelerators. The dry mix
process also has advantages in repair applications when it is
necessary to stop frequently, as the dry material is easily discharged
from the hose.

SD0207 7
Wet-mix process
Wet-mix shotcrete involves pumping of a previously
prepared concrete, typically ready-mixed concrete, to the
nozzle.
Compressed air is introduced at the nozzle to impel the
mixture onto the receiving surface.
The wet-gun procedure generally produces less rebound,
waste (when material falls to the floor), and dusts
compared to the dry-mix procedure.
The greatest advantage of the wet-mix process is that
larger volumes can be placed in less time.

SD0207 8
Dry MIX PROCESS WET MIX PROCESS
1)Control over mixing (1) Mixing water is controlled
water and consistency at the delivery equipment
of mix at the nozzle. and can be accurately
Measured.
(2)Better suited for placing (2) Better assurances that the
mixes containing mixing water is thoroughly mixed
light weight porous with other ingredients. This
aggregates. may also result in less rebound
and waste.
(3)capable of longer (3) less dust accompanies the
hose lengths. gunning operation.
SD0207 9
Use of gunite
1. Swimming Pools
2. Rockscapes
3. Artificial Rocks
4. Retaining Walls
5. Panel Building Systems
6. Zoos
7. Slope Stabilization
8. Refractory Spraying
9. Concrete Domes
10. Mine and Tunnel Support and Walls
11. Concrete Repair
12. Water Parks
13. Skateboard Parks
and many more applications...
SD0207 10
Retaining walls are constructed with
wet or dry shotcrete.
SD0207 11
SD0207 12
SD0207 13
Shotcrete is used to construct
artificial rocks and caves.
SD0207 14
SD0207 15
SD0207 16
SD0207 17
Artificial Rockwork by MACO, Auckland, New Zealand.

SD0207 18
SD0207 19
Shotcrete is used to construct
concrete domes.

SD0207 20
SD0207 21
SD0207 22
SD0207 23
SD0207 24
Shotcrete Panel Building System
Photos
SD0207 25
SD0207 26
SD0207 27
Rockscapes are made with either wet
or dry shotcrete.

SD0207 28
Shotcrete is used to stabilize a
hillside.
SD0207 29
Gunite (dry-process shotcrete) is
used to build pools, spas, and water
features.
SD0207 30
SD0207 31
SD0207 32
SD0207 33
Shotcrete Pump used with a robotic
shotcrete arm

SD0207 34
SD0207 35
SD0207 36
SD0207 37
SD0207 38
Shotcrete is used to spray refractory
materials for lining kilns, furnaces.
SD0207 39
Shotcrete is used to construct a
"watering hole" for the tigers
SD0207 40
SD0207 41
Gunite Pool...
SD0207 42
Gunite Pool...
SD0207 43
Gunite Pool...
SD0207 44
Gunite Pool...
SD0207 45
Gunite Pool...
SD0207 46
Gunite Pool...
SD0207 47
Rock Pool 2002
SD0207 48
Rock Pool 2003
SD0207 49
Pool with spa island 2002
SD0207 50
Gunite process
SD0207 51
Gunite process
SD0207 52
Shotcrete is the preferred material in the construction of many new
structures, especially those that have curved surfaces, such as tanks,
domes and pools. After years of trial and error, contractors
specializing in these structures have selected shotcrete because it
reduces the cost of placement by minimizing the need for forms,
provides the durability of concrete, and is particularly suited for
curved surfaces.

Repair and restoration of concrete is one of the fastest growing
segments of the construction industry. This growth is not restricted to
infrastructure, but extends to the private and industrial sectors. From
tanks and pools, to chemical and automotive, to retaining walls and
highway structures, the opportunities are endless. Shotcreting is often
the best alternative when repair and restoration are being
contemplated, and can be the ideal application method for both
reinforced and non-reinforced construction
SD0207 53
Property of gunite
Properly applied gunite is a structurally
adequate and durable material capable of excellent
bond with concrete, masonry, steel and other
materials. However, these favorable properties
are contingent on proper planning and supervision
and on the skill and continuous attention by the
operating staff.
water- cement ratio for gunite in place normally
fails within the range of 0.35 to 0.50 by mass
which is somewhat lower than for most
conventional concrete mixes.
SD0207 54
In general the physical properties of sound gunite in place
are comparable to those of conventional Mortar or
concrete of the same composition.
Most reported values For 28 days strength are in the
range of 200 to 500 kg/cm2.
It is Recommended that strength higher than 250 kg/cm2
be specified only for the most carefully executed gunite
jobs.
Drying shrinkage of gunite depends somewhat on the mix
proportions used, but generally falls within the range
of 0.06 to 0.10 percent, which is generally placed in
heavier sections using larger aggregate and leaner mixes.
It will tend to give more shrinkage, cracking and may
require a closer joint spacing. The durability of gunite
in laboratory tests and under field exposure has generally
been good.
SD0207 55
application of gunite

A.PREPARATION OF SURFACE :
A good base or foundation is necessary for prefer and
successful application of gunite. Where the gunite is to
be placed against Earth surfaces as in canal Linings,
such surfaces shall first Be thoroughly compacted and
trimmed to line and grade,
Gunite Shall not be placed on any surface which is
frozen, spongy or where there is free water. The surface
shall be kept damp for several hours before applying
gunite.
SD0207 56
In the cage of repairs of existing deteriorated concrete,
all unsound material shall be first removed, chapping
shall Continue until there are no offsets in the cavity
which will cause an abrupt change in the thickness of
the repaired surface.
NO square shoulders shall be left at the perimeter of the
cavity; all edges shall be critically examined to make
sure that it is sound and properly shaped.Improper
preparatory work is more often responsible for failures of
gunite in repair work than any other single factor.
After it hag been ensured that the surface to which gunite
is to be bonded is sound, it gain be cleaned of all loose
and foreign materials.If necessary the surface shall be
chiseled or sand-blasted to make it rough to receive
gunite. Expossd reinforcement shall be cleaned free of
scales, rust etc. Porous surfaces shall be kept damp
for several hours before gunite is applied.
SD0207 57
B.FORMWORK

The forms shall be ply-wood sheeting or other suitable
material true to line and dimension. they shall be
adequately braced to protect against excessive vibration,
and shall be constructed so as to permit the escape of
air and rebound during the gunning operation, this is of
particular importance in the case of thick structural
members. Short removable bulkheads may be used at
intersections. Forms shall be oiled or dampened, and
they shall be cleaned just before gunning.
SD0207 58
Adequate and safe scaffolding shall be provided
so that the operator can hold the nozzle at the
optimum angle and distance from the surface for an
parts of the work as described In 'Placing the
gunite'. The scaffolding shall be also given easy
access to the gunite surface for screeding and
finishing, if such is specified, scaffolding shall be
constructed to permit uninterrupted applications of
the gunite wherever possible.
SD0207 59
C.MATERIAL
(I) reinforcement
soundest gunite will be obtained where the reinforcing
steel as assigned and placed to cause the least
interference with placement depending on the thickness
and nature of the work, reinforcement may consist of
either round bars, or welded wire fabric, small sizes
of bars shall be used, a 16 mm diameter bar being the
normal maximum size, inhere large bars are
necessary, exceptional care shall be taken in encasing
with gunite.
sufficient clearance shall be provided around the
reinforcement to permit complete encasement with sound
concrete, the clearance needed depends on the maximum
size of aggregate in the mix and the size of
reinforcement .
SD0207 60
For repair work, the reinforcement shall be fixed to existing
masonry and concrete by wiring to nails driven into walls and
secured rigidly so that the vibration resulting from the
deposition of gunite will not impair or displace them.
(II) Cement
Portland conforming to IS shall be used
(III) Sand
Fine aggregate shall consist of washed sand and shall be hard,
dense, durable, clean sharp and graded evenly from fine to
course, as per zone in grading. It shall be free from
organic matter and shall not contain more than 5% by weight
of deleterious substances. The sand shall have a fineness
modulus of between 2.70 and 3.3. For proper placement of
'GUNITE sand should contain between 3% to 6% moisture by
weight.
Water used for hydration at the nozzle shall be fit for
drinking and shall be maintained at a uniform pressure, which
shall be at least 1 kg/cm above air pressure at the gun.

SD0207 61
D.PLACING THE GUHITS :
Each layer of gunite is built up by making several passes or
loops of the nozzle, over the working area. This may be
done by moving the nozzle rhythmically in a series of loops
from side to side and up and down.
The gunite shall energe from the nozzle in a steady,
uninterrupted flow.
If the flow becomes intermittent due to any cause, the
operator shall direct it away from the work until it again
becomes constant.
Tine distance of the nozzle from work (usually between 75
to 90 cm) shall be such as to give the best results for the
working conditions.
SD0207 62
The nozzle shall be held perpendicular to the surface to
application.
However, when guniting through and encasing reinforcing
bars, the nozzle shall be held closer and at a slight
angle from the perpendicular.
Also the mix shall be little wetter than normal, but not
so wet as to cause sloughing behind the bar.
This procedure forces the plastic gunite behind the bar
while preventing build-up on the front face of the bar.
Where bars are closely spaced, more than one bar nay
be shot from each position.

SD0207 63
In-correct nozzle to far away correct nozzle adequately close
SD0207 64
Equipment:-
The guniting Equipment consists of :-

1.cement Gun with rubber hose and nozzle.

2. Twin pressure water tank

3. Compressor.
SD0207 65
1.CEMENT GUN WITH RUBBER HOSE AND
Nozzle compressed air required for operating the
equipment is Minimum 6 cum/Min (210 cam) at 7 Kg/
cm2(100 psi) for a cement Gun with nozzle opening of
20 mm diameter.
For bigger openings larger quantities of air ere required,
and cement gun consists of two iron vessels usually of
conical shape, one above the other and connected -
each having compressed air inlet.
There is a cone valve at the junction of the two vessels..
The upper vessel ... is also fitted with an air release
valve, called blow-off valve, the lower vessel which is
the working chamber has at the bottom a feed wheel,
with thin radial teeth, operated by a gear and suitable air
mortar.
SD0207 66
The feed wheel is made to rotate at a speed of 10-15
r.p.m At one point, in the bottom of the lower vessel at
the edge of the wheel, there is an outlet for the
connection of the material hose.
Through the side of the Gun above this opening and just
over the feed wheel is a curve plate (deflector) down
to the pocket of the feed wheel, (pockets formed by the
radial teeth) and out through the outlet and to the material
hose as the feed wheel rotates, each pocket filled with
the material passes through the air stream and forces the
material to the material hose a pressure gauge is also
attached to the lower vessels to indicate the air pressure in
the chamber.
SD0207 67
SD0207 68
SD0207 69
THE MATERIAL HOSE :
The material hose of 30 mm internal; dia. and about 15
mm in length of sand blasting quality are fitted with a
claw coupling at one end and the nozzle at the other end.
Additional lengths of material hoses can be coupled for
longer leads, Material noses of diameters larger than 30
mm also can be used if the air available is more than 6
cmt (210 cft).
SD0207 70
GUNNITING NOZZEL:-
The Guniting nozzle is of Bronze or Gun Metal and is
made in three parts.
At one end is a screwed coupling which can be fixed to
the material hose pipe and the other is screwed on the
water body.
The water body is a circular hollow ring with
removable perforated rubber ring inside and water inlet
fitting with control valve on the side.
The water for hydrate a on of cement is added to the
cement-sand mix at the outlet and for proper hydration,
water is to be introduced at a greater pressure than the
material, the quantity of water can be controlled by
the wheel valve mounted, on the nozzle
SD0207 71
HOSE
SD0207 72
(2)TWIK WATER TANK:
water for Hydration of cement is added at a pressure
little higher than the pressure of the sand- cement mix
in the material, hose
The Equipment is provided with twin water tanks
connected in parallel with arrangement for feeding water
to the nozzle by one tank at a time, each water tank has
an inlet water pipe at top and cleaning pipe at the
bottom, both made water tight by a stopper.
Water tanks each having capacity approximately 100 liters
of water are mounted on a three wheel trolley.
These tanks are air pressurized and interconnected for
uninterrupted supply of compressed water through 12 mm
hose pipe to nozzle.
A handle is provided for manual pushing of trolley.
SD0207 73
Twin Water tank:-
SD0207 74
(3).AIR COMPRESSOR:
Air pressure should vary with different classes of work.
more than 3.5 kg/cm2(50 psi) is used only where very
large delivery is required, and only on flat or sloping
surfaces. Air pressure should not exceed 4.2 kg/cm
(60 psi) as impact becomes excessive and there is
danger that the great force with which the material
strikes, will blister the previously applied coating next to
the point of application, disturb it generally, and the
quality of the finished product.
SD0207 75
REBOUND
In the application of Gunite, rebound becomes a most
important consideration and for economy should be kept to
a minimum.
The amount of rebound depends on many factors such as
hydration efficiency, water cement ratio, and fine
aggregate content, nozzle velocity, sand grading, angle
of nozzle flow, distance of impact, application thickness
is and application skill of the nozzle men.
The quantity of rebound for well executed gunite work
would range from 15 to 30 percent for vertical walls and
25 to 50 percent for over head work, during the initial
stages the percentage of rebound is always excessive but it
soon diminishes after a plastic cement sand cushion has
been formed on the surface of application, permitting the
sand particles to become embedded in the freshly laid
gunite,
SD0207 76
The percentage of rebound is also affected by the distance
of the nozzle from the application surface.The amount of
rebound can generally be held to an acceptable minimum if
the distance between the nozzle and application surface is
about 90 cms- and the nozzle is nearly perpendicular to the
application surface as possible.
Grading of rebound is usually much coarser than the
original mix itself since only the larger particles
tend to fail back, lest indicate that the cement
content of the rebound ranges between 10 to 25 % of
the cement content of the gunite.
The re-use of rebound is not recommended. Should the
practice be contemplated the material be thoroughly
washed and dried prior to reintroctuction in the gunite.
SD0207 77
SD0207 78
Because of the variations in the amount of rebound it
is difficult to determine the volume of dry mix required
for a given volume of; gunite in place, impending on
the position of the work, the variation in the amount of
rebound may be as below :-
SD0207 79
CORRECT SHOOTING POSITION
SD0207 80
SD0207 81
ADMIXTURES FOR GUNITE
Admixtures are sometimes, incorporated in gunite, to
accelerate the rate of placing and to provide early
strength, such accelerators are used at places where rapid
gain in early strength is required and where thicker
layers of gunite are to be applied.
Accelerators for gunite differ from those for ordinary
concrete. generally, sodium aluminate and calcium
hydroxide are used as set accelerators in gunite.
Retarders could be added during hot weather if more
time is desired for finishing.
SD0207 82
1. Improved water tightness
2. Induced Rebound.
3. Simplified overhead guniting
4. Increased coat thickness
5. Reduced dust production
6. Better adhesion to wet and damp substructure.
7. Accelerates the hardening process
8. Increases water impermeability.
9. Provides plasticizing properties thereby jetting is mare easier.
10.Provides high early and final strengths.
11.Can be used even at lover temperatures.
12.Allows spraying on moist surfaces.
SD0207 83
DEVELOPMENT IN TECHNOLOLY:-
Fiber Reinforced Guniting is a major development in
guniting technology, which can use to make any
complicated shapes like parabolic, circular, done etc.
Steel, glass, nylon and polypropylene are some of the
fibers which have been tried, both experimentally and in
actual production, with the use of steel fibers
predominating.
They can be easily gunite with tremendous savings in time
and material.
Fiber Reinforced guniting eliminates the necessity of
reinforced concreting inside tunnels, This process has
been tried in India on an experimental basis and has
proved quite successful, with excellent compressive
strength, ductility and flexural tensile strength,
SD0207 84
equipment manufacturers in Britain have developed
special dispensers, by means of which the fibers may be
mixed with the cements and sand prior to conveying or
separately introduced at the nozzle trough an additional
pipeline.
Another important application of guniting is for ferrow
guniting which can produce amazing results with
compressive stress resistance in the order of 985
kg/cm2. This is a process of gunning the Mortar into a
mesh which consists of several layers of welded wire mesh
bound together.

SD0207 85
The refractory guniting is another major development a
slight modification in the machine can spray any
refractory cement -to the inside lining of various steel
making structures in steel melting shops. The machine
is equally useful for the civil repairing of kilns and bunkers
in cement plants, power projects and power plants.
Reformers, fluid catalytic cracking units, carbon
monoxide ducts, stacks and various other structures in
fertilizer plants, refineries and petro-chemical projects are
also required by the same spraying technique.

Now a days machines are provided with a remote control
system with Which the nozzle man can easily control
the operation of this machine.
SD0207 86
For walls, columns and beams, the application shall
begin at the bottom.
The first layer shall at least completely embed
reinforcement adjacent to the form. The thickness of
layer is governed mainly by the requirement that the
gunite shall not sag, where thick layers are applied,
it is important that the top surface is maintained on a
45 Slope approximately, and that rebound is kept out
of the work. Fig. shows;, a guniting operation on a
vertical wall, the top surface of the gunite is kept at
45o so that the rebound falls clear of the work in
shooting slabs, the nozzle shall be held at a slight
angle from the perpendicular so that rebound is blown
on to the completed portion from nozzle it can be
removed.
SD0207 87
Guniting on vertical wall from bottom to top. Guniting on vertical wall from bottom to top.
75 to 80 cm
Rebound
falling
SD0207 88
CASE STUDY:-
plan
At sector-12, gandhinagar,
Re-strengthening of Govt. Quarters
SD0207 89
CASE STUDY:-
Strengthening of bridge on Shelvo River
on Bagodara-Raipur-Vatman-Galiana
road
SD0207 90
INTRODUCTION:-
Road is a state highway no-8 of two carriage way.it
start at bagodara from the junction of N.H. 8A and it
ends at Galiana.
Shelvo bridge passes through saline area. Because of
saline water, It effect concrete surface of super
structure and sub structure of bridge results in
spalling of concrete and rusting of reinforcement.

SD0207 91
SD0207 92
SD0207 93
SD0207 94
SD0207 95
SD0207 96
The piers and slab of bridges having heaving spalling
of concrete cover and having corrosion of steel, so
are provided with 50 mm (clear cover) gunniting with
necessary additional steel.
Provided 50% of original steel as per design in slab.
Entire process is divided into five major part.



SD0207 97
<1>
Removing and scrapping old detoriated C.C.
surface with hammering up to the level of existing
reinforcement in super structure and in slab
structure, i.e. piers, up to 0.30 mt below the depth
of existing and bed level, cleaning the surface
including removing all loose concrete and debries
etc. without damaging existing structure.
SD0207 98
SD0207 99
SD0207 100
SD0207 101
SD0207 102
<2>
Carrying out treatment of cleaning surface of
concrete by sand blasting to reinforcement and
concrete to remove rust and loose concrete.



<3>
providing ms bar reinforcement for RCC work.
for welding using all machineries generator set,
welding roads etc at site with all lift and lead on
scaffolding.

SD0207 103
<4>
Applying C.M. 1:3 with gunninting process on RCC
surface using air pressure 4 kg/cm2 using potable
water, coarse sand free from salinity in minimum
thickness of 50 mm over reinforcement RCC surface-
clear cover.

<5>
injecting cement grout at a pressure of 5 kg/cm2.

SD0207 104
Providing and applying protective coating on exposed
surface using pure aliphatic acrylic resin (paint) after
preparing the concrete after preparing the concrete
surface by sand blasting and removing contamination
such as oil,grease,loose particle,decayed matter
mose aluge,growth tailance etc from exposed
concrete surface
SD0207 105
SD0207 106
SD0207 107
SD0207 108
SD0207 109
SD0207 110
RATE ANALYSIS:-
Applying C.M. 1:3 with gunninting process on RCC
surface using air pressure 4 kg/cm2 in minimmum
thickness of 50 mm over reinforcement RCC surface-
clear cover.

Approximate task work per day details for 20 smt

SD0207 111
NO DESCRIPTION Qty/unit Rate/Unit Amount
<A> Materials
1 Cement 42.83 kg/smt i.e.
42.83*20=856.60 smt
0.857
tone
2620 2245.34
2 1.07 smt sand is reqd. for 0.5
tonne cement=1.07*.857/0.5
1.84 cmt 50.00 92.00
3 Conveyance of cement up to 5
km= 78.80rs (add 1.74 rs/km)
0.857
tone
78.80 67.53
4 Conveyance of sand up to 5
km= 53.53 (add 2.25 rs/km)
1.84 cmt 53.53 98.50
total 2503.37
SD0207 112
NO DESCRIPTION Qty/unit Rate/Uni
t
Amount
<B> Hire/running charges for plan and machinery
5 Compressor machinery
having capacity 8.5 litr./day
L.S. 1375.00
6 Fuel oil lubricant etc 35
lit/day
L.S. 1125.00
7 Reqd nose pipe gun
scaffolding comp
L.S. 1125.00
total 3625.00
SD0207 113
NO DESCRIPTION Qty/unit Rate/Unit Amount
<C> Labour
1 Machine Operator Per 1 no 88.70 88.70

2 Gun operator Per 1 no 88.70 88.70
3 Nozel man Per 1 no 88.70 88.70

4 Mason-I Per 1 no 88.70 88.70
5 Labour Per 7 no 77.90 545.30
6 Labour for carting Per 6 no 77.90 467.40
Total 1367.50
SD0207 114
NO DESCRIPTION Amount
<A> Materials

2503.37
<B> Hire/running charges for plan and machinery 3625.00
<C> Labour 1125.00
Add 10% for near item no B + C 499.25
Total for 20 smt. 7752.62
Total fro smt=7752.62/20 387.63
SD0207 115
REFERENCES
American Concrete Institute
- ACI-506R
Concrete technology
-by M.S.Sheety
Concrete practice
- by- R.H.Elvery

SD0207 116